Lincoln Electric SVM186-A service manual Schematic Complete Machine ALL Codes G5647

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G-3	ELECTRICAL DIAGRAMS	G-3
SCHEMATIC - COMPLETE MACHINE - ALL CODES (G5647)

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	ENGINEERING CONTROLLED CHANGEDETAIL: RELEASEDFROM XA.02
G5647
	MANUFACTURER:	No			DISPLAY PRESET AT IDLE
				ACTUAL AMP WHEN WELDING
						NO HOLD FUNCTION
							3 DIGIT	FIRE_SCR
							METER
			OUTPUTCONTROL&			+5V (DISP1)
			MODESETTINGSARE
			MEMORIZEDATPOWER
			- DOWNANDRECALLED				METER
			ATPOWER- UP				INTERFACE

+15V	+5V	+24V	5J2
			6J2
			3J2
	SCR		8J2
			2J2
GATING & SNUBBER			1J2
			4J2
			7J2
+15V	PHASE

SCR1GATE			G1
SCR2 GATE			G2
SCR3 GATE			G3
SCR4GATE			G4
SCR3,SCR2 CATHODE	218
SCR1CATHODE		217
SCR4 CATHODE		216
SCR1,SCR4 ANODE		220

216

216A

Top rear

Center of machine

BYPASS ASSEMBLY

Attached to Power Switch

SEE CONNECTION DETAIL

G4

G4

15 - 20 OHM

MAIN

C1

4

SCR4

SCR3

Rear of machine attached to

G3

3

G3

GATE-CATHODE

TRANSFORMER

.0047/ 250VAC

base, below fan

G2

2

G2

-

MAIN SCR

+

RESISTANCE TYP.

T1

H3

HIGH

R4

220A

220

D1

POWER SWITCH C2

RECTIFIER

W

L1

12/100 EACH

G1

1

FREEWHEELINGDIODE SCR1

SCR2

X2

H2

LOW

R5

G1

PLUG

217

80 VAC

S1

INPUT

BACKGROUND RESISTORS

218

POWER-UPSEQUENCE					BG
METERANDMODEDISPLAYTHEPREVIOUSOUTPUT				+5Vref
CONTROL ANDMODESETTINGS. FANRUNSFOR5		+15V
SECONDS. IF MODEISTIG, GASFLOWSFORATIME
SETBYTHEPOSTFLOWKNOB. OUTPUT ISHOT IF
MODEISSTICK. INTIG MODEOUTPUT ISCOLDUNTIL	S1
TRIGGERISCLOSED
TYPICAL OCV	MODE		TOGGLEBETWEENTIG &		PHASE_FIRE
			STICK.		Iarc
65VINDC			HI-FREQ, GAS, BALANCE
			CONTROL, PULSE
75VINAC	+5Vref		FREQUENCY, &		SETPOINT
			MICRO-STARTCIRCUIT
			AREDISABLEDINSTICK
	OUTPUT CONTROL	C	A
			B
	(ENCODER)

MICRO-START

CIRCUIT

(DISABLED IN STICK)

+15V -15V

OUTPUT REGULATOR

+24V +5Vref

11J3

10J3

9J3

12J3

1J1 2J1

BACKGROUND ACINPUT	216A
BACKGROUND ( - )	245
BACKGROUND ( +)	244
BACKGROUND ACINPUT	240
TOROID	W 221
SHUNT (+)
SHUNT (-)	R 222
CURRENTFEEDBACK

DETERMINEIFHI-FREQ IS

CONTINUOUSORSTART

ONLY, MIN. CURRENT, AND

218A

R 222(-)

SHUNT

X1

H1

B

L2

IN-LINECONNECTORJ7

Right Side of SCR Bridge

Inside sleeving at top left side of

W 221(+)

400A/200mV

Rectifier. Top of Machine

RECONNECT ISDONEAT

G

Main Rectifier

AC

POS

behind Choke.

DC

OUTPUT

POWERSWITCH

L1

Right side of Machine

Front Panel Left side

above Choke Coil.

VOLTAGE RECONNECTION

INDUCTOR

Gang D

TWISTEDPAIRS

Gang C

Gang B

SEE RATING PLATE FOR SPECIFIC VOLTAGES

240

CBW

DC+

Gang G

DC+

230 or 400-415 or 575 VOLT CONNECTION

AC

AC

On top of Main

(AS SHOWN & AS SHIPPED FROM FACTORY)

Transformer

Gang A

DC-

CBW CBW CBWDC-

CBW=CONNECTED

CBW

H1 and H3 (HIGH) TO POWER SWITCH.

BYSWITCH

Lower left side of

CBW

AC

Gang H

AC

THESECONNECTIONS

H2 NOT CONNECTED; INSULATE.

