Lincoln Electric SVM166-A service manual Schematic Entire Machine G4198-1

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G-3

SCHEMATIC - ENTIRE MACHINE - (G4198-1)

1-G4198	ENGINEERING CONTROLLED RELEASED A.03 FROM "X"
	MANUFACTURER:	No

General Notes:

ξCodes 10864,11033 & 11035 do not support the high/low speed gear change. Only the high speed (1.8" diameter) gear may be used.

Error	Description	Cause and Remedy
Code
Err 0081	Average	The wire drive has exceeded the current rating:
	motor Over-	ƒ 10 amps for 0.5 seconds or
	current	ƒ 3.5 amps for 10 seconds.
	shutdown	Wait 45 seconds for the error to reset.
		Reduce the current load on the motor by:
		ƒ Verifying the electrode slides easily through the
		liner of the gun.
		ƒ Reduce the spindle brake resistance.
		ƒ Reduce the amount of tension in the wire drive

ELECTRICAL DIAGRAMS										G-3
			CAVITY NUMBERING SEQUENCE						GENERAL INFORMATION
			(COMPONENT SIDE OF P.C. BOARD)						ELECTRICAL SYMBOLS PER E1537
LN-15 ACROSS THE ARC MODEL
			3	4	4	6	5	8	W -	WHITE
			1	2	1	3	1	4	COLOR CODE
			J81,J82	J83,J88		J2,J47,J84			B -	BLACK
		Gas Solenoid	J1,J86		J85,J87				R -	RED
	Wire Drive		1	5		1	8		U -	BLUE
Boost Board		Circuit	6	10		9	16
	Circuit

	pressure arm.
	ƒ Use only Lincoln electrodes.
Err 0086 Trigger	The voltage into the feed head board exceeds 150
lockout	VDC.

Located on the right

Schematic M19752 side of the control box.

- INPUT

+ Vin

INPUT VOLTAGE MONITOR

(MOTOR FETS ARE BOTH

OFF WHEN INPUT VOLTAGE + MOTOR DROPS BELOW 20V)

+5V

MOTOR SUPPLY VOLTAGE MONITOR

FEED HEAD CONTROL

P.C. BOARD

Schematic G3883

Some inverters and choppers may have spikes on the

output that charge the capacitors inside the LN-15

beyond limits. If this error occurs, lower the OCV of

the power source. It may be likely that a different

power source is required.

WFS Display	Voltage Display
Voltage LED

Positive

Common		COM
to '-' input	ISOLATION
enabling	SWITCH (FET)
circuit		J47
		8
		7
Boost	COM	6	502
Circuit		5	501
		4	POS
		3	NEG
COM		2
		1

80VDC or weld voltage, whichever is higher

COM

FEEDHEAD SUPPLY

MOTOR SUPPLY

COM

J81

1

2

5023

5014

J83

POS 6

J82

NEG3

4

1

2

	+Vin
		POWER
J81-4	+ motor	SUPPLY
J82-4
J83-5
		+
J83-6	1200uF	Vin
		-
J81-3
J82-3
	COM
	+ MOTOR

+15V

-15V

-5V

+5V(TACH)

+5V

COM

ARC VOLTAGE

FEEDBACK

IN PUT

1M	J88	67
	4

78k

+	40k
-
	78k	21A
	1
	1M

Work

Electrode Voltage

		SPI DISPLAY	L11757-1
		YELLOW
RED	RED	RED	RED
		Not Used

The display board communicates to the feedhead board through the SPI bus. Only thepower supply signals can be monitored during servicing.

The WFS always shows the present WFS.

The voltage display shows the voltage while welding, plus holds the voltage for 5 seconds after the weld. It shows "-- -" when idle. A negative "-" sign will automatically be shown when welding with reverse polarity procedures.

All the LEDs, including those not used, will briefly light on power up. The LED's not used are visible behind the nameplate when lit.

