Lincoln Electric SVM144-B service manual Control PC Board Assembly G3521-1

Page 103

G-7

ELECTRICAL DIAGRAMS

G-7

CONTROL PC BOARD ASSEMBLY - (G3521-1)

 

 

1-3521

G

ITEM

REQ’D

PART NO.

IDENTIFICATION

C1,C2,C8,C9,C14,C20,C29

18

S16668-5

.022/50

 

C36,C37,C38,C39,C43,C44

 

 

 

C48,C52,C53,C55,C56

 

S13490-42

 

C3,C4,C11

3

1.0/35

C5,C6,C18,C19,C35,C51,C54

7

T11577-52

.0047 OR .005/1400

C7

1

S13490-73

20/50

S16668-11

C10,C22,C23,C24,C25,C30

16

.1/50

 

C31,C32,C33,C34,C40,C41

 

 

 

C45,C46,C57,C58

 

S16668-1

 

C12,C13

2

22pF/100

S13490-30

C15

1

39/10

S13490-92

C16

1

3300/50

S13490-39

C17,C28

2

18/15

T11577-28

C26

1

.22/100

S13490-118

 

C27

1

2200/63V

 

C47

1

S16668-7

820pF/50

C49

1

S13490-76

.001/400

C50

1

S13490-102

.047/100

C59

1

S24833-1

0.27/63V

Return to Section TOC

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Return to Master TOC

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~.04

6.00

5.80

.20

0

R38

R47

R37

 

C17

 

C15

 

R57

R36

D31

C44

D2

 

C2

R4

R5

R31

R32

 

Q9

Q3

R34

 

D12

 

 

 

 

 

 

R40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R104

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C49

 

 

 

 

 

 

 

 

R3

 

 

 

 

 

 

 

 

X4

 

 

 

R102

R103

 

 

 

X9

 

 

 

 

 

 

 

 

X5

 

R33

 

 

 

 

 

 

C36

 

 

 

 

 

 

 

C39

 

 

 

 

 

 

 

 

 

C37

 

 

 

 

R42

 

 

 

 

D24

 

 

 

 

 

 

 

 

R28

R84

R46

C11

R39

R2

R30

C8

R29

R106

R62

D20

D19

 

 

 

R41

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y1

 

 

 

 

R43

XXXXXXXXXXXXX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R35

C9

 

 

C14

C10

R44

R45

R90

 

 

XXXXXXXXXXXXXX

 

 

 

 

 

X1

 

 

 

 

C40

 

 

 

 

C16

D5

D6

 

 

 

 

 

 

 

 

 

 

 

 

XXXXXXXXXXXXXXXX

 

 

 

 

 

 

 

 

 

 

 

 

C13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

XXXXXXXXXXXXXXX

 

 

R107

D36

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C41

 

 

 

 

X3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R100

D34

 

R95

C43

R69

R68

 

C23

R101

D35

D33

C47

C46

 

Q10

 

R77

C30

C31

C22

R70

D21

D22

 

R75

 

 

 

 

 

 

 

 

 

R54

 

 

 

 

 

 

DZ4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R99

 

 

R86

R91

R92

R87

 

R76

R88

 

 

D26

R83

C29

 

D27

R73

 

R72

 

C25

R74

R71

C24

R98

 

 

 

Q7

 

 

R89

 

R78

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J2

 

 

 

 

 

 

 

 

 

 

 

J4

 

 

 

 

 

 

C33

C32

C34

D16

R65

R116 R60

 

R19 R112

C55

C56

R113

R21

Q1

R93

R94

R22

R13

R24

R80

 

C3

D9

R15

R27

D8

 

 

C6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Q2

 

 

OCI2

 

OCI1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C38

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R23 R14

D10

R26

X8

 

 

 

 

D13

D29

 

 

 

X6

 

 

 

 

 

 

 

 

 

 

 

 

C4

D11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D23

R79

 

 

 

 

R20

R18

 

 

 

 

 

 

 

 

C20

R58

R63

 

