Lincoln Electric SVM169-A service manual Schematic Entire Machine G4588

G-3	ELECTRICAL DIAGRAMS	G-3
SCHEMATIC - ENTIRE MACHINE - (G4588)

G4588	ENGINEERING CONTROLLED			CHANGE DETAIL: RELEASED FROM X A.02
	MANUFACTURER:	No			DISPLAY PRESET AT IDLE			+15V	+5V +24V		5J2
					ACTUAL AMP WHEN WELDING
						NO HOLD FUNCTION					6J2
											3J2
						3 DIGIT	FIRE_SCR		SCR		8J2
											2J2
						METER
								GATING & SNUBBER			1J2
						(DISP1)
											4J2
			OUTPUT CONTROL &
						+5V					7J2
			MODE SETTINGS ARE
			MEMORIZED AT POWER					+15V		PHASE
			- DOWN AND RECALLED			METER
			AT POWER - UP			INTERFACE

SCR1 GATE	G1
SCR2 GATE
	G2
SCR3 GATE	G3
SCR4 GATE	G4
SCR3,SCR2 CATHODE 218
SCR1 CATHODE	217
SCR4 CATHODE	216
SCR1,SCR4 ANODE	220
BACKGROUND AC INPUT

				216A	Top rear		Center of machine			Attached to Power Switch
					SEE CONNECTION DETAIL				BYPASS ASSEMBLY
		216
									C1
	G4	4	G4
					15 - 20 OHM		MAIN
	G3	3	G3	SCR4
Rear of machine attached to					SCR3 GATE-CATHODE	TRANSFORMER			.0047/ 250VAC
	G2	2	G2		RESISTANCE TYP.		T1
base, below fan
	220				MAIN SCR		H3
								HIGH
				-	RECTIFIER +				POWER SWITCH
R4	220A
				D1					C2
										L1
12/100 EACH									W
			FREE WHEELING DIODE SCR1							PLUG
		1			SCR2	X2	H2	LOW
R5	G1			G1
	217								S1	INPUT
BACKGROUND RESISTORS	218					80 VAC
	218A

POWER-UP SEQUENCE

METER AND MODE DISPLAY THE PREVIOUS OUTPUT CONTROL AND MODE SETTINGS. FAN RUNS FOR 5 SECONDS. IF MODE IS TIG, GAS FLOWS FOR A TIME

+5Vref

+15V

BG

MICRO-START

CIRCUIT

(DISABLED IN STICK)

11J3

10J3

9J3

12J3

BACKGROUND ( - )	216A
	245
BACKGROUND ( + )
	244
BACKGROUND AC INPUT
	240

	R 222(-)	SHUNT		X1	H1	L2
IN-LINE CONNECTOR J7					B
	W 221(+)	400A/200mV		Right Side of SCR Bridge
Inside sleeving at top left side of				Rectifier. Top of Machine
			POS		RECONNECT IS DONE AT	G
Main Rectifier				behind Choke.
		AC
					POWER SWITCH

SET BY THE POSTFLOW KNOB. OUTPUT IS HOT IF MODE IS STICK. IN TIG MODE OUTPUT IS COLD UNTIL TRIGGER IS CLOSED

TYPICAL OCV

65V IN DC

75V IN AC

METER, ENCODER, SWITCH, LEDs,

S1

MODE
		TOGGLE BETWEEN TIG &
		STICK.
		HI-FREQ, GAS, BALANCE
		CONTROL, PULSE
		FREQUENCY, &
+5Vref		MICRO-START CIRCUIT
		ARE DISABLED IN STICK
		A
	C
OUTPUT CONTROL
		B
(ENCODER)

PHASE_FIRE

Iarc

SETPOINT

+15V -15V

OUTPUT REGULATOR

+24V +5Vref

1J1

2J1

TOROID
	SHUNT (+)	W 221
	SHUNT (-)	R 222

CURRENT FEEDBACK

DETERMINE IF HI-FREQ IS

CONTINUOUS OR START

ONLY, MIN. CURRENT, AND

DC					Right side of Machine				Front Panel Left side
	OUTPUT
		L1			above Choke Coil.
									VOLTAGE RECONNECTION
	INDUCTOR
			Gang D
TWISTED PAIRS				Gang C		Gang B			SEE RATING PLATE FOR SPECIFIC VOLTAGES
				Gang G
	240								230 or 400-415 or 575 VOLT CONNECTION
		CBW	DC+			DC+
On top of Main					AC		AC		(AS SHOWN & AS SHIPPED FROM FACTORY)
		Gang A	DC-			DC-
Transformer					CBW				H1 and H3 (HIGH) TO POWER SWITCH.
				CBW		CBW	CBW	CBW = CONNECTED
		CBW-		Gang H				BY SWITC H	H2 NOT CONNECTED; INSULATE.
Lower left side of						AC		THESE CONNECTIONS
			AC	CBW				ARE MASE BY POLARITY
Polarity Switch							DC+	SWITCH, THEY ARE NOT	208 or 380 or 460 VOLT CONNECTION
		DC	DC+			DC-		PHYSICAL LEADS

