Schematic - Complete Machine (G4442 Code 10996 Cummins) - Lincoln Electric VANTAGE SVM178-B Service Manual

G-8
SchEmaTic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) paGE1
G4442
ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED FROM X A.01
No
MANUFACTURER:
Shunt on back of positive
output terminal
SHUNT
POSITIVE
50MV=400 AMPS
OUTPUT
TERMINAL
204S
206S
206B
206A
BY-PASS
PC BOARD
Located on back of
21
output panel 208
between terminals
208A
NEGATIVE
OUTPUT
TERMINAL
Open Circuit Volts:
Max
Min
CC 58 58
58
CV 58
26
Pipe 58
Tig 12 12
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
ARC
CONTROL 10K
Control board circuits associated with J2 are part
of engine electrical system and are common to
frame ground (negative battery terminal.
A
REMOTE
B
CONTROL
C
D
E
GROUND F
AMPHENOL
LEFT CHOPPER PC BOARD
IGBT'S, FLYBACK DIODES AND
R4 is located on top of
p/n L11845-1
FILTER CAPACITORS ARE INTEGRAL
chopper power module
TO CHOPPER MODULES AND NOT
assembly.
INDIVIDUALLY REPLACEABLE.
+COM
Chopper modules are located on power
B2 B5
10,000uF x4
module assembly behind output terminal
panel.
+
FLYBACK
R4
DIODES (6) RIGHT CHOPPPPER PC BOARD
50 OHM
FILTER p/n L11845-1
100 W
CAPACITORS (4)
+COM
IGBT (8)
B3 B1
C E
B2
B5
10,000uF x4
B6 B4
CURRENT LEVEL
FEED BACK SIGNAL
+
FLYBACK
B7 GATE SIGNAL
B8
DIODES (6)
WIREFEEDER
FILTER
VOLTMETER
LEFT CHOKE
PWM Signal to Chopper CAPACITORS (4)
POLARITY
15 volt @ 20 kHz
SWITCH
IGBT (8)
B1 B4
B3 E
C
B6
RIGHT CHOKE
Chokes are mounted on
power module assembly B7 B8 GATE SIGNAL
behind output terminal panel.
14A 13A
Power Supply
to Control
Board
14 13
TWISTED TWISTED TWISTED TWISTED
PAIR PAIR PAIR PAIR
204S (J6-1)
206S (J6-2)
+15V @ LOW IDLE TO PULL COIL BOARD
(J2-4) 404
208B (J3-15) Control board common is
at welder positive output
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
10 V
77 (J7-1) (J2-5) 226
and shunt
OUTPUT 0-10 V
R1 76 (J7-4) Swich closed for high idle.
0 V
CONTROL 10K
WELDCONTROL (J3-14) 257
IDLER SWITCH
0 V
75 (J7-5) (J3-7) 256
PCBOARD 15 V
2A
10 V (TO AMPHENOL)
P/N G4107-1
77A (J1-11) 15 V
(J1-4) 2
REMOTE -15 V (W/O POT.) W ELD TERM. SW.
76A (J1-14)
(J1-3) 4
CONTROL 10K
0 V
(TO AMPHENOL)
0 V Located on back of 4A
75A (J1-10)
control panel.
CV
(J7-9) 214
279 (J7-6)
PIPE
(SEE SHEET 2 FOR (J7-14) 218
MODE
CC
R2 278 (J7-7) SIMPLIFIED
SWITCH +12 VOLTS RUN
TIG
CONTROL BOARD
(J7-15) 220
277 (J7-8)
SCHEMATIC)
(J7-16) 222
TOROID-
SENSES AC
260 (J3-4)
+12V FROM RUN/STOP SWITCH
POW ER TO (J2-6) 232D
ACTIVATE 261 (J3-3)
IDLER
250 (J3-5)
Located on wiring behind
receptacles.
250 (J3-1) (J1-5) 500
Jumper required for output.
(J1-13) 500
5G (J2-3)
(J4-1 to 10) (J5-1 to 10)
500 I.D. JUMPER (Part
W ELD AMMETER W ELD VOLTMETER
of amphenol plug and
lead assembly.)
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for
approximately 5 seconds after welding stops.
During this hold display the right most decimal point will
blink.
J 31
115VAC
A
32
I 41A
42VAC
K 42A
W ORK H 21
77B
E 77A
76B REMOTE 77B
CONTROL F 76A
75B 76B
G 75A INPUT TO
2B CONTACTOR 75B AMPHENOL
D 4A
4B
4B
C 2A
GND-B 2B
GROUND B GND-A
AMPHENOL
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS
Rectifier is located on power module
assembly behind output control panel.
