Lincoln Electric SVM188-A service manual Control PC Board Assembly G3409-1

Page 96

TOC

TOC

G-6

ELECTRICAL DIAGRAMS

G-6

CONTROL PC BOARD ASSEMBLY - G3409-1

 

 

1-G3409

ENGINEERING CONTROLLED CHANGE DETAIL: REVISED C2 THRU C4

MANUFACTURER: No

N.C.

N.D.

ITEM

REQ'D

PART NO.

IDENTIFICATION

C1

1

S13490-48

47/160

C2,C3,C4

3

T11577-38K

.02/600

 

 

 

 

C5,C14

2

S13490-39

18/15

C6,C18

2

T11577-26

.1/100

C7

1

S13490-12

10/25

C8

1

T11577-32

.01/200

C9,C21,C22,C23,C24,C26,C27,

11

S16668-5

.022/50

C28,C29,C31,C35

 

 

 

C12

1

S13490-25

4.7/35

C13

1

S13490-63

.47/50

C16

1

S13490-102

.047/100

C17

1

S13490-61

6/150

C19

1

S13490-4

.022/200

C20

1

S13490-40

2.7/50

C25

1

S13490-67

2/50

C30

1

S13490-19

1.8/20

J2

DZ17

J3 C35

R1

 

 

 

R153

 

 

 

SCR1

 

 

 

D5

R123

R5

D37

C22

 

 

 

D38

 

 

 

LED1 LED3

D43

 

R114

 

 

 

 

R78

 

 

Q3

 

 

 

R2

 

 

 

 

 

 

 

R113

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TP1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R100

R99

D33

R103

D32

R14

R110

R109

D35

DZ12

R112

R111

R108

C20

R77

R121

R74

R69

R70

D34

C16

C18

R94

R96

R95

R104

R34

R28

D31

 

 

Q12

 

QU1

 

Q9

 

 

 

 

C19

 

 

 

 

 

 

 

 

 

 

 

 

D1

D2

R3

C1

 

 

 

 

D3

D4

 

 

 

 

 

 

 

 

DZ2DZ1

 

 

C32,C33

2

T11577-58

.0047/3000V

 

 

C34

1

S16668-3

100pF/100

 

 

D1,D2,D3,D4,D7,D9,D10,D19,

10

T12199-2

1N4007

 

 

D20,D21

 

 

 

 

 

D5,D11,D12,D13,D14,D15,D16,

33

T12199-1

1N4004

 

 

D17,D18,D22,D23,D25,

 

 

 

 

 

D26,D28,D29,D30,D31,D32,

 

 

 

 

 

D33,D34,D35,D36,D37,D38,

 

 

 

 

 

D40,D41,D42,D43,D44,D45,D46

 

 

 

 

 

D47,D48

 

 

 

 

 

DZ1

1

T12702-42

1N5353 ZENER DIODE

 

 

 

 

 

 

 

 

DZ2,DZ16

2

T12702-33

1N5347B

 

 

DZ4

1

T12702-27

1N4740A ZENER DIODE

 

 

DZ5

1

T12702-29

1N4744A

 

 

DZ7

1

T12702-19

1N4742A

 

 

DZ9,DZ12

2

T12702-38

1N4751

 

 

DZ13,DZ14,DZ15

3

T12702-30

1N5225B

 

 

DZ17

1

T12702-41

1N5359B ZENER DIODE

 

 

J1

1

S24020-12

HEADER, VERTICAL

N.B.

 

J2

1

S24020-10

HEADER, VERTICAL

 

 

J3

1

S24020-2G

HEADER, VERTICAL, GOLD

 

{

 

 

 

 

 

LED1,LED2,LED3,LED4,LED5,

6

T13657-2

RED LED

 

 

LED6

 

 

 

Return to

Return to Section TOC

Return to Section TOC

Return to

Return to Master TOC

Return to Master TOC

C26

D44

R127

Q1,Q2,Q4,Q8,Q10

5

T12704-36

2N4857

N.B.

