Lincoln Electric SVM189-B service manual Thermostat TMP FAN TS1, M20410-3 a COmpacT WirE WElDErS

Page 107

Section TOC

Master TOC

G-5

ElEcTrical DiaGramS

G-5

WiriNG DiaGram -cOmplETE machiNE - cODE 11442 ONly - (m20410-3)

 

 

WIRING DIAGRAM

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WARNING

HIGH VOLTAGE can kill

Do not operate with covers removed.

Disconnect input power by unplugging power cord before servicing.

Do not touch electrically live parts

Only qualified persons should install, use or service this machine.

 

SPOT TIMER J1 M20961-2

 

 

 

 

WORK

1 2 3 4 5 6 7 8

 

 

 

P5

 

1 2 3 4 5

6

 

N.D.

 

 

 

 

J5

 

215B 203B W 4B 2B

543B

2C

544B

4C

N.B.

4C 2C B

 

 

 

 

 

 

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FILTER PCB

6A

 

 

 

 

 

1A

 

BLUE LEAD

 

 

 

 

 

V

 

U

 

5

 

BROWN

CB1

S1

GND

LEAD

 

 

 

 

 

1

6

THERMAL

LED

P6

J6

 

1

 

2 3

 

4

GUN

WIRE FEED MOTOR

MOT+ MOT-

2A 4A 543A 544A

TO EARTH

N.A.

 

N.A.

GROUND

 

X1

CAPACITOR

PER NATIONAL,

 

 

OUTPUT

TS2

L13344-1

 

6

 

CHOKE

X1

H1

FAN

CONTROL BOARD

H1

 

R2

TOC

TOC

LOCAL OR OTHER

 

D1

 

APPLICABLE

 

 

ELECTRICAL CODES.

 

 

 

(GREEN/YELLOW LEAD)

X2

N.A.

C1

 

 

 

 

 

TRANS- FORMER

T1

1

 

2

J4

3

 

4

 

R1

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FAN

 

 

FAN

FAN

 

 

SOL

SOL

CAP-

CAP+

 

 

GAS

X2 H2

THERMOSTAT

TMP

H2

FAN

1

TS1

TMP

 

 

 

 

J3

 

 

 

 

1

2

3

4

5

6

7

8

9 10

CAP- GND SOL MOT+ MOT- TMP TMP

 

SOL CAP+

 

 

J5

 

 

 

1

2

3

4

5

6

543B 215B

2B 203B 544B

4B

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SOLENOID

NOTES:

N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND (DOW CORNING 340) WHEN REATTACHING.

N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDING. N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE

OF CONNECTORS.

N.D. PIN NEAREST THE FLAT EDGE OF LED LENS ALIGNS WITH WHITE LEAD OF LED SOCKET.

LOCATED IN TRANSFORMER

 

 

 

 

 

 

 

 

544A

543A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P3 N.C.

J6 N.C.

P4, N.C.

P5 N.C.

1

5

1

1

2

1

2

3

2

3

4

 

 

 

 

 

 

 

 

 

2

3

3

4

4

5

6

6

7

8

9

10

4

 

 

 

 

 

LATCH

 

 

 

 

 

 

 

 

 

ELECTRICAL SYMBOLS PER E1537

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M20410-3 A

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

cOmpacT WirE WElDErS

Image 107
Contents SVM189-B Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill ARC Rays can burn Iii Welding CuttingFor Electrically Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications InstallationTilting Safety PrecautionsSelect Suitable Location StackingIdentify and Locate Components Table of Contents Operation Section Wear eye, ear and body protec- tion OperationProduct Description Product Capabilities Common Welding AbbreviationsSee Figure B.2 Controls and SettingsSee Figure B.1 Drive Roll Tension Thumbscrew Turning See Figure B.3Number Part Number Wire Diameter Drive Roll Drive Roll Part Inner Wire GuideItems Needed for Flux Cored Welding Setting UP and Making a FLUX-CORED WeldMachine Load Wire SpoolConnect Leads and Cables on Figure B.9 025 MIG Conversion Kit K2526-1Shielding GAS Install Shielding GASConnect Leads and Cables on the Machine 11OPERATIONDo not Remove or Conceal Warning Labels 12OPERATIONFigure B.20 Compact Wire Welders Table of Contents Accessories Section K2377-1 Small Canvas Cover AccessoriesK2525-1 Spot Timer Kit K2532-1 Magnum 100SG Spool GunK520-Utility Cart K2275-1 Welding Cart Unpacking the Spool GUN Technical Specifications Magnum 100SG Spool GUN K2532-1Locating Spool GUN Components Features Safety PrecautionsFigure C.3 Assembly of Items Inside the Magnum Spool GUNSpool GUN Safety Precautions Welding MachinesRecommended Welding Machines Open the Machine Spool GUN / Wire Drive Selector Switch InstallationDisconnect input power from the machine 11.C. Connect harness P8 6-pin to board J5 6- pin Electrical Connections11.B. Connect P5 6-pin to harness J8 6-pin 544A 543A If Machine does have Optional Spot Timer .A. thru 12.DRE-ASSEMBLE Machine AS Follows Mounting the SwitchPreparing the Spool GUN ACCESSORIESC-13Disconnect input power to the machine Routine Welding Machine PreparationFigure C.5 Loading Aluminum WireFigure C.11 Figure C.17 Connecting the GUN to the Welding MachineTable of Contents Maintenance Section Routine Maintenance MaintenanceMaintenance Safety Precautions For Magnum 100L GUN GUN and Cable MaintenanceOverload Protection Liner trim length Changing LinerGUN Handle Parts Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationInput Line VOLTAGE, FAN Motor & Main Transformer Figure E.3 Input Power CircuitsFigure E.4 Output Circuits Output CONTROL, Rectification & Voltage FeedbackFigure E.5 TRIGGER, GAS Solenoid & Wire Drive TRIGGER, GAS Solenoid and Wire DriveFigure E.6 SCR Operation SCR OperationElectronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Materials Needed Case Cover Removal and Replacement ProcedureTest Description Figure F.1 Case Removal ProcedureGAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test MOT-MOT+ Test ProcedureMain Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Volts 10Volts 20ms Scope SettingsTypical Output Voltage Waveform Machine Loaded Abnormal Open Circuit Voltage Waveform Control Board Removal and Replacement Procedure See Figure F.7 Nameplate Control Knob Compact Wire Welders Power Module Removal and Replacement Procedure Viewed from Rear of Machine Center Panel PolarityPanel CenterPanelScrews OutputStuds Compact Wire Welders Misc. Hand Tools Dow Corning Fine Steel Wool See Figure F.12 Dow Corning Figure F.12 DOW Corning Application Areas Transformer Compact Wire Welders Wire Drive Motor Removal and Replacement Procedure Lincolnelectric Phillips Mounting Screws Compact Wire Welders FAN Motor Assembly Removal and Replacement Procedure Viewed from Rear of Machine Center Panel CenterPanelScrews Locking Tabs Fan Open Circuit Voltage Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Retest After Repair 140 AMP UnitsTroubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section COmpacT WirE WElDErS Wiring DiagramSpool GUN Interface Wiring Diagram Wiring Diagram Thermostat TMP FAN TS1 M20410-3 a COmpacT WirE WElDErSSchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24