Lincoln Electric PRECISION TIG SVM186-A Service Manual page 99

CHANGEDETAIL: RELEASEDFROM XA.02
ENGINEERING CONTROLLED
No
MANUFACTURER:
G5647
DISPLAY PRESET AT IDLE
ACTUAL AMP WHEN WELDING
NO HOLD FUNCTION
3 DIGIT
METER
(DISP1)
OUTPUT CONTROL &
+5V
MODE SETTINGS ARE
MEMORIZED AT POW ER
- DOW N AND RECALLED
METER
ATPOWER - UP
INTERFACE
POW ER-UPSEQUENCE
METERANDMODEDISPLAY THEPREVIOUSOUTPUT
+5Vref
CONTROL ANDMODESETTINGS. FANRUNS FOR5
SECONDS. IF MODE IS TIG, GAS FLOW S FORA TIME
+15V
SET BY THEPOSTFLOWKNOB. OUTPUT ISHOT IF
MODE ISSTICK. INTIG MODEOUTPUT ISCOLDUNTIL
S1
TRIGGERISCLOSED
MODE
TOGGLE BETWEEN TIG &
TYPICAL OCV
STICK.
HI-FREQ, GAS, BALANCE
65V INDC
CONTROL, PULSE
75V INAC
FREQUENCY, &
MICRO-START CIRCUIT
+5Vref
ARE DISABLED IN STICK
A
C
OUTPUT CONTROL B
(ENCODER)
5 - 230A
A1
METER, ENCODER, SWITCH, LEDs,
AND ALL POTENTIOMETERS ARE
ACand DC DET_REM Polling signal
MOUNTED ON PC BOARD
REM_SENSE Hi = Local
REM_POT Remote control
+5Vref
From Auto Loc/Rem
MAX. PENETRATION
CW CW
BALANCECONTROL IS R1
BALANCE
DISABLEDINSTICKAND
DCTIG MAX. CLEANING 10K
AUTO
+5Vref
DATA
20 HZ
SCLK
CW CW
XRES
PULSE FREQUENCY IS R2
PULSE FREQUENCY
DISABLEDINSTICK
0.1 HZ
10K
OFF
+5Vref
30 S
CW CW
R3
POSTFLOW
10K
MICRO-
1S
PROCESSOR
+5V
LED INTERFACE
LED 3
LED 1
STICK TIG
(RED) (GREEN)
NEXT TO MODE SWITCH NEXT TO MODE SW ITCH
LED 2
LED 4 LED 5
THERMAL
AUT0BALANCE FREQUENCY
(GREEN) (YELLOW)
(GREEN)
NEXT TO PULSE NEXT TO METER
OFF IN STICK AND DC TIG NEXT TO BALANCE POT.
OFF IN STICK, BLINKS AT
FREQUENCY POT.
FREQUENCY RATE
+5V
TO MICRO
PROCESSSOR
AUTO TRIGGER
INTERFACE
LOCAL/ +15V
REMOTE
AUTO LOCAL/REMOTE
CONTROL -15V
STICK MODE: ALW AYS LOCAL
TIG MODE: REMOTE IFPLUGGED
LOCAL IFUNPLUGGED
J1 2 PIN
RECEPTACLE RF
CHOKES
Left front
1J5 4 PIN(W HITE)
U A
PROGRAMMING
MICRO-PROCESSOR
CONNECTOR
10K N B 3J5
X1
J6
2J5
R C
OUTPUT CONTROL
SOFTW ARE
B 5J5 LOCAL
D
VERSION LABEL
W E 6J5
FREQUENCY
F
POSTFLOW
TOROID
6 PIN J5 MICRO
START
OPTIONAL AMPTROL REMOTE TM
CONTROL AND ARC START SWITCH
HI-FREQ BYPASS CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT
HI-FREQBYPASSCONNECTION
(VIEWED FROM COMPONENT SIDE)
CONNECTION
FROM BOTTOM LEFT
TROUBLE SHOOTING LED'S PRESENT ONLY ON
MOUNTINGHOLE TOSHEET
PCB REVISION B OR LATER
METAL
+15V +5V +24V
SCR1 GATE G1
5J2
6J2 SCR2 GATE G2
G3
3J2 SCR3 GATE
G4
8J2 SCR4 GATE
FIRE_SCR
SCR 218
2J2 SCR3,SCR2 CATHODE
Rear of machine attached to
GATING & SNUBBER 1J2 SCR1 CATHODE 217
4J2 SCR4 CATHODE 216
220
7J2 SCR1,SCR4 ANODE
+15V
PHASE
BACKGROUND RESISTORS
BACKGROUND AC INPUT
11J3 216A
MICRO-START
10J3 BACKGROUND ( - ) 245
BG
CIRCUIT
BACKGROUND ( + )
9J3 244