THREE PHASE
60 TO 65 VAC PHASE TO PHASE
RECTIFIER
AT HIGH IDLE
W1 W6
W1 W6
W2 STATOR
W2
DC BUS VOLTAGE W ELD
FOUR POLE 1800 RPM ALTERNATOR
W3
90+/-10VDC @ HI IDLE WINDINGS
W3
W4 W5
W4 W5
41
Field capacitor and diode bridge
42 VOLT AC located on lower rear of fan baffle
ROTOR FIELD
WIRE FEEDER on right side of machine.
SLIP RINGS
POWER
200
42 200A
160 VDC
3
3200uf
300vdc
120 V AC
AC AUX.
201
POWER
240 V AC
5
REVOLVING FIELD
RESISTANCE APPROX.
5A
25 OHMS @ 75F
120 V AC
6A
120 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
6
5H
+12 VOLTS RUN
232D
RUN-STOP SWITCH
SHOWN IN RUN POS.
236B
CB 15A
236A 238B
232H
YELLOW
ALT.
LAMP
238A
231
238
B
P L
IG
ENGINE
ENGINE +
STARTER
ALTERNATOR
Battery voltage:
SOLENOID
12 VOLT
12.6 volts at rest
BATTERY
14 volts engine
ENGINE
running
STARTER
FRAME
GROUND
+12 VOLTS RUN
OIL
FUEL PRESS. TEMP.
4 1 4 1 4 1
FUEL LVL.
SENSOR
229
241
5J 230 OHMS EMPTY
228
30 OHMS FULL
PERIPHERAL
Located on rear
of control panel
PCBOARD
left side.
(J32-6) 234
247 (J32-1)
Low oil
pressure or
high
Engine protection
temperature
circuit. Lamp test
ENG. YELLOW shutdown
PROT.
LED and 30second
delay onengine
Temperature Switch
start.
(SIMPLIFIED closes on high
BOARD temperature.
SCHEMATIC)
405B (J32-8)
405A (J31-12)
+10 Volts
405 (J31-11)
403 (J31-3)
(J31-4) 232F
271 (J32-7)
+
270 (J31-8)
+20Volts from pull
coil board
(J31-6) 262A
(J31-9) 5T
PULL COIL Located on lower left
(SIMPLIFIED BOARD
side of control
PCBOARD SCHEMATIC)
compartment
232N (B2)
Voltage
Regulators
+10 Volts
0.2 OHM
+20 Volts
IDLE SOL.
PULL COIL
227 (B1)
SHUT DOWN
270 (J43-6) PULL COIL
271 (J43-4) 265 (B3)
403 (J43-7)
0.2 OHM
405 (J43-5)
3/4 Second
Timer
5S (B4)
3/4 Second
404 (J43-8)
ROTOR FLASHING Timer
200 (J43-3)
START BUTTON SWITCH
Rotor Flashing: +12 volts
@ 0.5 amps
until generator builds up
then +160 volts @ 0 amps.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
THE INFORMATION ON THIS DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: VANTAGE500 (CUMMINS)
PRINT IS FOR REFERENCE
DRAWN BY: bmuter Reference
ONLY. COMPONENTS AND SUBJECT: MACHINESCHEMATIC
ENGINEER: SCALE:
CIRCUITRY MAY BE DIFFERENT
MATERIAL APPROVAL PROJECT
FROM AN ACTUAL MACHINE. UF
APPROVED: NONE 03/20/2003
DISPOSITION: DATE: NUMBER:
G-8
Oil Pressure Switch
closes on low
10 OHMS @ 0 PSI
oil pressure.
100 OHMS @ 75PS1
OIL PRESSURE
SWITCH SENDER
TEMPERATURE
SWITCH SENDER
500-600 OHMS COLD
50-100 OHMS HOT
+12 VOLTS RUN
HOUR
METER
_
+
11 OHMS
IDLE SOL.
HOLD COIL
SHUT DOWN
HOLD COIL
11 OHMS
LEAD COLOR CODE: COMPONENT VALUE UNITS:
B-BLACK OR GRAY CAPACITOR: MFD/VOLTS
G-GREEN
RESISTOR: OHMS/W ATTS
O-ORANGE
R-RED OR PINK
CONNECTOR PIN NUMBERS:
U-BLUE
W-W HITE EX. 12 PINCONNECTOR
Y-YELLOW
1 2 6
LABELS:
COMMON
7 12
FRAME GROUND LATCH
EARTH GROUND
VIEWOF CONNECTORONPCBOARD
1 2
PAGE ___ OF ___
DOCUMENT DOCUMENT
NUMBER: REVISION:
G4442 A
CRM35043
vaNTaGE® 500