AND ALL POTENTIOMETERS ARE MOUNTED ON PC BOARD

BALANCE CONTROL IS

DISABLED IN STICK AND

DC TIG

PULSE FREQUENCY IS

DISABLED IN STICK

5 - 185A IN DC		A1		DET_REM
7 - 185A IN AC				REM_SENSE
	+5Vref			REM_POT
			From Auto Loc/Rem
MAX. PENETRATION			CW
BALANCE		R1
MAX. CLEANING			10K
AUTO
	+5Vref
20 HZ			CW
PULSE FREQUENCY		R2
0.1 HZ			10K
OFF

Polling signal

Hi = Local

Remote control

DATA

SCLK

XRES

		5J3
AC/DC	INTERFACE
		6J3
THERMOSTAT		2J3
	INTERFACE
		1J3
	+24V +5Vref
		1J6
		2J6
		3J6
	+5Vref	4J6

BALANCE CONTROL

MICRO SWITCH INPUT

THERMOSTAT INPUT

DISABLE OUTPUT & HI-FREQ IF THERMOSTAT OPEN

PROGRAMMING CONNECTOR FOR SOFTWARE UPGRADE

311	311	CBW	CBW			H1 and H2 (LOW) TO POWER SWITCH.
312	CLOSED	Gang E	Gang F	S2		H3 NOT CONNECTED; INSULATE.
	IN DC	N.C.		POLARITY SWITCH
						C1 AND C2 MUST ALWAYS BE CONNECTED
314	312			Front Panel Center
				SEE CONNECTION DETAIL		ACROSS TRANSFORMER PRIMARIES
313	MICRO SWITCH CLOSED IN DC
	OPEN IN AC	284	285
CHOKE TSTAT				Inside hi-freq box on
				right side of machine
(NORMALLY CLOSED				near front
OPEN AT 135C TYP.)
		BYPASS/STABILIZER				TO0 COPPER BAR
			PCB					SHUNT
									W 222
		(SCHEMATIC S22530)
		(PCB AS'BLY L10121-1)							R 222
				220	220A	218	218A		ALUMINUM BAR
		284A	285A						D1
			100/100

+5Vref

R2 SCR1 SCR2 SCR3 SCR4

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30 S

POSTFLOW

1 S

LED 1 STICK (RED)

CW
R3
10K	MICRO-	PHASE
	PROCESSOR	TRIGGER
	+5V

LED INTERFACE

LED 3 TIG

(GREEN)

+15V

115V CIRCUIT

TRIAC & OPTO-TRIAC

DRIVER

4J4

1J4

3J4

2J4

Left side of Machine
near front
HI-FREQ (115VAC)		236
GAS (115VAC)
	235
115VAC IN	232
FAN (115VAC) 260

		284B
		HOLDING RESISTORS
		285B
In Front of main	Inside hi-freq box on	R1
transformer,	right side of machine
Attached to Base	near front	100/100

HI-FREQ OFF IN STICK

START ONLY IN DC TIG

CONTINUOUS IN AC TIG

	HIGHVOLTAGE		ARC STARTER ASSEMBLY
	TRANSFORMER
200/100	T2		238
R3		L2	C3	Mounted to front side
	237			of hi-freq box on
236B	S			right side of machine
C4		12.5 OHM TYP.	.0015/12KV	near front.
15/250 5.5 OHMS

Right side of machine, front of gas solenoid, attached to Base

								DC
SCR
HEATSINK								(
			+)(					_)
	G1	G2			G3		G4
FARTHEST LEFT	217			POS	216 216A	X2	FARTHEST RIGHT SCR
							(VIEWED FROM
SCR (VIEWED		BOTTOM
							FRONT)
								7 GA. FLEX LEAD
FROM FRONT)		COPPER
		BAR
					6 GA. FLEX LEADS
	AC				DC
	Gang D					Gang A

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14.5 KOHMS SPARK

NEXT TO MODE SWITCH NEXT TO MODE SWITCH

TYP. HIGH FREQ. T3

LED 4

AUT0BALANCE

(GREEN)

NEXT TO BALANCE POT.

OFF IN STICK AND DC TIG

DET REM	REM SENSE	REM POT	TO MICRO
			PROCESSSOR

AUTO	+15V
LOCAL/
REMOTE

LED 5

FREQUENCY

(GREEN)

NEXT TO PULSE

FREQUENCY POT.

