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G5691
ENGINEERING CONTROLLED
CHANGE DETAIL:
RELEASED FROM X A.02
No
MANUFACTURER:
Push & hold
at power up = defaults
1
S3
2
344
MENU
3
347
METER
J7
BOARD
4
SWITCH
345
Meter shows
343
316D
preset & actual
Caliberation: see new control bd. instructions
346
Menu Switch hold to get to TIG options
lift TIG, upslope
Menu Switch hold to get to Stick options
tig hot start levels, micro start
arc force levels
pre flow/after flow time extended
hot start levels
see IM for details and more
CW
MAX
R1
OUTPUT
10K
CW
CW
MIN
R4
OUTPUT
10K
313B
311A
CW
CW
R2
BALANCE
10K
313C
REMOTE
317
LOCAL
316
316A
CW
CW
(SHOWN IN REMOTE)
R3
POST FLOW
10K
313A
313
MIN A
321
A
316C
TIG
VOLT
315
STICK
319
MODE SWITCH
DISPLAY SWITCH
(SHOWN IN STICK)
CONTROL PANEL
STICK
GAS
AUTO BALANCE
REMOTE
(GREEN)
(RED)
(GREEN)
(GREEN)
W
B
W
B
W
B
B
331
332
333
LED LIGHTS
FREQUENCY
ON TIME
DOWN SLOPE
401C
401D
CW
CW
402
405
10K
10K
min
min
min
403
406
SPOT
SPOT
B
BACK GROUND
(RED)
W
401A
B
OFF
4-STEP
W
2-STEP
PULSE
PULSE
TRIGGER
(GREEN)
flashes with
(SHOWN IN 2-STEP)
pulse frequency
ADVANCED CONTROL PANEL (OPTIONAL ON PT275)
REMOTE
RECEPTACLE
U
A
4J22
10K
N
B
2J23
1J22
3J23
R
C
2J22
4J23
B
3J22
D
5J23
W
E
6J22
7J23
1J23
F
5J22
PROTECTION
TOROID
PCB
TM
OPTIONAL AMPTROL REMOTE
(SCHEMATIC M16115)
CONTROL AND ARC START SWITCH
® ®
TOROID
TOROID
SCR1 GATE
menu options( jumper IN)
no menu options ( jumper out)
1J13
SCR2 GATE
1J4
2J13
SCR3 GATE
5J4
GND
343
3J13
SCR4 GATE
2J4
344
Data
4J13
4J4
SCR1,SCR2 CATHODE
Clock
345
5J13
SCR drive
Menu Switch
9J4
SCR3 CATHODE
346
6J13
ckts
+5
347
7J13
6J4
SCR4 CATHODE
&
8J13
SCR3,SCR4 ANODE
10J4
snubbers
7J4
3J4
X
8J4
J8 (6pin)
X
TOROID
not used
1J6
SHUNT (+)
amp
SHUNT (-)
2J6
TOROID
TOROID
+10V
311
1J9
6J11
MICRO SWITCH ON POLARITY SWITCH
PRESET (0 - 10V)
312
2J9
MICRO SWITCH ON POLARITY SWITCH
12J11
IC chip
VOLT FEEDBACK, ELECTRODE
+1.5V
1J11
314
4J9
controller
scaling
VOLT FEEDBACK, WORK
MIN OUTPUT (0 - 1.5V)
9J11
320
10J9
BALANCE (0 - 10V)
322
12J9
+15V
316
6J9
REMOTE (+15V)
317
7J9
POSTFLOW (0 - 15V)
318
8J9
DISPLAY MIN A (+15V)
321
11J9
TOROID
DISPLAY VOLT (+15V)
115VAC IN
315
5J9
AC STICK
1J12
STICK (+15V)
319
9J9
5J12
COM
313
3J9
115VAC IN
DC STICK
IC chip
opto
either is ref
controller
triac
to 231A
opto
triac
large cap and
resistor filter
R
TOROID
BACKGND FILTER CAP., POS
3J11
B
BACKGND FILTER CAP., NEG
331
6J10
11J11
stick
W
331
1J10
10J11
B
BACKGND AC OUT
332
7J10
2J11
opto
BACKGND AC IN
auto
W
triac
THERMAL
332
2J10
(YELLOW)
B
8J10
OCV clamp
333
remote
W
3J10
333
1J7
B
9J10
334
W
B
W
gas
3J7
W
opto
334
4J10
2J7
triac
B
10J10
335
5J7
334
335
thermo
opto
4J7
W
335
5J10
triac
6J7
opto
TOROID
triac
max current range:
TOROID
CW
ADVANCED CONTROL
HI-FREQ (115VAC)
6J12
407
PCB
GAS (115VAC)
3J12
10K
(SCHEMATIC G4760-X)
115VAC IN
4J12
(OPTIONAL ON PT275)
TOROID
FAN (115VAC)
2J12
J2
FREQ. (.08 - 15V)
402
2J1
403
3J1
10 pin molex
ON TIME (1-15V)
405
5J1
406
6J1
408
DOWNSLOPE
7J1
407
8J1
Dip Switches select:
CW
9J1
10J1
a. re-start enable
409
PULSE ON (15V)
b .ramp down to zero
404
4J1
+15V
c . see IM for details
401
1J1
10K
2-STEP (15V)
and more.