D17

 

R61

D18

 

C58

 

C57

R50

 

 

 

R49

R66

R67

R59

R64

 

 

C26

R114

R25

C5

 

 

Q6

 

 

 

 

 

 

 

 

 

 

 

 

D14

 

 

 

 

 

 

 

 

 

 

 

 

 

Q8

 

 

 

 

 

X12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R110

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R111

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R48

R53

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Q11

 

 

 

 

DZ2

R52 R51

R56

R55

D15

DZ1

C28

 

 

 

 

 

 

 

 

 

Q4

 

 

 

 

 

D37

L4

L3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C53

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OCI3

D1

 

D3

R6

C1

 

X10

 

 

 

D25

 

 

X11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R108

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D32

 

 

R109

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C52

 

 

 

 

 

 

R82

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R81

 

 

 

 

 

 

 

 

C45

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R12

 

 

Q5

 

 

 

 

 

 

 

 

 

R96

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRI1

 

 

 

 

 

C7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R97

 

 

 

 

 

 

 

DZ3

R105

C48

 

 

X7

 

D7

 

D4

 

R9

 

R7

 

C27

 

 

 

 

 

C18 C19

 

 

TP3

 

 

 

TP7

C51

TP1

 

C50

 

 

D28

 

 

R11

R10 L2

L1

 

 

R8

R115

 

 

 

 

 

 

TP4

 

 

 

 

 

C35

C54

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J1

 

 

 

J8

 

 

 

 

 

 

J3

 

 

 

 

 

 

 

 

 

 

J5

 

 

 

J6

R117

CONTROL G3521-1

TP2

D1,D2,D3,D31

4

 

1N4007

 

D4,D5,D6,D7,D8,D9,D10,D11,D12,D13,D14,

31

T12199-1

1N4004

 

D15,D16,D17,D18,D19,D20,D21,D22,D24

 

 

 

 

D25,D26,D27,D28,D29,D30

 

 

 

 

D32,D33,D34,D35,D36

 

T12705-23

 

 

D23,D37

2

1N5818

 

 

 

DZ1

1

T12702-40

1N4735

 

DZ2,DZ3,DZ4

3

T12702-45

1N4746A

J1

1

S18248-8

HEADER

 

J2

1

S18248-14

HEADER

 

J3

1

S18248-12

HEADER

 

J4

1

S24020-10

HEADER,VERTICAL

 

J5

1

S18248-16

HEADER

 

J6

1

S18248-6

HEADER

 

S18248-2T

 

J8

1

HEADER

 

L1,L2,L3,L4

4

T12218-7

330uH

 

OCI1,OCI2

2

S15000-30

OPTOCOUPLER TRIAC DRIVER 800V

OCI3

1

S15000-31

OPTOCOUPLER,TRIACDRV,RANDOM,800V

Q1,Q2,Q3,Q6,Q11

5

T12704-68

2N4401

 

Q4

1

S18105-4

HEATSINK ASBLY

Q5,Q9

2

T12704-35

NPN TRANSISTOR

Q7,Q10

2

T12704-88

TRANSISTOR,NMF,T220,45A,100V(SS)

Q8

1

T12704-69

2N4403

 

R1,R2,R6,R41,R42,R65,R75

11

S19400-1002

10K 1/4W

R79,R84,R112,R113

 

 

 

 

R3,R7,R25,R26,R114,R117

6

S24002-1200

120 2.5W

R4,R51

2

S19400-1502

15K 1/4W

R5,R9,R12,R30,R35,R45,R70

8

S19400-4751

4.75K

 

 

 

R90

 

 

4.75K

7/16W

R8,R115

2

S19400-1211

1.21K 1/4W

R10,R11,R62,R63,R76,R77

10

S19400-1000

100 1/4W

 

R78,R82,R95,R105

 

 

1.21K 1/4W

R13,R22,R93,R94

4

S19400-6810

681 1/4W

R14,R15,R23,R27

4

S19400-15R0

15 1/4W

 

