Lincoln Electric INVERTEC V275-S Service Manual page 106

G-6
SCHEMATIC - ENTIRE MACHINE CODE 11164,11165,11224,11225
ENGINEERING CONTROLLED CHANGE DETAIL: NEW
No
MANUFACTURER:
FRONT PANEL
INPUT SWITCH
WHITE L1
INPUT
RED L2
LINES
L3
BLACK
A1
GREEN
SLOW BLOW
GND
H1B
BETWEEN RECONNECT SWITCH
AND INPUT RECTIFIER
H1A
FAN RELA Y
4
8
CR1
CR1
0 1
6 2
12VDC
BASE, LEFT,
82 OHMS
NEAR DIODE
383 MODULES
H1C H1D
230VAC
BOTH FANS ARE
ON REAR PANEL 580 OHMS
BOT.
AIR LOWS TOP
FAN H3A
INTO FAN
RECONNECT PANEL
MACHINE
H3D
LEFT SIDE, BEHIND DOOR
H3C
THERMAL LIGHT
- Y +
B
W
POWER
- G +
B
W
OUTPUT CONTROL
10K R1
MIN (5A)
(275A) MAX
375
LOCAL POT WIPER
376
4.5V to POT when HS off
377
375B
SWITCH CLOSED: NO
OFF
HOT START HS ENABLE
324
SWITCH OPEN: HOT
ON
START
HOT START
(PREVENT MISCONNECTION
BETWEEN J1 & J2)
ARC FORCE
R2
10K
(+10)MAX MIN(-10)
328
AF CONTROL
327
MODE
B
SWITCH OPEN: TIG
+15V TO SWITCH
304
TIG=0V, STICK=15V
SWITCH CLOSED: STICK 303
LOC/REM
SWITCH CLOSED: REM
LOC=0V, REM=15V
330
LOCAL POT WIPER
277
SWITCH OPEN: LOCAL
77
D,E,F ARE NOT
L4
PRESENT IN ES275i
F
E A 77
REMOTE TOROIDAL CHOKE
76
D B
AMPHENOL
C 75
( 3 PIN IN ES275i ) 2
TRIGGER LEADS ARE SHORT
4 TOGETHER IN ES275i
LEADS #77 & #75 ARE REVERSED IN ES275i (RED-D-ARC MODEL)
RIGHT SIDE, BEHIND CONTROL BOX
D4 SWITCH PC BOARD
INPUT BRIDGE
250J
660V
AC3 POS
209
TP3 TP2
AC2
- +
207
207A 202A
TP1
AC1 204
NEG 201
C2
C1
POWER SUPPLY
208
A
205
+ -
0.6 AMP
VOLT.
206 203A
209 REG.
SWITCH BOARD CONNECTION
LAYOUT
(VIEWED FROM COMPONENT SIDE)
H3A SW_COM
H1 H2 H3 H4 H5 H6
J5 1 6 2 3 4 5
202A
H1 H2 H3 H4 H5 H6
BEHIND SWITCH BD.
TOP CAP.
S2A S2B
PRIMARY RECONNECT SWITCHES
(REAR VIEW)
(SHOWN IN 380-575V POSITION)
LEFT SIDE, BEHIND DOOR
18VAC SUPPLY FOR CONTROL BOARD
C3 B
W
J1-3 J1-2 J1-6 J2-7 J2-8 J2-1 J2-2
J1-7
47.5
J1-1 12V SHORT: CR1 ON, MACHINE OUTPUT ON
Vref from OPEN: CR1 OFF, MACHINE OUTPUT OFF
J1-9 100
PWM
5.1V
STICK
J1-5
ocv
400mS
HOT START CKT
Timing components: C13 & R2
J1-3 LOCKING PIN
FAN-OFF
DELAY TIMER
(7 MINUTES)
J1-10 1K SHORT_ARC
13.5V
J1-4
3K
J1-11 +15V
LOC. WIPER
MAX OUTPUT
J1-8
STICK
REM. WIPER CLAMPING CIRCUIT
J1-12
LOCAL POT WIPER
J2-12 56
REMOT POT WIPER TURN ON THERMAL LIGHT
76
J2-3
75 J2-9 56
2 J2-11 56 +15V
TRIGGER
4 56 TSTAT & TRIGGER CIRCUIT
J2-10
STICK
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS
SWITCH BOARD FUNCTIONAL DESCRIPTION
1. PROVIDING OUTPUT POWER
THOUGH Pulse Width Modulation OF THE TWO IGBT MODULES, THE SWITCH BOARD DELIVERS POWER TO
MOUNTED ON TOP OF C1 & C2, ON THE RIGHT SIDE MACHINE OUTPUT. IGBT MODULES OPERATE AT 30KHz FREQUENCY AND ARE 180 DEGREE OUT OF
PHASE, TAKES TURN SWITHCING THE CORRESPONDING PRIMARY SIDE OF THE MAIN TRANSFORMER ON
AND OFF. AS A RESULT THE SECONDARY SIDE OPERATES AT 60KHz FREQUENCY
(SCHE. L12016-XXX
2. PROTECTING MACHINE
ASBLY G4385-XXX)
THROUGH CONNECTION AT PINS 1 & 7 OF J10 (LEADS NUMBER 311 & 313), THE SWITCH BOARD SIGNALS
THE CONTROL BOARD TO DISABLE CR1 WHICH DISCONNECTS MAIN CAPACITORS FROM INPUT POWER
AND TO SHUT DOWN THE PWM OUTPUT WHICH STOPS TRIGGERING IGBT MODULES WHEN THERE IS A
209
MISCONNECT OR OVER OR UNDER INPUT VOLTAGE CONDITION
(8 X 51/5W)
408 POWER SUPPLY IS DERIVED FROM MAIN CAPACITOR C1
PRECHARGE
CR1
PRECHARGE
RELAY
W R
206 205
LEFT
TERMINAL
(1:125 RATIO) T4
BOTTOM CAP.