411
11J1
d .most old options
410
W
PULSE LED
12J1
on menu feature now.
+5 LED +15 LED
413
1J20
W
2J20
HOT START TRIMMER
not used: see
2J5A
menu options
ARC FORCE TRIMMER
3J5A
4J5A
J3 1
2 3 4
5J5A
10 pin molex
MOVE THIS PLUG FROM
7J5A
J5 TO J5A FOR ROBOTIC INTERFACE
1J5A
6J5A
8J5A
WHEN ADVANCED CONTROL
TOROID
PCB IS NOT INSTALLED
COOLER, +12VDC IN TIG WELDING
DISCONNECT FOR
5J11
MAX
A
2J5
DOUBLE PRE/POST FLOW
COOLER, COMMON
13J11
WIPER
B
3J5
com
To & From
driver
MIN
C
4J5
IC chip
14J11
TSTAT
+8
D
5J5
TSTAT
4J11
opto
com +12
E
7J5
8J11
F
1J5
CONTROL BOARD SUPPLY
16J11
6J5
TOROID
to thermo
7J11
8J5
led & CPU
TRIGGER CIRCUIT
15J11
CONTROL PCB
K870 foot pedal jumper
to enable Pot (R1) max output
( SCHEMATIC G4762-X)
limiter fearure. Jumper not used
in Robotic molex position J5A
This diagram is for reference only. It may not be accurate for all machines covered by this manual.
216
G1
G2
G4
G3
G1
G4
G2
218
217
220
216
220
Free Wheeling diode
G3
217
218
W 221
R 222
R 222(-)
W 221(+)
265
266
252
253
AC & DC STICK OCV BOOST CIRCUIT,
middle section
PRESENT ONLY ON PRECISION TIG 375
right front lower
224
256
225
225A
228
255
CR3
CR2
CR3
Sets weld tables
CR2
& CR2 ,CR3 control
OCV BOOST
257
258
RECTIFIER
8/300W
DC
AC
CR2
CR3
BOOST
BOOST
R14
226
115VAC
115VAC
227A
220B
231C
CR3
115V common
231B
375 ONLY
BACKGROUND CIRCUIT
275 ONLY
ENABLED IN BOTH TIG
current limiting resistors
& STICK, AC & DC
to main rectifier
275 = 5/50W 4 ea
left front lower
375 = 25/25W 4 ea
upper section near lift bale
271
229A
375 ONLY
BACKGND
RESISTORS
269
BACKGND
RECTIFIER
229
PT375 use ONLY
min current range:
375=2 to 65A
275=2 to 55A
HI-FREQ INTENSITY
(bottom right side)
375=340A
275=420A
(bottom behind fan)
R13
PRESENT ONLY ON
HIGH VOLTAGE
(right side in box)
PRECISION TIG 375
board mounted parts
TRANSFORMER
3/25W
T2
200/100W
238
236
R5
L2
C6
237
235
236B
233A
S
12.5 OHM TYP.
C7
.0015/12KV
15/250V
260
5.5 OHMS
14.5 KOHMS
SPARK
TYP.
HIGH FREQ.
TYP.
12.5 OHM TYP.
GAP
.015"
TRANSFORMER
L3
F
HI-FREQ CIRCUIT
239
115V common
(right side)
GAS
SOLENOID
ELECTRODE
inside side box right
(115VAC)
115V common
235
SV1
231A
233A
Fans "ON" @
outside of right side box
15A in stick mode
2A in tig mode
COOLER RELAY
"ON" 8 minutes after
(12VDC)
weld stops
262
PRECISION
231F
TIG 375 ONLY
CR4
TOP FAN
BOTTOM FAN
(115VAC)
FAN
FAN
(115VAC)
c.c. w
263
c.w.
intake
exhaust
260
260A
262
PLUGGED TO
COOLER RECEPTACLE
263
PRECISION TIG 275 ONLY
214
212
Make sure that the rear EXTERNAL
baffle is inplace and not damaged.