R18,R20,R24,R80

4

S19400-5620

562 1/4W

R19,R21,R58,R83

4

S19400-2211

2.21K 1/4W

R28,R46,R61

3

S19400-6811

6.81K 1/4W

R29,R100,R110

3

S19400-1501

1.5K 1/4W

R31,R106

2

S19400-5621

5.62K 1/4W

R32

1

S19400-2672

26.7K 1/4W

R33,R37,R38

3

S19400-2212

22.1K 1/4W

R34,R40

2

S19400-33R2

33.2 1/4W

R36

1

S19400-2671

2.67K 1/4W

R39,R68,R71,R72,R91,R92

7

S19400-3321

3.32K 1/4W

R111

 

 

 

 

R43

1

S19400-1004

1M 1/4W

 

R44,R109

2

S19400-1001

1K 1/4W

 

R47

1

S19400-1301

1.3K 1/4W

R48

1

S19400-2801

2.8K 1/4W

R49,R50

2

T14648-22

50 5W

 

R52,R98

2

S19400-3011

3.01K 1/4W

R53

1

S19400-5111

.25 OHM, 7W RESISTOR

R54

1

T12300-75

5.11K 1/4W

R55,R56

2

S19400-26R7

26.7 1/4W

R57,R108

2

S19400-2670

267 1/4W

R59,R66,R69,R73,R74,R86,R87

7

S19400-4422

44.2K 1/4W

R60

1

S19400-2432

24.3K 1/4W

R64,R67

2

S19400-5110

511 1/4W

R81

1

T14648-5

3.3K 5W

 

R88,R89

2

S19400-1622

16.2K 1/4W

R96,R103

2

S19400-4752

47.5K 1/4W

R97

1

T14648-19

1K 5W

 

R99

1

S19400-1652

16.5K 1/4W

R101,R102

2

S19400-1372

13.7K 1/4W

R104

1

S19400-7500

750 1/4W

R107

1

S19400-4750

475 1/4W

0

9.00 ~.04

R116

1

S19400-2802

28.0K 1/4W

TP1,TP2

2

T13640-15

15J

TP3,TP4

2

T13640-9

20J

TP7

1

T13640-18

MOV,120J

.20

3.20

8.80

TRI1

1

S15161-27

T2500D

X1

1

S24392-4

ROM ASSEMBLY (SS)

X2

1

M15102-3

IC,S8054HN,CMOS,UNDERVOT-SENSING(SS)

X3

1

S17900-8

14 PINI.C.(SS)

X4,X5

2

S15128-11

14 PIN QUAD COMPARATOR

X6

1

S15128-16

IC,LT1014,LINEAR INTEGRATED CIRCUIT

X7

1

S23060-1

IC,SWITCH,LO-SIDE(SS)

X8

1

S15018-4

MC14584(SS)

X9

1

S15018-6

DIGITAL INTEGRATED CIRCUIT(SS)

X10,X11

2

S15128-10

IC,431,VOLTAGE REF.

X12

1

S15128-5

+5V REG.

Y1

1

S16665-5

8.0 MHZ

 

 

 

 

 

 

Ch’ge. Sht. No.

11-16-2001D

 

 

 

 

THE LINCOLN ELECTRIC CO.

EQUIP.

POWER MIG 255

 

 

 

 

 

 

 

 

 

XE-RW

A

 

 

 

 

TYPE

 

 

 

 

 

 

 

 

 

 

 

3-12-99

 

 

 

 

 

 

CLEVELAND, OHIO U.S.A.

 

 

 

 

 

CONTROL P.C. BOARD ASSEMBLY

 

 

 

 

 

 

 

7-9-99H

 

 

 

 

 

 

SCALE

FULL

 

SUBJECT

 

 

 

 

 

 

 

 

 

7-28-2000J

 

 

 

 

 

 

 

 

 

 

 

G2803-1

 

 

SHT.

G 3521-1

 

 

 

 

 

 

 

 

 

 

 

DR C.S./

DATE12-18-98 CHK

 

REF.