A1 IGBT MODULE (HALF)
6.6K BEHIND MAIN
TRANSFORMER
GATE CKT
15V
C1
PT
2200 uF
GATE CKT
-
500V
CONNECTION MADE
ON D1 MODULE
A1 IGBT MODULE (HALF)
RIGHT TERMINAL
203A 208
W R
SW_COM CONNECTION MADE
202A 204
ON SHUNT
(1:125 RATIO) T3
RIGHT
A2 IGBT MODULE (HALF)
TERMINAL
BEHIND MAIN
CONNECTION MADE
C2 TRANSFORMER
GATE CKT
ON D2 MODULE
2200 uF
PT
500V
- GATE CKT
LEFT TERMINAL
A2 IGBT MODULE (HALF)
207A 201
MISCONNECT & UNDER/OVER VOLT. T1
PROTECTION CIRCUIT
MAIN TRANSFORMER
10
PULSE
12VDC MOUNTED ON BASE, NEAR FRONT
TRANSFORMER
82 OHMS
PT
PRECHARGE RELAY
CR1
10
SW_COM
J10-7 J10-1 J10-4 J10-8 J10-2 J10-6
W R W R
Leads 308 &
309 may be
reversed.
J3-9 J3-7
J3-8 J3-10 J3-4 J3-5 J3-6J3-1J3-3J3-2
2uS @ OCV
15V
(When dis-
12V
connected
(+) (-) (+) (-)
30KHz
from switch
-15V bd.)
PRECHARGE
PT DRIVER PRIMARY CURRENT FB VOLT_FB CUR_FB
TIMER
(3 SECONDS)
OUTA OUTB
SLOPE
OUTPUT
SHUT
I+ COMPENSATION
SHUT_DOWN
CURRENT CONTROL
AMPLIFIER
V+
OVER CURRENT 13V
PWM FOLDBACK
(290A)
CONTROL PC BOARD
(SCHE. G4371-XXX
ASBLY G4372-XXX)
LEFT SIDE, NEAR REAR, MIDDLE MODULE
D3 MODUE (HALF)
ON BASE, IN FRONT OF MAIN TRANSFORMER
OUTPUT CHOKE
REACTOR
X7
229
L1 L3
MOUNTED ON TOP OF
R3 100/25
MAIN TRANSFORMER,
REAR COIL
150 MOUNTED ON TOP OF
.0047
CHOKE, UPPER ONE
X8 MOUNTED ON TOP OF
CHOKE, LOWER ONE
X1
D1 MODULE
200mV/400A R4 100/25
LEFT SIDE, NEAR REAR,
TOP MODULE SHUNT
.0047
10
X4
HEATSINK
CONNECTION CONTROL BD.
381
COMMON
.0047
X2 10
LEFT SIDE, NEAR REAR,
BOTTOM MODULE
X3
X6
D2 MODULE
MOUNTED ON TOP OF
.0047
150
MAIN TRANSFORMER,
FRONT COIL
REACTOR
L2
X5
D3 MODULE (HALF)
SNUBBER PCB
(SCHE. S24761-XXX
ASBLY. M19532-XXX)
MOUNTED ON TOP OF DIODE MODULES
L5
TOROIDAL CHOKE
POWER-UP SEQUENCE
AT POWER-UP RELAY CR1 OF SWITCH BOARD IS OPEN, THE TWO MAIN CAPACITORS
Varc ARE PRECHARGED THROUGH CURRENT LIMITING RESISTORS. DURING THIS TIME
229
J2-6 THERMAL LIGHT AND FANS ARE ON.