OFF IN STICK, BLINKS AT

FREQUENCY RATE

+5V

TRIGGER

INTERFACE

LED 2

THERMAL (YELLOW)

NEXT TO METER

TRIGGER

TO MICRO PROCESSOR

		TO MICRO PROCESSOR
		AND SCR GATING
	LED 6	PHASE
	THERMAL
	(YELLOW)
	NEXT TO METER
	TWO THERMAL LEDs TO
	LIGHT THROUGH	PHASE
	BACK-LIT THERMAL
		DETECTOR
	SYMBOL
	+5V
+24V
+15V		7J3
+5V
	POWER SUPPLY
+5Vref
		8J3
-15V

DO NOT REVERSE LEADS 209 & 210, USED FOR SCR PHASE TIMING

209 X5 18VAC

CONTROL BOARD SUPPLY

210 X6

	115V	TYP.	12.5 OHM TYP.	GAP .020	TRANSFORMER
		5000V	L3
		F
231A					Center front
		HI-FREQ CIRCUIT			WORK
				239
Rear Panel	GAS				ELECTRODE
	SOLENOID				Right front
Right Side
	(115VAC)
235	SV1	231
232					232
		435 OHMS TYP.

231

T1

				OUTPUT INDUCTOR
240
			Gang F		285
	Rear gang H
POS					UNUSED TERMINAL
		Gang E		Rear gang G	311
					MICRO SWITCH
					X1
284	Gang C			gang B	312
					GANG LOCATIONS ARE
					VIEWED FROM REAR OF
				MOUNTING HOLE	SWITCH
		POLARITY SWITCH		MICRO SWITCH
	AC	A-C, D-E, B-F		OPEN

AUTO LOCAL/REMOTE

STICK MODE: ALWAYS LOCAL

CONTROL -15V

T1

X7

115VAC	FAN RUNS FOR 5 S AT POWER-UP
		115VAC

DC+	B-D, C-E, A-F, G-H	CLOSED
DC-	B-D, A-E, C-F, G-H	CLOSED

EN-170

TIG MODE: REMOTE IF PLUGGED LOCAL IF UNPLUGGED

RECEPTACLE

Left front

	U	A
10K	N	B

RC

B D

W E

F

TOROID

TM

OPTIONAL AMPTROL REMOTE

CONTROL AND ARC START SWITCH

HI-FREQ BYPASS CONNECTION

FROM BOTTOM LEFT

MOUNTING HOLE TO SHEET

METAL

	J1	2 PIN			4J3
RF				J2	3J3
CHOKES
1J5	4 PIN (WHITE)		+15V	8 PIN
			(GREEN)
	PROGRAMMING	MICRO-PROCESSOR
3J5	CONNECTOR
		X1
			MODE
2J5	J6			J3
			+5V
	OUTPUT CONTROL
5J5	+5Vref	SOFTWARE	(GREEN)
		VERSION LABEL
	(GREEN)
				12 PIN
6J5
	POSTFLOW	FREQUENCY	BALANCE	J4
		J5 6 PIN		4 PIN
	CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT
	HI-FREQ BYPASS	(VIEWED FROM COMPONENT SIDE)		CONTROL PC BOARD
	CONNECTION
					SCHEMATIC G4550-

ASSEMBLY G4551-

201 X3

18VAC

TRIGGER CIRCUIT

204 X4

AUX. WINDINGS OF MAIN TRANSFORMER T1

Front Panel Top

12 OHMS TYP.	STOPS AT IDLE 8 MINUTES
		X8
	AFTER WELDING.
FAN
260	TYP. RPM:
	1600 RPM 60Hz	Right rear side of Main
	1340 RPM 50Hz
		Transformer
Right front side of	Between SCR Bridge halves
	behind choke.
Main Transformer

SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL
LEAD COLOR CODE:	COMPONENT VALUE UNITS:
B-BLACK OR GRAY	CAPACITOR: MFD/VOLTS
G-GREEN	RESISTOR: OHMS/WATTS
O-ORANGE
R-RED OR PINK	CONNECTOR PIN NUMBERS:
U-BLUE
W-WHITE	EX. 12 PIN CONNECTOR
Y-YELLOW	1	2	6
LABELS:
COMMON
	7		12
FRAME GROUND			LATCH
EARTH GROUND	VIEW OF CONNECTOR ON PC BOARD

			THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
	PROPRIETARY & CONFIDENTIAL:
COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED			TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
	THE INFORMATION ON THIS	DESIGN INFORMATION		REFERENCE:		Precision Tig 185		PAGE 1	OF 1
FROM FRONT OF MACHINE UNLESS STATED	PRINT IS FOR REFERENCE			Reference	EQUIPMENT TYPE:
		DRAWN BY:	Jbarto					DOCUMENT	DOCUMENT
OTHERWISE	ONLY. COMPONENTS AND				SUBJECT:	MACHINE SCHEMATIC
				SCALE:				NUMBER:	REVISION:
	CIRCUITRY MAY BE DIFFERENT	ENGINEER:	TNguyen		MATERIAL	APPROVAL	PROJECT	G4588	A
	FROM AN ACTUAL MACHINE.	APPROVED:	Approve	NONE	DISPOSITION: UF	DATE: 02/20/2004	NUMBER: CRM36191

SOLID EDGE

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

PRECISION TIG 185