Lincoln Electric SVM189-B service manual SchEmaTic cOmplETE machiNE m21240

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G-6	ElEcTrical DiaGramS	G-6
SchEmaTic - cOmplETE machiNE m21240

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M21240	ENGINEERING CONTROLLED	CHANGE DETAIL: UPDATED FOR CE MACHINE.
	MANUFACTURER: No	208/230v retail and industrial require no reconnect of input.
		But, at 208v input, the output is derated to 17.6vdc rated
Two versions of INPUTS		loading.
					Same switch for all machines
180A units: 208/230v retail and industrial
(NEMA) 6-50 plug, 20 amps normal (use 40 super lag) Different cord and plug for both voltages					120 and 230 input = 25A / 250VAC
125A and 140A units: 120v retail and industrial		5	6		Front Center
			S1
(NEMA) 5-15 plug, 20 amps		CB1
		TopRear
	Air flow is back to front						TS2 6
	(all versions of all units)
							FAN
							H1
		Different fan for 120			120V use	P4	J4
		and 230 input		FILTER P.C. BD
		Fan runs all the time
				ON CE MACHINES			3
				ONLY

CONTROL P.C. BOARD PRIMARY SIDE

	CONTROL P.C. BOARD
	SECONDARY SIDE
			TopFront (laysflat)		Different case front and nameplate from retail to industrial versions.
					Industrial version has aluminum extruded lifting handle and a
	Schematic: G4822		Industrial & Retail version :		plastic case back attached to the rear sheet metal back.
			has a potted tray			All measurements made with
			Retail early version :
						respect to Board Common
			are humi-sealed board
						203 at 4-J5 or 1-J3
			Same blank ,different
								Voltage Control
			voltage control parts.
								Continuous Control = 10K ~ 2 to 5 vdc across pot. (industrial versions only)
		Trigger Status	fixed					TAP Control 5 positions	D to A =6.6v ( retail versions only)
									B = 7.6v
+15vdc			burn-back						C = 8.7 v
			control	Voltage Control
							Right Front		F = 9.8 v
				circuit					G = 14.2 v
							CONTROLS ARE		open= 15v
15vdc

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	FAN
	Can not change plug to
	make work with different
	input power levels in the
T1	field (factory use only)
	PCBpower use
BaseFront belowchoke
	3" stack for 125A version
	4" stack for 140 and 180A versions
	Copper for the 180, and
	aluminum for the 125 and 140.

230V use

120V use

1 2 4

H2

FAN

1

TS1

SCR Control

opto

isolation

regulator

BOARD MOUNTED

and isol

Trigger

PWM

Amplifier

Circuits

Control

Left Front

19 - 30 VDC to run

WFS 10K ohms .7v to 9.1v

203 Common

continuous control (no tap control)

solenoid and one WFS

WFS Control

MotorOverload

motor at a time

FET

and Feedback

= spot timer option & wiring

FET Controller bleeder resistor

+15VDC

PWM Control

turns on after trigger release

= spool gun options & wiring

and Overload

for a fixed time.Three 5W,

Protection

51ohm resistors in parallel.

203

= factory connections to control bd.

+15VDC

R

THERMAL LED

203

PM180C (CE) VERSION ONLY

Trigger

J3

J5

Upper left corner of

from gun

9

6

7

10

5

4

1

5

3 6

4 2

CaseFront

when measuring from

2

3 8

1

S26766

pin 2 to ground

P7

-MOTB

MOTB+

P9

harness plug

OPEN = 0V

NDG

SOL

SOL

TMP

TMP

-CAP

CAP+

354B

B544

2B 4B

203B 215B

(timmer option)

CLOSED = 9.8V

+

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EN-170

		different bridge for
		230v input versions
AC	D1	AC
	MAIN	left outer plate
right outer plate	BRIDGE

left andright side

rear area

M21182 harness plug (spool gun option)

TopRear	Solenoid not found in 125A retail units.
	Must order kit and install.
GAS
SOLENOID	12vdc rated 22 ohms
	Pull = 12vdc, Hold = 6vdc
open circuit	overload protected by PC board.
typically equals	Shut off is approx. 1.25A of current draw
board input volts