Voltage Feedback

ON/OFF

SWITCH

526B

526C

Input

Power

Circuit

TOROID

67

BOOST BOARD

	The boost board takes the weld voltage
	and boosts it to 80VDC for the rest of
	the LN-15. There are two supplies on
	the boost board, one for the motor and
	the other for the feedhead board. With
	two supplies, even if the motor supply
	should droop because of heavy loads,
	power to the feed head board is not
	affected.
	The rectifier allows the LN-15 to
	be powered either electrode
21A	positive or electrode negative
	without any switches for the
	customer to set.

Located under the cover
in the control box ably.
BRIDGE
RECTIFIER	526
526B
+	526C
-
21B
567
FEEDPLATE
TOROID

+INPUT

-INPUT

AVERAGE

DRIVE

CURRENT

PWM

LIMITING

526A

527A

MOTOR

CPLD

CONTROL

TOROID

BRAKE

PULSE BY PULSE

TOROID

PEAK CURRENT

LIMIT (27 AMPS)

J2

J83

Motor +

8

550

1

Motor -

7

551

2

+15V

552

Gas Solenoid + 552

3

This large MOV

Gas Solenoid - 553

4

absorbs the

6.5 VDC when gas flowing

see power

5

inductive energy in

supply section

Coil measures 21 ohms

6

COM

the weld cables and

molex

MICRO

power source when

W B

Measure B to U

Located under the cover at

gas

the contactor

120 Hz @ 50 in/min

553

CONTROLLER

the rear of the feeder

solenoid

opens.

1.6 kHz @ 700 in/min

+5V (TACH)

150V, 300J

GAS

15 VDC Tach Supply

563

J84

PWM control

MOTOR /

1

SOLENOID

1

ckts

GEARBOX

2

2

2.6 VDC @ 50 in/min

Tach Signal

3

TACH INPUT

R

3

562

27.4 VDC @ 700 in/min

7

TACH.

MOV ASBLY

8 sec average Current

U

4

Tach COM

561

4

limit = 3.5 Amps

Located in the control box next

B

5

to the Feedhead board.

(Limit is software set)

Wiper to COM

COM

TOROID

6

WIRE FEED SPEED 10K Ohms

5 VDC at 700 ipm

WFS

Located behind the insulating

0 VDC at 50 ipm

J84

ANALOG

Access this connector

CONTROL

3-1/2 turns

577 POT Supply

INPUT

wire drive panel. Remove the

8

COM

by removing the wire

POTENTIOMETER

1

576

Wiper

6

A=1

wire drive ably ot gain access.

drive asbly.

2

+5V

Located on the case

3

575

COM

15- 110 VDC

5

A=1

front. Remove the wire

MOV ASBLY

drive asbly to gain

INTERNAL

527

Not a PC board; no schematic.

access.

GND-B

N.C.

2k

SWITCH

EXTERNAL

+15V

COM

2k

INPUTS

SWITCH

Located behind the wire drive

INPUTS

4.75k

2k

COM

1M ohms

GND-A

500

COM

4.75k

500

500

320V, 150J

320V, 150J

4.75k

4.75k

For programming at LECo factory only.

+15V

4.75k

4.75k

Not field reprogrammable.

J87

+Vin

J83 5

J88

PWM5

CONTROL

FOR

CONTACTOR

4.5 A PEAK CURRENT LIMIT

SPI

CKTS

J86

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	15-110 VDC from
	welding power
	source
	All LED’s light
	briefly
	Show CC/CV
	mode and HI/LO
	gear
GAS PURGE SWITCH DEPRESSED
		GAS PURGE SWITCH OFF

Enter Press and

Spin Mode

	Idle:
	Display WFS, “---”
	Wire Drive: OFF
EN-170	Gas Solenoid: OFF

.0047/.005 mfd,

GND-C

5

6

7

8

9 10 11

13 14 15

1612

4

1

2

3 J85

1

2 3 4 5 6

7

8 9 10 11 12 13 14 15

16

1

2

3

4

5

6

7

8

9 10

567A

1400VDC

The contactor is

558

located behind

512

554

555

COM

+ 15V

Master In Slave Out

Master Out Slave In COM

Bussbar from input

the glastic panel

559

Gas Purge

556

+ 5V

+ 15 VDC SPI

Chip Select 1

Chip Select 2

Chip Select 3

Serial Clock

21

next to the motor.