AREMASEBYPOLARITY

Polarity Switch

DC+

CBW

DC-

DC+

SWITCH, THEYARENOT

208 or 380 or 460 VOLT CONNECTION

DC-

METER, ENCODER, SWITCH, LEDs,	5- 230A	A1
AND ALL POTENTIOMETERS ARE				DET_REM	Pollingsignal	AC/DC
MOUNTED ON PC BOARD
	ACandDC			REM_SENSE	Hi =Local
		+5Vref		REM_POT	Remotecontrol
				FromAuto Loc/Rem		THERMOSTAT
	MAX. PENETRATION			CW
BALANCECONTROLIS		R1
	BALANCE
DISABLEDINSTICKAND			10K
DCTIG	MAX. CLEANING
	AUTO	+5Vref
					DATA
	20HZ
PULSEFREQUENCYIS				CW	SCLK
	PULSE FREQUENCY	R2			XRES
DISABLEDINSTICK

INTERFACE	5J3
	6J3
INTERFACE	2J3
	1J3
+24V +5Vref
	1J6
	2J6
	3J6

BALANCECONTROL

MICRO SWITCH INPUT

THERMOSTAT INPUT DISABLEOUTPUT&HI-FREQ IFTHERMOSTATOPEN

PROGRAMMINGCONNECTOR FORSOFTWAREUPGRADE

311	311		CBW	CBW	PHYSICALLEADS	H1 and H2 (LOW) TO POWER SWITCH.
					S2
312	CLOSED	N.C.	Gang E	Gang F		H3 NOT CONNECTED; INSULATE.
314	IN DC				POLARITY SWITCH	C1 AND C2 MUST ALWAYS BE CONNECTED
	312				Front Panel Center
					SEECONNECTIONDETAIL	ACROSS TRANSFORMER PRIMARIES
313	MICRO SWITCH CLOSED IN DC		284	285
CHOKE TSTAT	OPEN IN AC
					Inside hi-freq box on
					right side of machine
(NORMALLY CLOSED					near front
OPEN AT 135C TYP.)			BYPASS/STABILIZER
						TO0 COPPERBAR
				PCB			SHUNT	W 222
			(SCHEMATIC S22530)
			(PCB AS'BLY L10121-1)					R 222

0.1HZ	10K
OFF
	+5Vref
30S	R3 10KCW
POSTFLOW		MICRO-	PHASE
1S	+5V	PROCESSOR	TRIGGER
	LED INTERFACE
LED 1	LED 3
STICK	TIG
(RED)	(GREEN)
NEXT TO MODESWITCH	NEXT TO MODESWITCH
LED 4	LED 5		LED 2
AUT0BALANCE	FREQUENCY	THERMAL
(GREEN)	(GREEN)	(YELLOW)

+5Vref 4J6

+15V

115V CIRCUIT

TRIAC & OPTO-TRIAC

DRIVER

4J4

1J4

3J4

2J4

TOMICRO PROCESSOR

ANDSCRGATING

LED 6 PHASE

THERMAL

(YELLOW)

220 220A

218

ALUMINUM BAR

284A

285A

218A

D1

100/100

SCR1

SCR2

SCR3

SCR4

284B

R2

( DC

HOLDINGRESISTORS

285B

SCR

(

In Front of main

Inside hi-freq box on

R1

G1

G2

+

G4

_)

transformer,

right side of machine

) G3

Attached to Base

near front

HI-FREQ OFFINSTICK

100/100

Right side of machine,

217

216 X2

FARTHEST LEFT

FARTHEST RIGHT SCR

front of gas solenoid,

BOTTOM

(VIEWEDFROM

STARTONLYINDCTIG

attached to Base

SCR(VIEWED

FRONT)

7GA. FLEXLEAD

Left side of Machine

CONTINUOUSINACTIG

FROM FRONT)

COPPER

BAR

near front

HIGH VOLTAGE

ARCSTARTERASSEMBLY

200/100

TRANSFORMER

6 GA. FLEX LEADS

HI-FREQ (115VAC)

236

T2

L2

238

C3

AC

DC

R3

237

Mounted to front side

GAS (115VAC)

of hi-freq box on

115VAC IN

235

236B

S

right side of machine

232A

C4

12.5 OHM TYP.

.0015/12KV

near front.

FAN (115VAC)

SPARK

Gang D

Gang A

C5

260

15/250

5.5 OHMS

14.5 KOHMS

12.5 OHM TYP.

HIGH FREQ.

T3

OUTPUT INDUCTOR

115VAC

C6

TYP.

TYP.

GAP .020

TRANSFORMER

240

115V

5000V

L3

.22/400V

F

Center front

Rear gang H

Gang F

285

231B

HI-FREQ CIRCUIT

WORK

POS

UNUSED TERMINAL

231A

239

Rear gang G

311

EN-170

FREQUENCYPOT.

TWOTHERMAL LEDs TO

OFFINSTICKANDDCTIG

NEXT TO PULSE

NEXT TO METER

NEX TO ETER

OFFINSTICK, BLINKSAT

LIGHTTHROUGH

NEXT TO BALANCEPOT.

