Control Pc Board Assembly (G6682-1) - Lincoln Electric POWER WAVE S500 Service Manual

G-6
CONTROL PC BOARD ASSEMBLY (G6682-1 PG 1)
ENGINEERING CONTROLLED
MANUFACTURER:
.74
N.E.2, N.G.3
N.A.6
N.A.5
11 12
N.E.4
N.E.2, N.G.3
N.E.1
3
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
ELECTRICAL DIAGRAMS
REVISED ITEM 9 PART NUMBER
CHANGE DETAIL:
Yes
N.E.9
N.E.8
7 N.A.1 9
N.E.5
D1 D3
J5 J6
D4 D6
D8
Q1
D2 D5
X4
Q24
X13
Q11
Q25
X18
O O
N N
S3 S1
Q10
X33
X83 X82 X29 X28
Y1
X81
BT1
Y2
R12
X46
X48
L7
R15
X49
C255
Y3
X62
X53 R24
Q18
X1
OCI7 OCI8
DZ31 DZ32
OCI10 OCI9
Q19
O X59
N D38 D39
S2
OCI5 OCI6
C15
X64
X68
D35
X67
J13 J2 J4
J11
X57
N.E.5
7
N.A.1
7 TOP VIEW
N.A.1
8 7 N.E.7
N.E.5 N.A.1
N.E.5
Q3 Q6
J7 J8
X100
X94 X96 X95 X97 D16
X5 X9
X99
X93 X98
X22
Q31
X75
X19
X20
X41 X25
Q16 X34
L14
X92
R510 X35
FTP1
R6
X50
D54
R21
X51
LED9
C9 C10
Q20
C11 C12
D30
T2
C14
C13
D40 D41
C19 C22
D42
C20
C18
X70
C21
C292
OCI12
10
ASSEMBLY NOTES
N.A.1 PLACE CONNECTOR KEYING PLUG, ITEM 7, OVER CONNECTOR PIN AT LOCATION SHOWN. PLUG
SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE.
N.A.2 PROGRAM X18 WITH ITEM 8.
N.A.3 PROGRAM X32 WITH ITEM 9.
N.A.4 PROGRAM X49 WITH ITEM 13.
N.A.5 INSERT BT1 INTO ITEM 11 SO (+) FACE (SMOOTH) OF BT1 IS AGAINST THE WALL OF ITEM 11. THIS
STEP MUST BE PERFORMED DURING PC BOARD TEST ONLY. INSERTING BT1 PRIOR TO TEST CAN
DRAMATICALLY REDUCE LIFE OF BT1. INSERT BT1 WHILE BOARD IS ON A FLAT SURFACE.
N.A.6 PLACE ITEM 12 OVER ITEM 11. PROTRUSION OF ITEM 12 MUST ALIGN WITH PROTRUSION OF ITEM 11 .
N.E.6
BOTTOM OF ALL FOUR SIDES OF ITEM 12 SHOULD BE IN CONTACT WITH SURFACE OF P.C. BOARD
BLANK. ITEM 12 MUST BE PLACED AFTER BT1 IS INSTALLED.
N.A.7 PRINT G6682-[ ] (LATEST DASH NUMBER AND I.D. CODE) ON LABEL AND PLACE OVER THE EXISTING
PART NUMBER IN AREA SHOWN.
ENVIRONMENTAL NOTES
N.E.1 SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM 3 (2 PLACES). HAND TIGHTEN SCREW UNTIL
SCREW HEAD TOUCHES BOARD AND THEN BACK OFF 1/2 TURN.
N.E.2 AFTER POTTING, THE TOPS OF THESE COMPONENTS MUST BE FREE OF MASKING AND POTTING
MATERIAL.
J9 N.E.3 PRIOR TO POTTING APPLY ITEM 5 TO SEAL THE BOTTOM OF THE CONNECTOR CAVITIES TO PREVENT
D19
POTTING MATERIAL FROM GET TI NG ONTO THE PINS. (AFTER APPLYING GREASE, A NON-PINNNED
MATING CONNECTOR MAY BE USED TO PUSH THE GREASE INTO THE BOTTOM
D22 OF THE CAVITIES.
3
N.E.4 SEAL BASE OF COMPONENT J15 ON ALL 4 SIDES WITH ITEM 14. RTV MUST FLOW COMPLETELY
AROUND COMPONENT WITH NO GAPS. COMPLETELY COVER MOUNTING HOLES AND BLACK PLASTIC
X26
D17 MOUNTS. ALLOW RTV TO CURE PRIOR TO POTTING.