R80

 

R39

 

 

 

R159

J1

R63

C27

R79

LED2

R13

R12

D9

C32

R42

D17

TP3

TP2

C8

R157

R156

R125

 

R31

C9

 

 

R155

R117

R30

 

 

 

 

 

 

 

 

 

R71

R73

R120

 

R72

R68

R115

R97

R90

 

 

 

 

 

 

 

 

 

R101

R106

R107

C21

 

R105

 

 

 

 

 

 

X1

 

 

C34

R82

R83

R87

R4

 

R18

R126

R102

 

 

 

D36

R76

C23

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Q11

 

 

 

R89

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LED4

 

LED5

 

R27

D13

R25

R6

 

 

 

 

C6

 

 

 

 

 

 

D47

DZ5

DZ4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D48

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D42

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R23

R91

C31

R138

 

 

X3

 

 

 

 

R134

R137

D25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D22

R55

 

 

 

 

 

 

 

 

C12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R46

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D28

 

 

 

 

 

 

D29

R81

R93

R92

R85

DZ14

C29

R64

 

 

 

 

 

 

 

 

 

Q6

 

 

C25

 

+

 

R86

 

 

 

 

 

 

R62

 

 

 

 

 

 

 

 

 

 

R41

 

 

 

 

 

C14

 

 

D26

 

 

 

 

 

 

 

 

 

 

R61

 

 

R65

 

 

 

 

 

 

 

 

 

 

Q8

 

R88

 

 

R56

 

 

 

 

 

 

 

 

 

 

 

Q10

 

R47

 

 

 

R67

 

 

 

 

 

 

D19

 

 

 

 

 

 

C17

Q3,Q5,Q6,Q11

4

T12704-68

2N4401

Q9,Q12

2

T12704-69

2N4403

QU1

1

T12707-4

2N6027

R1,R2

2

T14900-1

200 20W

R3

1

T14648-17

270 5W

R4,R46

2

S19400-3320

332 1/4W

R5,R98,R123,R136

4

S19400-1503

150K 1/4W

R6,R23,R48,R154

4

S19400-8252

82.5K 1/4W

R7,R22,R24,R29,R44,R45,

7

S19400-1001

1K 1/4W

R102

 

 

 

R8,R72,R78,R79,R88,R97,

8

S19400-2211

2.21K 1/4W

R103,R150

 

 

 

R9,R34,R42,R56,R57,R64,R71

11

S19400-6811

6.81K 1/4W

R96,R125,R156,R157

 

 

 

R10,R11,R155

3

S24000-3300

330/.75W

R12,R61,R93,R106

4

S19400-4752

47.5K 1/4W

R13,R62,R120

3

S19400-4753

475K 1/4W

R14,R124

2

S19400-39R2

39.2 1/4W

R15,R160

2

S19400-2431

2.43K 1/4W

R16,R118

2

S19400-1372

13.7K 1/4W

R17

1

S19400-3011

3.01K 1/4W

N.B.

 

 

 

 

 

R10

 

R11

 

 

 

 

 

R38

C3

D10

R16

 

 

C33

C4

R17

R118

R15

 

 

R160

 

 

D12

D7

 

 

C2

 

LED6

 

 

 

 

R36

R52

D15

C5

D14

R22

R29

D41

R139

R135

R136

R133

R148

R149

R54

 

D21

 

 

 

C24 R98

 

 

 

 

+

 

 

 

 

 

 

D20

 

 

 

 

 

 

 

 

C7

 

 

 

 

D30

R53

 

 

Q1

 

Q2

 

 

 

 

 

 

 

 

 

 

X2

 

 

 

 

 

 

 

D11

R51

 

 

 

R66

D23

 

R58

 

DZ13

R50

 

 

 

Q4

C13

Q5

DZ9

DZ7 R48 R57 C28

 

 

R18,R101

2

T10812-77

20K 1/2W TRIMMER

R19,R58,R65,R81,R105,R133,

7

S19400-1002

10K 1/4W

R134

 

 

 

R20,R21,R50

3

S19400-1003

100K 1/4W

R25,R51,R67,R73,R77,R107,

8

S19400-1004

1M 1/4W

R121,R137

 

 

 

R26,R38

2

T10812-68

1K 1/2W TRIMMER

R27,R37,R41,R76,R91,R114,R115

7

S19400-4751

4.75K

R28,R87,R108

3

S19400-4750

475 1/4W

R30,R104

2

S19400-2670

267 1/4W

R8

R26

DZ16

X4

 