SUP’S’D’G

 

 

 

 

 

 

10-5-2001C

 

 

 

 

 

 

NO.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 provided 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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER MIG 255

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Contents Power MIG Safety Electric Shock can kill Welding Sparks can cause fire or explosion SafetySûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsTechnical Specifications Power MIG InstallationUncrating the Power MIG Safety PrecautionsLocation Power MIG Figure A.2 Triple Voltage Machine Input Connections Shielding GAS GUN and Cable InstallationSection B Operation SectionFumes and Gases can be dangerous OPERATIONB-2Limitations OperationProduct Description Welding CapabilityDescription of Controls Wire Reel Loading READI-REELS, SPOOLS, or Coils Procedure for Changing Drive and Idle Roll SetsTo Start the Welder Feeding Wire ElectrodeSetting RUN-IN Speed on STAN- Dard Power MIG Feeder Idle Roll Pressure SettingMaking a Weld Avoiding Wire Feeding ProblemsInput Line Voltage Protection FAN ControlSection C Accessories SectionDual Cylinder Mounting KIT K1702-1 AccessoriesDrive Roll Kits K363P READI-REEL AdapterOperating Instructions For Timer KIT Spool GUN Adapter KIT Making a Weld with the Spool GUN, Spool GUN InstalledSection D Maintenance SectionRoutine and Periodic Maintenance MaintenanceGUN Tubes and Nozzles Figure D.1 Component Locations Liner Removal Replacement Contact TIP and GAS Nozzle InstallationTo open up the handle 5MAINTENANCED-5Description English Size Metric Size Table D.2Section E Theory of Operation SectionInput Line Voltage Theory of OperationMain Transformer Feedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal and Overload Protection Wire Feed Overload ProtectionOvercurrent Protection Figure E.6 SCR Operation SCR OperationPower MIG Section F Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairWorkstations PC Board Troubleshooting ProceduresOutput Problems SCR Rectifier Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Test Description Main Transformer TestMain Transformer Test Test ProcedureFigure F.1 Troubleshooting and Repair Test Description Rectifier Diode Bridge TestMaterials Needed Rectifier Diode Bridge Testing 208R 206 28 VAC 209R Power MIG Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Open switch SW-1 Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test 515B 206B 15 VDC 5J1 1J1 Test for Supply Voltage to Tachometer555 206B To 3.5 VDC 6J1 1J1 Test for Feedback Voltage to Control BoardVolts Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Power MIG Description Control PC Board Removal and Replacement ProcedureControl PC Board Removal and Replacement ProcedureFigure F.11 Control Board Mounting Power MIG Wire Drive Assembly Removal and Replacement Procedure 41TROUBLESHOOTING & REPAIRF-41Procedure Wire Drive Assembly Removal and ReplacementTOC Power MIG SCR Output Rectifier Removal and Replacement Procedure SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG Capacitor Bank Removal and Replacement Procedure Capacitor Bank Removal and Replacement Troubleshooting & Repair Main Transformer and Output Choke Removal and ReplacementTOC Power MIG FAN Motor Assembly Removal and Replacement Procedure FAN Motor Assembly Removal and Replacement Open Circuit Voltage Troubleshooting and RepairWire Speed Range Retest After RepairPower MIG Electrical Diagrams Section Wiring Diagram Entire Machine Code 10563 L10979 Power MIG 255 208/230VWiring Diagram Entire Machine Code 10583 L10980 Power MIG 255 230/460/575VWiring Diagram Entire Machine Code 10986 L11980 Power MIG 255 230/460/575Wiring Diagram Entire Machine Code 10990 L11979 Power MIG 255 208/230Control PC Board Schematic G3520-1D1 3521 Control PC Board Assembly G3521-1Powermig Display PC Board Schematic L10951Lincoln Electric CO Display PC Board Assembly L10952-124374 S Snubber PC Board Schematic S2437400 ~.04 Snubber PC Board Assembly M19248-1SVM Error Reporting Form
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