BACKGROUND AC INPUT
(DISABLED IN STICK) 12J3 240
+15V -15V
TOROID
PHASE_FIRE
1J1 SHUNT (+) W 221
OUTPUT REGULATOR 2J1 SHUNT (-) R 222
Iarc
CURRENT FEEDBACK
SETPOINT
DETERMINE IF HI-FREQ IS
+24V +5Vref
CONTINUOUS OR START
ONLY, MIN. CURRENT, AND
BALANCE CONTROL
5J3 311
AC/DC INTERFACE
MICRO SWITCH INPUT
6J3 312
2J3
THERMOSTAT
INTERFACE
THERMOSTAT INPUT
1J3
DISABLE OUTPUT &HI-FREQ
IF THERMOSTAT OPEN
+5Vref
+24V
1J6
PROGRAMMINGCONNECTOR
2J6
FORSOFTW AREUPGRADE
3J6
+5Vref 4J6
+15V
PHASE 115V CIRCUIT
TRIAC & OPTO-TRIAC
TRIGGER
DRIVER
Left side of Machine
near front
4J4 HI-FREQ (115VAC)
236
1J4
GAS (115VAC) 235
236B
3J4 115VAC IN
232A
2J4 FAN (115VAC) 260
C5
TO MICRO PROCESSOR C6
115VAC
AND SCR GATING
.22/400V
PHASE
LED 6
231B
THERMAL
(YELLOW) 231A
TWO THERMAL LEDs TO
NEXT TO METER
233
LIGHT THROUGH PHASE 232A
BACK-LIT THERMAL
DETECTOR
SYMBOL 20A (208V/230V)
CB1
6A (380V & ABOVE)
+5V
Rear Panel
+24V DO NOT REVERSE LEADS
Right Side
209 &210, USED FOR SCR
PHASE TIMING
+15V
7J3 209
X5
+5V
TRIGGER POWER SUPPLY 18VAC
+5Vref CONTROL BOARD SUPPLY
X6
TO MICRO 8J3 210
-15V
PROCESSOR
T1
SCR1
201 X3
4J3
SCR3 18VAC
J2 TRIGGER CIRCUIT
3J3 X4
204
SCR2
8 PIN
+15V AUX. WINDINGS OF
SCR4
(GREEN)
MAIN TRANSFORMER T1
MODE
J3
12 PIN
BALANCE
J4
4 PIN
GAS FAN HF AC
GREEN LED'S
COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED
CONTROL PC BOARD
SCHEMATIC G5640-
ASSEMBLY G5641- Front Panel Top
This diagram is for reference only. It may not be accurate for all machines covered by this manual.
216A
216
G4 4 G4
G3 3 G3
SCR4
SCR3
G2 2
G2 - +
220 MAIN SCR
base, below fan
RECTIFIER
220A
R4
D1
12/100 EACH
FREEW HEELINGDIODE
SCR1
1 SCR2
G1 G1
R5
217
218
218A
R 222(-)
SHUNT
IN-LINECONNECTORJ7
W 221(+)
400A/200mV
Inside sleeving at top left side of
AC
Main Rectifier
DC
OUTPUT
L1
INDUCTOR
Gang D
TW ISTED PAIRS
240
DC +
DC -
On top of Main
Transformer Gang A
CBW
Gang H
AC
Lower left side of - +
DC
DC
Polarity Switch
311
CBW
CLOSED
IN DC N.C.
Gang E
314
312
313 MICRO SWITCH CLOSED IN DC
OPEN IN AC
284
CHOKE TSTAT
(NORMALLY CLOSED
OPEN AT 135C TYP.)
BYPASS/STABILIZER
PCB
(SCHEMATIC S22530)
(PCB AS'BLY L10121-1)
284A
100/100
R2
284B
HOLDINGRESISTORS
R1
In Front of main Inside hi-freq box on
right side of machine 100/100
transformer,
Attached to Base near front
HI-FREQ OFF IN STICK
START ONLY IN DC TIG
CONTINUOUS IN AC TIG
ARCSTARTERASSEMBLY
HIGH VOLTAGE
TRANSFORMER
T2
200/100 238
R3 L2 C3
237
Mounted to front side
of hi-freq box on
S
C4 12.5 OHM TYP. .0015/12KV right side of machine
15/250
near front.
5.5 OHMS
HIGH FREQ. T3
14.5 KOHMS SPARK
TYP.
TYP. GAP .020 TRANSFORMER
115V 12.5 OHM TYP.