 

 

 

DZ15

D46

R152

 

R124

R7

D45

 

R151

R150

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C30

 

 

 

 

 

 

 

 

 

 

 

 

R44

 

 

 

 

R45

 

 

 

R154

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R9

R37

 

R40

R140

R141

D40

R19

 

R20

R24

R21

 

 

 

 

 

 

 

D18

 

 

 

R43

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DC600 CONTROL

G3409-1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTES

R31,R85,R99,R151

4

S19400-1501

1.5K 1/4W

R36,R94,R126,R127

4

S19400-1502

15K 1/4W

R39,R63,R80

3

T10812-39

50K 1/2W TRIMMER

R40,R83,R89,R139

4

S19400-6812

68.1K 1/4W

R43,R68,R82,R90,R92

5

S19400-2212

22.1K 1/4W

R47,R110,R117

3

S19400-1301

1.3K 1/4W

R52,R141

2

S19400-2213

221K 1/4W

R53,R54,R55,R159

4

S24000-1000

100/.75W

R66

1

S19400-5622

56.2K 1/4W

R69,R100,R109

3

S19400-6810

681 1/4W

R70,R86,R140

3

S19400-1821

1.82K 1/4W

R74

1

S19400-3923

392K 1/4W

R95,R138

2

S19400-3322

33.2K 1/4W

R111

1

S19400-47R5

47.5 1/4W

R112

1

S19400-1000

100 1/4W

R113

1

T12300-68

250 10W

R135

1

S19400-3922

39.2K 1/4W

R148,R149

2

S19400-2432

24.3K 1/4W

EN-170

N.B. DO NOT COAT WITH ENCAPSULATION MATERIAL.

N.C. O .30 AREA TO BE FREE OF ENCAPSULATION MATERIAL BOTH SIDES OF BOARD (TOTAL 5 PLACES)

N.D. RESISTOR FEET MUST BE FLAT AGAINST BOARD. APPLY ITEM 2 TO R1 AND R2 RESISTOR FEET TO ANCHOR

TO BOARD.

1

CAPACITORS = MFD/VOLTS

RESISTORS = OHMS

 

ITEM

REQ'D

PART NO.

IDENTIFICATION

 

1

1

G3409-C

CONTROL P.C.

 

 

 

BOARD BLANK

 

 

 

 

N.D.

2

.04oz.

E2861

RTV COATING

R152

1

S19400-2001

2.0K 1/4W

R153

1

T14648-23

20 5W

SCR1

1

S15161-19

8A.,400V. SCR

TP1

1

T13640-11

45J

TP2,TP3

2

T13640-18

160J

X1

1

S15128-16

IC,LT1014,LIN.INT. CIR.

X2,X3

2

S15128-4

IC,LM224,OP-AMP

X4

1

S15128-10

IC,431,VOLTAGE REF.

FOR PARTS ORDERS:

SEAL TRIMMERS WITH A DROP OF E4018.

AND INCLUDE T11590-90.

PROPRIETARY & CONFIDENTIAL: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.

MANUFACTURING TOLERANCE PER E2056

CONTROL: CLEVELAND

SCALE:

EQUIPMENT TYPE:

 

 

DC 600

 

1

1

UNLESS OTHERWISE SPECIFIED TOLERANCE:

 

 

 

ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)

DRAWN BY:

fivory

-

 

 

 

 

 

PAGE ___ OF ___

ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)

SUBJECT:

 

CONTROL PC BOARD ASSEMBLY

DOCUMENT

DOCUMENT

IF PRINTED

 

ON ALL ANGLES IS ± .5 OF A DEGREE

 

 

 

REVISION:

 

 

@ A1 SIZE

 

NUMBER:

MATERIAL TOLERANCE ("t") TO AGREE

ENGINEER:

 

 

 

 

 

 

 

 

G3409-1

C

WITH PUBLISHED STANDARDS.

 

 

UNITS:

MATERIAL

 

APPROVAL

 

PROJECT

REFERENCE:

DO NOT SCALE THIS DRAWING

APPROVED:

-

INCH

DISPOSITION:

UF

DATE:

11-16-2007

NUMBER: CRM39073

G1504-4

Insight

SOLID EDGE

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.