2 Step

2 Step

Trigger Supply

Trigger

+ 5 VDC SPI

Slave Select

stud to contactor

15 VDC

Cold Inch

Trigger Input

TRIGGER

83% Input

15 VDC when Trigger and 83%

Switch Open

CONNECTOR

587

589

Input

9 VDC when Trigger Open, 83%

Located on the lower left

Switch Closed

0 VDC when Trigger Closed

of the front of the case.

J3

GUN

Voltage

CONTACTOR

556

A

TRIGGER

300A 60%

2-STEP

554

B

250A 100%

2 Step Trigger

TRIGGER

C

INPUT

Protection

Coil measures 4.4 ohms.

15 VDC for 2 Step

83%

578

0 VDC for InterlockINTERLOCK

555

D

PROCEDURE

SHIELDED CABLE

0 VDC Open

E

DRAIN LEAD

WFS

2.3 VDC Closed

507

589

83% Procedure Input 554A

INPUT

INPUT ELECTRODE

12 VDC coil

S2

0 VDC Normal

CABLE CONNECTION

PWM Controlled

587

9 VDC 83% switch Closed

The 83% procedure reduces the

and Trigger Open

WFS to 83% of the set point, but

WORK

Control

Gas Purge

no less than 50 in/min. It is used

N.A.

most often when pipe welding.

CLIP

15 VDC when Purge OFF

COLD INCH/

0 VDC when Purge ON

GAS PURGE

Circuit

1

2

3

4

5

6

7

8

9 10

558 (BLK)

J1

S1

DISPLAY P.C. BOARD

512

Schematic L11756-x

559 (RED)

N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF BOARD.

Cold Inch

Contactor

15 VDC when Inch OFF

N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.

0 VDC when Inch ON

N.C. TOGGLE SWITCHES AND POTENTIOMETERS SHOWN FROM CONNECTION SIDE OF SWITCH.

Model

Ranger 8,9

Classic

Ranger 250, 305

V350

DC-400, 600

Square Wave TIG

Miller Inverters

STT II

Note:

Interlock

Gun Trigger

Display

Commander 300,400,500

(Common Digital

300/355

Most semiautomatic

Circuit

Circuit

Board

(Common Analog

Controls)

wire welding

Inch/Purge

Controls)

processes perform

K1870-1,-2 Across ƒ

Recommended

ƒ Recommended for CV

ƒ Recommended for CV ƒ

Recommended for

ƒ Recommended

ƒ Not recommended

ƒ Recommende ƒ

Not

better using constant

Circuit

the Arc

all CV operation.

operation. (Wire

operation.

CV operation.

for CV and CC

for CC operation

d for CV

recommended

voltage power sources.

Circuit

Feed Module

operation.

because the

voltage sense

for STT

Be sure the proper

Required)

customer may

operation.

operation.

power source is used

experience short

for your application.

contactor life from

Contactor life may be

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

inductive nature of

shortened in

PROPRIETARY & CONFIDENTIAL:

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

the power source.

applications using CC

UNLESS OTHERWISE SPECIFIED TOLERANCE

DESIGN INFORMATION

REFERENCE:

EQUIPMENT TYPE:

LN-15 (ACROSS THE ARC)

PAGE 1

OF 1

machines with high

MANUFACTURING TOLERANCE PER E2056

EDGE

ON 2 PLACE DECIMALS IS ± .02

G4198

OCV.

ON 3 PLACE DECIMALS IS ± .002

DRAWN BY: E. ENYEDY/KJ

SUBJECT:

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

ON ALL ANGLES IS ± .5 OF A DEGREE

NUMBER:

REVISION:

ƒ

ENGINEER:

E. ENYEDY

SCALE:

MATERIAL TOLERANCE ("t ") TO AGREE

G4198-1

A

SOLID

WITH PUBLISHED STANDARDS.

MATERIAL

APPROVAL

PROJECT

CRM35166

DO NOT SCALE THIS DRAWING

APPROVED:

NONE

DISPOSITION:

NA

DATE:

05/27/2003

NUMBER:

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

LN-15