Lincoln Electric SVM 117-A service manual To Section

Page 100

G-5

ELECTRICAL DIAGRAMS

G-5

Wiring Diagram (208/230) Code 9799

Return to Master

TOC

OPTIONAL

 

 

 

 

 

TIMER

 

 

 

*

 

 

 

BOARD

J14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

}

 

 

1

 

2

3

4

5

 

6

7

8

260

262

261

263

265

 

264

266

267

 

 

 

 

 

 

 

 

251

 

R3

 

 

 

WIRE SPEED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

252

 

 

 

 

 

 

 

 

256

 

R4

 

 

 

ARC VOLTAGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

253

 

A

541B

B

539B

260

1

262

2

261

3

263

4

265

5

264

6

2667

2678

1

2

3

4

5

6

7

8

9

10

2541

2522

2533

2554

251

5

} J1

*

 

J2

*

 

SPI TEST

}PLUG

} J10

*

 

(J7) *

1 2 3 4

SCI TEST

PLUG

 

 

1

 

 

2

 

 

3

 

 

4

 

*

5

(J5)

6

7

 

 

 

 

8

 

 

9

 

 

10

11

 

 

CONTROL BOARD

 

 

 

 

1

 

 

 

(J8)

*

2

 

 

 

*

(J4)

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

2

3

4

 

5

6

7

8

 

 

(J9)

*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

515

325A

324A

206A

541A

495

542

543

1

2

3

4

5

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

202

1

 

555

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

204A

2

 

206B

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

203

3

 

515B

 

 

 

 

 

206

4

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

325

 

 

 

 

 

207

5

 

 

 

 

 

 

 

 

 

 

 

 

 

G1

5

 

 

 

 

 

 

 

 

GND

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

204

6

 

 

 

 

 

 

 

 

209

7

 

 

 

 

324

 

 

 

 

 

 

 

 

G2

7

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

 

 

 

*

 

 

 

8

 

539

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

541

 

 

 

 

 

 

10

(J6)

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

 

205

11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

 

 

 

 

 

 

 

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12

(J3)

*

GAS

SP - 250

SPOOL GUNSOLENOID MODULE

1541B

2321

3324B

6539B

 

 

(J12)

 

 

7

322

 

 

 

*

 

 

8

325B

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

10

 

 

 

(J11)

*

 

 

 

 

 

 

 

 

 

 

1

2

3

4

5

6

7

8

8651

-31-92

L

1

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK

W - WHITE

R - RED

U - BLUE

*INDICATES CONNECTOR CAVITY NO.

to Master

POWER-ON INDICATOR

+

-

254

C

322

(J13)

 

D

321

255

E

325B

F

324B

 

OPTIONAL SPOOL

OR PULL GUN

RECEPTACLE

256

6

12

13

14

206S

13

325A

14

32015

208 16

515

325A

324A

206A

541A

495

542

543

Return

Return to Section TOC

Return

Return to Master TOC

 

GND

 

 

 

 

 

 

 

GND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

515B

1

515B

 

 

 

 

 

 

 

 

 

 

 

555

2

555

 

 

 

 

 

GUN

2

2

325

 

 

539

3

539

 

 

 

 

 

 

 

 

 

 

206B

4

206B

 

 

 

 

 

TRIGGER

 

 

 

 

 

 

 

 

 

 

1

4

324

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

541

6

541

 

 

 

 

 

TO

 

 

 

 

 

 

 

 

 

 

 

 

 

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

N.A.

 

 

 

 

 

 

 

 

W

 

541

 

 

 

 

 

 

 

 

 

MOTOR/

 

 

 

 

 

 

 

 

 

 

 

 

T

R

515B

 

 

 

 

 

 

 

 

 

GEARBOX

 

 

 

 

 

 

 

 

 

 

 

P.M.

A

U

555

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

H

B

206B

 

 

 

 

 

 

 

 

 

 

 

B

 

539

 

 

 

 

 

 

203

207

N.B.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

320

 

N.C.

328

325A

 

 

 

 

 

 

 

 

 

 

 

N.D.

 

 

 

R.F. FILTER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THERMOSTAT

 

 

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S3

 

 

S4

 

 

 

 

 

 

X5

202

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X6

 

 

 

 

 

 

H4

P2

 

 

 

 

 

204A

 

 

 

 

 

W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H2

H3

 

 

 

 

 

X7

 

 

208

 

 

 

 

 

 

 

 

203

 

 

 

 

L1

 

 

 

 

 

 

X1

 

 

G1

 

 

LOW V.

HIGH V.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H1

 

 

 

 

 

 

 

JUMPER

 

 

 

 

H1

 

 

 

 

SCR 1

 

 

B

 

 

 

 

 

 

 

 

 

 

250V

 

 

 

 

 

 

 

 

 

 

 

204

 

470A

 

 

L2

 

 

 

 

 

 

 

 

 

 

 

 

 

L1

L2

 

 

 

X2

 

 

 

SCR HEATSINK

 

 

 

 

 

 

 

 

 

 

 

TO SINGLE PHASE

SUPPLY LINE L1

L2

GND TO GROUND PER

NATIONAL ELECTRICAL CODE

R.F. CHOKE AS'BLY.

NOTES

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.

N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY "POSITIVE". TO CHANGE POLARITY, TURN THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK STUD.

N.C. THERMOSTATS MOUNTED ON CHOKE COIL

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO POWER TRANSFORMER.

N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET

.

N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

Return to Section TOC

Return to Master TOC

 

 

 

 

H2

 

 

 

 

ASBLY

GND.