Page 95 Page 97
Image 96
Page 95 Page 97
Contents DC-600 ISAFETYi Safety Electric Shock can killFumes and Gases Can be dangerousPowered equipment For ElectricallyPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications DC-600Safety Precautions Electric Shock can KillSelect Proper Location Fuse and Wire Sizes Electrical Input ConnectionsGround Connection Reconnect Procedure Connection for Highest Rating Plate VOLTAGE, 50 or 60 HZConnection for 440 Volts 50 or 60 HZ V 60HZ See Machine Rating Plate for Required Input Supply Voltage Output Connections ELECTRODE, Work and #21 LeadConnections Auxiliary Power Control Connections Terminal Strip 1 T.S.1Terminal Strip 2 T.S.2 DC-600 Table of Contents Operation Section Safety Precautions OperationDesign Features Advantages General DescriptionRecommended Processes and Equipment Meanings of Graphical Symbols on Case Front OFF Input PowerWelding Capability Output Control Output Voltage CurrentMeaning of Graphical Symbol for Ground CON- Nection Controls and SettingsAuxiliary Power in MS-RECEPTACLE OVERLOAD, OVERCURRENT, and Fault ProtectionRemote Control of Machine Operation Welding Procedure RecommendationsOperating Steps NA-3 Automatic Wire Feeder RemoteLN-8 or LN-9 SEMI-AUTOMATIC Wire Feeder LN-7 and Other Constant Wire FeedersDC-600 Table of Contents Accessories Section Accessories Wire Feeders and TractorsFactory or Field Installed Options Field Installed OptionsFigure C.2 MULTI-PROCESS Switch Cable Connections Accessories Table of Contents Maintenance Section Maintenance Safety Precautions Electric Shock can KillRoutine and Periodic Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Input Circuit and Main TRANS- FormerFiring CIRCUIT, Control CIR- Cuit and Rectification RectificationFiring Board Thermal Protection SCR Operation DC-600 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair PC Board Troubleshooting ProceduresControl Feeder. See Protective Devices Check all three phase input Output Control J1,Pin2. See Wiring Diagram Wiring Diagram PC Board Troubleshooting Guide Test DescriptionMaterials Needed PC Board Troubleshooting Guide Control Board Figure F.2 Control Board LEDsDC-600 Internal Trigger Circuit Test Procedure Internal Trigger Circuit TestInternal Trigger Circuit Test 75 76DC-600 Firing Board Test Firing Board Test Control Board Test Control Board Test Figure F.7 Control BoardMain Transformer Voltage Test Main Transformer Voltage Test Figure F.8 Input Contactor and Reconnect PanelFigure F.9 Transformer Secondaries Main Transformer Voltage Test Control Transformer Test Procedure Control Transformer TestInput Contactor Test Input Contactor Test Voltage TestSCR Bridge Test Anode Cathode Remove Insulating Paint SCR Bridge TestActive Test Scope Settings Maximum Output Setting no Load Minimum Output Setting no Load 35TROUBLESHOOTING and REPAIRF-35 2V/Div Volts DC-600 Input Contactor CR1 CLEANING/REPLACEMENT Input Contactor CLEANING/REPLACEMENT Procedure Cleaning ProcedureContactor Replacement Procedure SCR Rectifier Bridge Removal and Replacement Procedure 42TROUBLESHOOTING and REPAIRF-42 Removal and Replacement ProcedureRemoval Procedure SCR Rectifier BridgeReplacement Procedure Insulator Lock Washer Plain Washer Output Snubber LeadDC-600 Main Transformer and Choke Removal and Replacement Removal and Replacement Main Transformer and ChokeRemoval Procedure Weld Input Idle Amps and Watts Maximum Open Circuit VoltagesDC-600 Table of Contents Diagram Section Electrical Diagrams Wiring Diagram 230/460/575 Volt Machines G3506-1 Schematic Complete Machine G3575 Schematic Control PC Board G3408-1 Control PC Board Assembly G3409-1 Schematic Firing PC Board G3741-1
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