PHASE

DET REM REM SENSE REM POT

FREQUENCYRATE

BACK-LITTHERMAL

+5V

+24V

SYMBOL

+5V

DETECTOR

TOMICRO

PROCESSSOR

AUTO

TRIGGER

TRIGGER

+15V

7J3

+15V

+5V

POWER SUPPLY

LOCAL/

INTERFACE

TOMICRO

+5Vref

8J3

AUTO LOCAL/REMOTE

REMOTE

-15V

PROCESSOR

-15V

CONTROL

STICKMODE: ALWAYSLOCAL

SCR1

TIG MODE: REMOTEIFPLUGGED

J1

2 PIN

4J3

LOCALIFUNPLUGGED

RED LED'S

SCR3

J2

RECEPTACLE

RF

3J3

Left front

CHOKES

SCR2

+15V

8 PIN

U

A

1J5

4PIN(WHITE)

4

SCR4

(GREEN)

10K

N

B

3J5

PROGRAMMING

MICRO-PROCESSOR

MODE

CONNECTOR

X1

R

C

2J5

J6

SOFTWARE

J3

B

D

5J5

LOCALOUTPUTCONTROL

VERSIONLABEL

12 PIN

W

E

6J5

FREQUENCY

BALANCE

F

POSTFLOW

J4

6 PIN

J5

MICRO

GAS

FAN HF

AC

TM

TOROID

4 PIN

OPTIONAL AMPTROL REMOTE

START

GREEN LED'S

CONTROL AND ARC START SWITCH

HI-FREQ BYPASS

CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT

FROM BOTTOM LEFT

TROUBLE SHOOTING LED'S PRESENT ONLY ON

CONTROL PC BOARD

HI-FREQBYPASSCONNECTION

CONNECTION

(VIEWED FROM COMPONENT SIDE)

SCHEMATIC G5640-

MOUNTINGHOLETOSHEET

PCB REVISION B OR LATER

METAL

ASSEMBLY G5641-

233

Gang E

MICRO SWITCH

CB1232A

ELECTRODE

20A (208V/230V)

Rear Panel

GAS

284

Gang C

gang B

X1 312

6A (380V & ABOVE)

Right Side

SOLENOID

Right front

GANG LOCATIONS ARE

DO NOTREVERSELEADS

(115VAC)

VIEWED FROM REAR OF

209&210, USEDFORSCR

235

SV1

231

231

MOUNTING HOLE

SWITCH

PHASETIMING

209

X5

232

232

T1

18VAC

435OHMSTYP.

POLARITYSWITCH

MICROSWITCH

CONTROL BOARD SUPPLY

AC

210

X6

X7

A-C, D-E, B-F

OPEN

T1

FANRUNSFOR5SATPOWER-UP

DC+

B-D, C-E, A-F, G-H

CLOSED

201

115VAC

115VAC

DC-

B-D, A-E, C-F, G-H

CLOSED

X3

12OHMSTYP.

FAN

STOPSATIDLE8MINUTES

X8

18VAC

AFTERWELDING.

SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL

TRIGGER CIRCUIT

260

TYP. RPM:

204

X4

AUX. WINDINGS OF

1600 RPM 60Hz

Right rear side of Main

LEADCOLORCODE:

COMPONENTVALUEUNITS:

1340 RPM 50Hz

Transformer

MAIN TRANSFORMER T1

Right front side of

Between SCR Bridge halves

B-BLACKORGRAY

CAPACITOR: MFD/VOLTS

behind choke.

Main Transformer

G-GREEN

RESISTOR: OHMS/WATTS

O-ORANGE

R-REDORPINK

CONNECTORPINNUMBERS:

U-BLUE

W-WHITE

EX. 12 PINCONNECTOR

Y-YELLOW

1

2

6

LABELS:

COMMON

7

12

FRAMEGROUND

LATCH

EARTHGROUND

VIEW OFCONNECTORONPCBOARD

COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED

PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

THEINFORMATIONONTHIS

TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

DESIGN INFORMATION

REFERENCE:

EQUIPMENT TYPE:

PrecisionTig225

PAGE

1

OF ___

Front Panel Top

FROM FRONT OF MACHINE UNLESS STATED

PRINTIS FORREFERENCE

DRAWN BY:

Jbarto

G4588

DOCUMENT

1DOCUMENT

OTHERWISE

ONLY. COMPONENTSAND

ENGINEER:

RSamodell

SCALE:

SUBJECT:

MACHINESCHEMATIC

NUMBER:

REVISION:

SOLIDEDGE

CIRCUITRY MAYBE DIFFERENT

APPROVAL

FROMANACTUAL MACHINE.

APPROVED:

Approve

NONE

MATERIAL

NA

PROJECT

G5647

A

DISPOSITION:

DATE:

06/20/2006

NUMBER: CRM38254

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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

PRECISION TIG® 225