Iarc
J4-2 W221 UNDER NORMAL CONDITION, THE PRECHARGE TIME LASTS ABOUT 3 SECONDS,
(+)
THEN CR1 CLOSED, FAN RELAY OPENS (FANS OFF) AND THERMAL LIGHT TURNS OFF.
J4-1 R222
(-) PWM IS SHUT DOWN DURING PRECHARGE TIME, THEREFORE MACHINE OUTPUT IS
DISABLED REGARDLESS OF WELD MODE.
CONTROL BOARD FUNCTIONAL DESCRIPTION
UNDER ABNORMAL CONDITONS SUCH AS EITHER THE VOLTAGE OF THE TWO MAIN
CONTROLS OUTPUT, HOT START AND ARC FORCE CAPACITORS IS TOO LOW (LESS THAN 200V) OR TOO HIGH (HIGHER THAN 450V), THE
TURNS ON AND OFF THE SWICH BOARD RELAY CR1 SWITCH BOARD PROTECTION CIRCUIT WILL DISABLE THE CONTROLL BOARD
ACCORDINGLY. PRECHARGE TIMER , CR1 NEVER CLOSES AND MACHINE OUTPUT IS NEVER ENABLED
TRIGGERS SWITCH BOARD THROUGH PULSE TRANSFORMER
TURNS FANS ON AND OFF. TYPICAL OCV
CONTROL BOARD COMMON IS DIFFERENT FROM SWITCH STICK MODE - OUTPUT CONTROL SET AT 40A OR HIGHER: 63V, IGBT
BOARD COMMON.
REGULATED ON-TIME, INPUT INDEPENDENT
- OUTPUT CONTROL SET BELOW 40A: AROUND 35V, IGBT
POWER SUPPLY:
MIN ON-TIME, INPUT DEPENDENT
18VAC FROM AUX. TRANSFORMER, PINS 1 & 2 OF J2
TIG MODE - OUTPUT CONTROL SET BELOW 150A: 35V, IGBT MIN ON-TIME,
INPUT DEPENDENT
- OUTPUT CONTROL SET AT 150A OR HIGHER: 63V, IGBT REGULATED
ON-TIME, INPUT INDEPENDENT
FAN-AS-NEEDED
ALL TSTATS ARE NORMALLY
FANS TURN ON WHEN WELDING CURRENT IS AT 15A OR HIGHER AND STAYS ON
J2-4 316 CLOSED
FOR 7 MINUTES AFTER STOP WELDING
REMOTE TRIGGER
STANDARD MODEL
NEEDED ONLY IN REMOTE CONTROL TIG MODE TO TURN ON OUTPUT
SWITCH BD.
BEHIND HEATSINK,
HEATSINK NEAR TOP CAP. RED-D-ARC MODEL
TSTAT
REMOTE TRIGGER IS NOT NEEDED, OUTPUT IS HOT ALL THE TIME
OUTPUT
ABOVE AUX. TRANSFORMER,
RECT.
NEAR BOTTOM MODULE
LAST NUMBERS USED
HEATSINK
C4
TSTAT
D4
L5
R4
CHOKE
TP6
TSTAT
ON CHOKE COIL
( NOT PRESENT IN
EARLIER MACHINES )
320
J2-5
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.
REFERENCE:
THE INFORMATION ON THIS DESIGN INFORMATION EQUIPMENT TYPE: V275-S/ES275i
PRINT IS FOR REFERENCE
G4369
DRAWN BY: FEI
ONLY. COMPONENTS AND SUBJECT: MACHINE SCHEMATIC
CIRCUITRY MAY BE ENGINEER: SCALE:
DIFFERENT
MATERIAL APPROVAL PROJECT
FROM AN ACTUAL MACHINE. NA
APPROVED: - NONE 04/26/2004
DISPOSITION: DATE: NUMBER:
G-6
384
TP6 C3 TP4
.
05uF
150V 320V
600V
80J 160J
386
TP5
320V
. 05uF
C4 160J
600V
OUTPUT BYPASS
ASSEMBLY
RTV TO CASE FRONT, AT OUTPUT STUDS
MACHINE OPERATION
COMPONENT VALUE UNITS:
LEAD COLOR CODE:
B-BLACK OR GRAY CAPACITOR: MFD/VOLTS
G-GREEN
RESISTOR: OHMS/WATTS
O-ORANGE
R-RED OR PINK
CONNECTOR PIN NUMBERS:
U-BLUE
W-WHITE EX. 12 PIN CONNECTOR
Y-YELLOW
1 2 6
LABELS:
COMMON
7 12
FRAME GROUND LATCH
EARTH GROUND
VIEW OF CONNECTOR ON PC BOARD
1 1
PAGE ___ OF ___
DOCUMENT
DOCUMENT
NUMBER: REVISION:
G4369-1 A
CRM33791
V275-S