5000V
L3
F
WORK
Center front
HI-FREQ CIRCUIT
239
ELECTRODE
GAS
SOLENOID
(115VAC)
Right front
SV1 231
235
232
232
435 OHMS TYP.
FAN RUNS FOR 5 S AT POW ER-UP
12 OHMS TYP. 115VAC
STOPS AT IDLE 8 MINUTES
AFTER W ELDING.
FAN
TYP. RPM:
260
1600 RPM 60Hz
1340 RPM 50Hz
Between SCR Bridge halves
Right front side of
behind choke.
Main Transformer
PROPRIETARY & CONFIDENTIAL:
FROM FRONT OF MACHINE UNLESS STATED
THE INFORMATION ON THIS
OTHERWISE PRINTIS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
FROMAN ACTUAL MACHINE.
Top rear BYPASS ASSEMBLY
Center of machine Attached to Power Switch
SEE CONNECTION DETAIL C1
MAIN
15 - 20 OHM
GATE-CATHODE TRANSFORMER
T1
.0047/ 250VAC
RESISTANCE TYP.
H3
HIGH
POWER SWITCH
C2
W
H2 LOW
X2
S1
80 VAC
H1
X1
B
Right Side of SCR Bridge
RECONNECT ISDONEAT G
Rectifier. Top of Machine
POW ERSWITCH
behind Choke.
Front Panel Left side
Right side of Machine
above Choke Coil.
VOLTAGE RECONNECTION
SEE RATING PLATE FOR SPECIFIC VOLTAGES
Gang C 230 or 400-415 or 575 VOLT CONNECTION
Gang B
Gang G
(AS SHOWN & AS SHIPPED FROM FACTORY)
+
DC
AC
AC
DC -
H1 and H3 (HIGH) TO POWER SWITCH.
CBW H2 NOT CONNECTED; INSULATE.
CBW
CBW =CONNECTED
BYSW ITCH
AC
THESE CONNECTIONS 208 or 380 or 460 VOLT CONNECTION
- +
DC ARE MASE BY POLARITY
DC
SWITCH, THEY ARE NOT H1 and H2 (LOW) TO POWER SWITCH.
PHYSICAL LEADS
CBW
H3 NOT CONNECTED; INSULATE.
S2
Gang F POLARITY SWITCH C1 AND C2 MUST ALWAYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES
Front Panel Center SEE CONNECTION DETAIL
285
Inside hi-freq box on
right side of machine
near front
TO0 COPPER BAR
285A
285B
SCR
HEATSINK
Right side of machine, FARTHEST RIGHT SCR
FARTHEST LEFT
(VIEW ED FROM
front of gas solenoid,
SCR (VIEW ED BOTTOM
attached to Base FRONT)
COPPER
FROM FRONT)
BAR
6 GA. FLEX LEADS
DC
Gang A
Gang D
OUTPUT INDUCTOR
240
285
Gang F
Rear gang H UNUSED TERMINAL
311
Rear gang G
Gang E
MICRO SWITCH
X1
312
Gang C gang B
GANG LOCATIONS ARE
VIEW ED FROM REAR OF
MOUNTING HOLE
SWITCH
T1
MICROSWITCH
POLARITY SWITCH
OPEN
AC A-C, D-E, B-F
X7
CLOSED
DC+ B-D, C-E, A-F, G-H
CLOSED
DC- B-D, A-E, C-F, G-H
115VAC
X8
SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL
Right rear side of Main LEADCOLORCODE: COMPONENT VALUEUNITS:
Transformer
B-BLACKORGRAY CAPACITOR: MFD/VOLTS
G-GREEN
RESISTOR: OHMS/W ATTS
O-ORANGE
R-REDORPINK
CONNECTORPINNUMBERS:
U-BLUE
W-W HITE
EX. 12 PIN CONNECTOR
Y-YELLOW
1 2
LABELS:
COMMON
7
FRAMEGROUND
EARTHGROUND
VIEW OF CONNECTORON PC BOARD
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.
Precision Tig 225
EQUIPMENT TYPE:
DESIGN INFORMATION REFERENCE:
PAGE ___ OF ___
G4588 MACHINE SCHEMATIC
DRAWN BY: SUBJECT:
Jbarto DOCUMENT
SCALE: NUMBER:
ENGINEER: RSamodell
MATERIAL APPROVAL PROJECT CRM38254
NONE NA
06/20/2006
Approve DISPOSITION: DATE: NUMBER: G5647
APPROVED:
L1
L2
W 222
R 222 R 222
ALUMINUM BAR
7GA. FLEX LEAD
6
12
LATCH
1 1
DOCUMENT
REVISION:
A