RECONNECT PANEL

 

 

 

 

 

 

 

H2

 

X3

 

SCR 2

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

250V

 

 

 

 

 

 

 

 

 

 

 

X4

 

 

470A

 

 

 

 

 

 

 

 

 

 

 

H3

 

 

G2

 

 

 

 

N.C.

 

H1

H4

 

 

 

 

 

 

 

 

 

 

 

 

 

H3

 

 

 

 

209

 

 

 

 

 

 

 

 

SHUNT

 

 

 

 

 

 

 

 

 

 

P2

 

 

 

POWER TRANSFORMER

 

D1

 

 

 

 

 

 

T1

 

 

 

 

 

 

 

300V

T1

 

 

T2

P1

P2

 

H1

+

 

 

 

 

 

85A

 

 

 

 

 

 

-

 

 

 

 

 

 

 

 

FAN

 

 

 

 

LINE

 

 

 

 

 

 

 

206

 

 

 

 

S2

 

 

 

 

 

 

 

 

 

 

MOTORS

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S1

205

 

 

 

 

 

 

 

15 OHMS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

 

 

 

 

 

 

206S

C1

C2

 

C3

C4

C1 THRU C4

100 W

 

 

 

 

 

 

 

 

 

 

 

R2

 

 

 

 

 

 

30,000 MFD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.5K

 

 

 

 

 

 

+

 

+

+

 

+ 50V

204

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

N.E.

10W

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

207

 

 

 

 

 

 

J1

1

4

1

 

5

1

6

J4

 

 

J2

 

 

J3

 

J11

 

 

J12

 

 

 

 

J14

 

 

 

 

 

7

12

 

5

8

6

 

10

 

 

 

1

 

7

1

8

 

 

J5

 

 

J6

 

 

 

 

 

8

 

14

9

16

 

 

 

1

2

1

3

 

 

 

 

J7

 

J9

 

 

 

 

 

J8

 

J10

 

 

 

 

 

3

4

4

6

 

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

WIRE-MATIC 250

Page 99 Page 101
Image 100
Page 99 Page 101
Contents WIRE-MATIC Safety Depends on YouSafety ARC Welding can be hazardousCylinder may explode if damaged Electric and MAG- Netic Fields IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcWIRE-MATIC Table of Contents Table of Contents Installation Duty Cycle Amps Volts at Rated Amps Current RangeFuse Superlag Type 750C CopperSafety Precautions Select Proper LocationInput Connections StackingFuse and Wire Sizes Input Power Connections and Ground ConnectionsConnect Shielding GAS Reconnect Procedure Figure A.4 Input Air Supply ConnectionsFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Installation Install the Work ClampConnect Output Components GUN Liner and Contact Output Polarity ConnectionWire Size Conversion Parts GUN and Cable InstallationWIRE-MATIC Operation General Description Safety InstructionsWELDING, Cutting Design Features Advantages Unit FeaturesPower Source Features Recommended Processes and EquipmentWire Feeder Features Machine CapabilityLimitations Duty Cycle Amps VoltsControls and Settings Figure B.1 Operator ControlsProcedure for Changing Drive Roll Using the Wire Drive RollLoading the Wire Reel Feeding Electrode Proper Wire FeedingTo mount 10 to 30 lb. spools 8 and 12 diameter Operating Steps Setting Idle Roll PressureStarting the Welder Making a Weld WIRE-MATIC Accessories Installing the K607-1 Spool GUN Adapter KIT OPTIONS/ACCESSORIESK607-1 Spool GUN Adapter KIT Installation Spool GUN Module BoardSpool GUN Connection BOX Installation Return Return to Section TOCSpool GUN Connection Spool GUN PreparationMaking a Weld with the Spool GUN Adapter K607-1 Installed Making the WeldTimer KIT K585-1 Steel Wire Sizes Part Number Aluminum Wire SizesDrive Roll Kits To Make Spot Plug WeldsMaintenance Routine and Periodic Maintenance Perform the following dailyMaintenance Contact TIP and GAS Nozzle Installation Cable CleaningDrive Rolls and Guide Tubes GUN Tubes and Nozzles DROP-IN Reel Spindle and ClipsLiner Removal Replacement Figure D.2 Liner maintenanceGUN Handle Disassembly To open up the handleDescription English Size Metric Size WIRE-MATIC Theory of Operation Input Line Voltage and Main TransformerOutput Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal Protection SCR Operation Figure E.6 SCR OperationWIRE-MATIC Troubleshooting & Repair HOW to USE Troubleshooting Guide Recommended Course of ActionElectric Shock can kill PC Board Troubleshooting ProceduresBoard can be dam- aged by static electricity Main Transformer Rectifier Assembly Test To Section TOC Perform the SCR Rectifier Perform the Wire Drive Motor Liquid elec Trolyte in these capacitors isPerform the Output Rectifier Test Description Main Transformer TestMaterials Needed Main Transformer Test Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads Figure F.7 SCR Tester Circuit SCR connectionsWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Supply Voltage to Tachometer Test for Feedback Voltage to the Control BoardScope Settings Normal Open Circuit Voltage WaveformMachine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine LoadedMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Removal and Replacement Procedure Control PC Board Removal and ReplacementMaterials Needed Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Figure F.11 Wire Drive Assembly RemovalSCR Output Rectifier Removal & Replacement Right side heat sink See Figure F.14 Disconnection Heat Sink LeadCapacitor Bank Removal and Replacement Bank Removal Replacement ComponentsMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement FAN Motor and FAN Removal and Replacement Procedure Figure F.16 Fan Motor and Fan Removal ComponentsTroubleshooting & Repair Wire Speed Range Open Circuit VoltageInput Volts/Hertz 230/60 375WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Spool GUN Option Wiring Diagram 208/230 Code To Section Available from Lincoln Control PC Board G2332 Layout
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