X11 N.E. 5 SEAL BASE OF X18, X19, X20, X32, X47, X48 AND X50 WITH ITEM 14 ON ALL 4 SIDES ON COMPONENT
SIDE OF BOARD. RTV MUST FLOW COMPLETELY AROUND COMPONENTS WITH NO GAPS. ALLOW RTV
X10
TO CURE PRIOR TO POTTING.
N.E.6 PLACE BARCODED ASSEMBLY NUMBER LABEL IN AREA SHOWN.
X24 N.E. 7 PLACE BARCODED SERIAL NUMBER ID LABEL IN AREA SHOWN.
C6
N.E.8 PLACE MAC ID NUMBER LABEL IN AREA SHOWN.
C8
2 N.E.9 AFTER THE POTTING MATERIAL IS CURED, CHECK BOTTOM POTTING TRAY SURFACE FOR WARPAGE.
THE SURFACE IS TO BE FLAT WITHIN .05 F.I.M.
N.E. 10 REMOVE PREHEATED ASSEMBLY FROM OVEN AND IMMEDIATELY DISPENSE POTTING MATERIAL
Q14
X38
BET WEEN TRAY / BOARD ALLOWING THE MATERIAL TO FLOW UP AROUND ALL FOUR SIDES PRIOR TO
X21
DISPENSING OVER THE TOP. POTTING MATERIAL SHOULD BE TO A MINIMUM DEPTH SUCH THAT ALL
SURFACE MOUNT AND THROUGH-HOLE IC CHIPS, BODIES AND LEADS ARE COVERED. BRUSH COAT
BODIES AND LEADS OF L5, L 10, L11 , L12 AND L14.
N.E. 11 DISPENSE RTV ON SECONDARY SIDE OF BOARD TO COMPLETELY COVER MOUNTING HOLES AND
BLACK PLASTIC MOUNTS FOR BT1 AND J15. ALLOW RTV TO CURE PRIOR TO POTTING.
X36 X85 X12 N.E. 12 PRE BAKE UNPOTTED ASSEMBLY FOR 25-35 MINUTES AT 145-155F DEGREES.
N.E.13 POST BAKE POTTED ASSEMBLY FOR 4 HOURS MINIMUM AT 120-125F DEGREES.
GENERAL NOTES
N.G.1 CAUTION: THIS ASSEMBLY IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.
N.G.2 THERE ARE COMPONENTS ON BOTTOM SIDE OF P.C. BOARD.
N.G.3 S 1, S2, S3 SWITCHES MUST BE IN THE "ON" POSITION AFTER POTTING,
N.G.4 KEEP AREA AROUND CONNECTOR LOCKING TABS FREE OF POTTING MATERIAL A MINIMUM OF 0. 15"
IN ALL DIRECTIONS.
N.G.5 RTV ON BOTTOM SIDE OF BOARD COULD TAKE 4 HOURS MINIMUM AT ROOM TEMPERATURE TO
CURE. RTV MUST BE LEVEL DURING CURE.
N.G.6 RTV ON COMPONENT SIDE OF BOARD COULD TAKE 6 HOURS MINIMUM AT ROOM TEMPERATURE TO
CURE. RTV MUST BE LEVEL DURING CURE.
N.G.7 BOARD MANUFACTURER MAY USE LOCTITE 5140 OR DOW CORNING 3140 IN PLACE OF E2519-1 (ITEM
14) RTV.
FTP3
10
CT1
X63
N.A.7
L11 L12
Q22 Q23
SEEELECTRONIC FILE FORADDITIONAL INFORMATION.
X72 X73 X74
N.G.1
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
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.
MANUFACTURING TOLERANCE PER E2056 SCALE:
CONTROL: CLEVELAND EQUIPMENT TYPE: POWER SOURCES
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) 2:1
DRAWN BY: fivory
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
IF PRINTED SUBJECT: DIGITAL CONTROL P.C. BD. ASSEMBLY
ON ALL ANGLES IS ± .5 OF A DEGREE
@ A1 SIZE
MATERIAL TOLERANCE (" ") TO AGREE t ENGINEER: EF
UNITS:
WITH PUBLISHED STANDARDS. MATERIAL APPROVAL
UF 8/24/2012
DO NOT SCALE THIS DRAWING APPROVED: BS INCH DISPOSITION:
DATE:
G-6
REVISION CONTROL
G6682-1M0
PART NO. IDENTIFICATION
CODE
TEST PER E4338-C
POT W ITHE2527
SCHEMATICREFERENCE: G4799-4M0
BUYAS G6682-1M0 PERE3867
8 LAYERBOARDBLANKPANEL PERE3281-ROHS
1 3
PAGE ___ OF ___
DOCUMENT DOCUMENT
REVISION:
NUMBER:
G6682-1
F
PROJECT REFERENCE:
CRM44934
G4800-3
NUMBER:
Power Wave ® S500