BOARD POWER

			right front (forwardstud)
19 - 30 VDC to run		CHOKE	ELECTRODE
solenoid and one WFS		belowpcboard
motor at a time		(aluminum)
baserear
C1	59,000mf/50vdc fpr 120v input welders
	120,000mf/50vdc fpr 230v input welders
OUTPUT CAP
	Use Dow Corning		WORK
	joint compound
	(T12837) to		right front (rear stud)
	reconnect cap

when measuring

between pins 1 and 2

OPEN = 15V

CLOSED = 0V

timer option

B543 4B54

2C 4C

J9

1 5

3 6

Control Board

2B

4B

W

203B

B215

B

2C

4C

OPTIONAL

4 2

Trigger Circuit

P1

SPOT TIMER

P8

OPEN = 0V

P.C. BOARD

spool gun

1 5

3 6

4 2

CLOSED = 13.8V

8

7

6

5 4

3

2 1

J1

Schematic M20960-1, -2 (CE VERSION)

wirereel center panel area

GND

TMP

TMP

CAP+

MOTA-

MOTA+

option

SOL

SOL

CAP-

+15VDC

+15VDC

wirereel center panel area

J7

2

9

3

8

6

7

1

10

5

4

spool gun

J8

4 2

Spool-gun/

Logic

1 5

3 6

option

standard gun

Spot Time

CW

switch

2

9

3

8

6

7

1

10

5

4

standard

P5

1 5

3 6

4 2

(option)

Full CCW

P3

shown in std. gun position

= OFF

use plug-in

Adjusts from

200mS to 10S

CCW

Toolless Drive Roll Change Over

Twist lock type drive roll retainer clip.

inner / outer wire slide guide

Load compensated type control for this

MOT-

MOT+

Comes with unit: .025 smooth

motor. Does not tend to stall if liner is

Woundinsideof

WFS Range :

clogged like in older small SP’s.

.035 smooth

Feeder

50 to 500 + ipm

TMP maintransformer

TMP

Motor

.030/.045 knurled

1.5 to 12.5 vdc

(non-replaceable)

Retail version has a plastic

N.C.

gear front housing.

right side

brass

Current Limit to approx 2.5 amps

Industrial version has a metal

bushing

Duty Cycle (retail & industrial):

180 amp unit :

same thermostat on all machines

housing (silver in color).

Gear Box

30% duty 130 amps @ 20 v

30 to 180 amps

OCV RANGE

TRIGGER

OCV = 33 vdc

10 - 35V (INPUT VOLTAGE DEPENDENT)

BACKOF OUTPUT STUD

GUN STANDA RD

140 amp unit :

20% duty 90 amps @ 19.5v

(onCEversiononly)

30 to 140 amps

OCV = 33 vdc

use one or the other but

not both at the same time

125 amp unit :

LEAD COLOR CODE:

COMPONENT VALUE UNITS:

20% duty 90 amps @ 19vdc

B-BLACK

CAPACITOR: MFD/VOLTS

4

W

30 to 125 amps

G-GREEN

RESISTOR: OHMS/WATTS

1

2

W

TRIGGER

SPOOL

OCV = 32 vdc

O-ORANGE

R

+

-

R-RED

2

3

543A

GUN

U-BLUE

CONNECTOR PIN NUMBERS:

4

544A

B

MOTOR

W-WHITE

EX. 12 PIN CONNECTOR

Y-YELLOW

1

2

6

lower casefront

J6

Spool-gun option K2532-1

Same motor control

LABELS:

Magnum 100 SG

circuits, but for a smaller

COMMON

motor

FRAME GROUND

7

12

LATCH

EARTH GROUND

VIEW OF CONNECTOR ON PC BOARD

PROPRIETARY &

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN

GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

CONFIDENTIAL:

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:

SMALL WIRE FEEDER WELDERS

1

1

UNLESS OTHERWISE SPECIFIED TOLERANCE:

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

NONE

PAGE ___ OF ___

EDGE

DRAWN BY:

cstuble

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

SUBJECT:

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

ON ALL ANGLES IS ± .5 OF A DEGREE

IF PRINTED

REVISION:

MATERIAL TOLERANCE ("t") TO AGREE

ENGINEER:

B. STELLER

@ A1 SIZE

NUMBER:

WITH PUBLISHED STANDARDS.

UNITS:

MATERIAL

APPROVAL

PROJECT

CRM39439

REFERENCE:

M21240

D

SOLID

DO NOT SCALE THIS DRAWING

APPROVED:

.

INCH

DISPOSITION: NA

DATE:

6/6/2008

NUMBER:

-

Insight

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

cOmpacT WirE WElDErS