OPTIONAL
209
X7
213
215
SV2
WATER
20VAC
SOLENOID
lead
wounded into
N.C.
N.C.
X8
(115VAC)
210
mounted
KIT
primary
T1
SECONDARY TSTAT
X9
PRIMARY TSTAT
201
20VAC
(OF MAIN TRANSFORMER T1)
PRECISION TIG 375
X10
204
turns off SCR's
TOP FAN
ONLY
AUX. WINDINGS OF
MAIN TRANSFORMER T1
PROPRIETARY & CONFIDENTIAL:
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
FROM AN ACTUAL MACHINE.
left heat-sink
right heat-sink
SCR4
SCR1
MAIN
+
-
RECTIFIER
very top of welder
D1
SCR3
SCR2
MAIN
TRANSFORMER
PT375 = 86 vac
center of base mounted on its side
PT275 =75 vac
SHUNT
T1
H5
400A/200mV
to X2
upper left
H4
HIGH
POWER SWITCH
H3
MID
PT375 ONLY
OUTPUT
X1
H2
LOW
L1
223
INDUCTOR
RECONNECT
X13
PANEL
75vac
(375 only)
X2
H1
DC +
+
DC
AC
AC
DC -
DC -
H1
AC
AC
265
C1
C2
C3
-
+
-
+
DC
DC
DC
DC
CLOSED
IN DC
in reconnect area
N.C.
POWER FACTOR
266
CAPACITORS
POLARITY
250
SWITCH
252
SEE NOTE A
253
S2
front
PT375: STANDARD, C1=C2=C3=60/460V
PT275: OPTIONAL, C1=C2=50/460V
C3 NOT PRESENT
BYPASS/STABILIZER
PCB
bottom right in RF section
(SCHEMATIC S22530)
X5
T1
63.5V
X6
HOLDING RESISTOR
R1
50/100W
base front
WORK
FRONT
(right front)
ELECTRODE
(STICK WELDING)
NOTE A:
LEAD #250 FROM POWER FACTOR CAPACITORS
CONNECTS ACCORDING TO THE INPUT VOLTAGE
208/230/460
115V common
LEAD #250 CONNECTS TO "HIGH" TERMINAL ON
RECONNECT PANEL, ALONG WITH CORRECT LEAD
T3
FROM MAIN TRANSFORMER (T1)
5KV
220/380/415
LEAD #250 CONNECTS TO THE H5 LEAD OF
REAR
THE MAIN TRANSFORMER (T1)
233A
(TIG WELDING)
230/460/575
LEAD #250 CONNECTS TO THE "MID" TERMINAL
CB1
115 V
ON THE RECONNECT PANEL, ALONG WITH CORRECT
(TOP of plug)
115V/15A
RECEPTACLE
LEAD FROM THE MAIN TRANSFORMER (T1)
"ON" with input power sw.
233
232
460/575
X3
233B
LEAD #250 CONNECTS TO THE "LOW" TERMINAL
COOLER
ON THE RECONNECT PANEL, ALONG WITH CORRECT
(BOTTOM of plug)
115VAC
RECEPTACLE
LEAD FROM THE MAIN TRANSFORMER (T1)
"ON" with output
X4
T1
231
234
ELECTRICAL SYMBOLS PER E1537
C8
C9
(top rear)
105VAC
LEAD COLOR CODE:
.22/400V
.22/400V
CB2
B-BLACK OR GRAY
X14
G-GREEN
220V 2A
O-ORANGE
RECEPTACLE
220V/5A
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
50/60HZ MACHINES ONLY
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
SCALE:
DESIGN INFORMATION
EQUIPMENT TYPE:
PRECISION TIG
NONE
DRAWN BY:
bburkhart
IF PRINTED
SUBJECT:
MACHINE SCHEMATIC
@ A1 SIZE
ENGINEER:
burkhart
NONE
UNITS:
MATERIAL
APPROVAL
PROJECT
REFERENCE:
NA
CRM38261
APPROVED:
-
G4075
DISPOSITION:
DATE:
7-27-2007
NUMBER:
50HZ MACHINE ONLY
50/60HZ MACHINE
ONLY
BYPASS ASSEMBLY
C4
in reconnect area
.0047/
3KV
C5
L1
L2A
BYPASS PCB
SCHE. S24206-X
L1A
L2
MICRO SWITCH
near power switch
N.O.
212
PRECISION TIG 375
ONLY
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2
6
7
12
LATCH
VIEW OF CONNECTOR ON PC BOARD
1
1
PAGE ___ OF ___
DOCUMENT
DOCUMENT
NUMBER:
REVISION:
G5691
A
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