Lincoln Electric SVM 117-A service manual Electrical Diagrams

Page 97

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G-2

Wiring Diagram (230/460/575) Code 10004

OPTIONAL

 

 

 

 

TIMER

 

 

 

*

 

 

BOARD

J14

 

 

 

 

 

 

 

}

 

 

1

2

3

4

5

6

7

8

ELECTRICAL DIAGRAMS

260

1

}

 

 

 

(J7)

 

 

CONTROL BOARD

 

 

1

 

 

 

 

 

 

 

2

262

2

 

 

 

*

 

 

 

 

*

 

 

 

 

(J8)

*

 

 

 

 

 

 

 

(J4)

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

261

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

263

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J1

1

2

3

4

 

 

 

 

 

 

 

 

*

 

265

5

 

 

 

 

 

 

 

 

(J9)

 

 

 

 

 

 

1

2

3

4

5

6

7

8

 

264

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

266

7

 

 

SCI TEST

 

 

 

 

 

 

 

 

 

 

 

267

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PLUG

 

 

 

 

 

 

 

 

 

 

 

 

G-2

GAS

SOLENOID

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Return to Master TOC

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515

325A

324A

206A

541A

495

542

543

1

2

3

4

5

6

 

 

 

 

 

 

260

262

261

263

265

264

266

267

1

2

3

TO

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

 

251

R3

WIRE SPEED

 

 

252

 

256

R4

ARC VOLTAGE

 

 

253

+

254

POWER-ON

 

INDICATOR

 

-

255

 

 

4

 

 

 

*

 

 

 

 

 

 

 

 

5

 

 

J2

 

 

 

1

202

1

 

 

6

 

 

 

1

555

 

2

 

 

 

 

 

 

 

204A

2

 

 

7

 

SPI TEST

2

206B

 

3

 

 

 

 

203

3

 

 

8

 

PLUG

3

515B

206

4

 

 

 

 

4

 

 

9

}

 

 

4

325

207

5

 

 

 

 

 

G1

5

 

 

10

}

 

 

*

5

 

GND

6

204

6

 

 

 

 

 

6

 

209

7

(J3)

254

1

 

 

324

G2

7

 

 

(J5)

7

 

8

*

8

*

252

2

 

 

*

8

539

 

9

 

253

3

 

 

 

9

 

 

 

 

 

 

 

 

 

J10

9

541

 

10

(J6)

 

 

 

10

 

255

4

 

 

 

10

 

205

11

 

 

251

5

 

 

 

 

 

11

 

 

 

 

11

 

 

12

 

 

256

6

 

 

 

 

206S

 

12

 

 

 

 

 

 

 

12

 

13

 

 

 

 

 

 

 

 

 

13

 

325A

14

 

 

 

 

 

 

 

 

 

14

 

320

15

 

 

 

 

 

 

 

 

 

 

 

208

16

 

 

 

COLOR CODE:

SPOOL GUN

B - BLACK

OPTIONW - WHITE

R - RED

U - BLUE

*INDICATES CONNECTOR CAVITY NO.

 

 

 

 

 

 

 

 

 

 

 

GND

 

 

 

 

 

 

 

 

 

R.F. CHOKE AS'BLY.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

515B

1

515B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

555

2

555

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GUN

2

 

2

325

 

 

 

539

3

539

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

206B

4

206B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRIGGER

1

 

4

324

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

NOTES

 

 

 

 

 

 

 

 

 

 

541

6

541

 

 

 

 

 

 

 

 

 

 

 

 

TO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CURRENT AND DUTY CYCLE OF IMMEDIATE AND

 

N.A.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUTURE APPLICATIONS.

 

 

 

 

 

 

 

 

 

 

 

 

 

W

 

541

 

 

 

 

 

 

 

N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY

 

 

 

 

 

 

 

 

 

MOTOR/

P.M.

T

R

515B

 

 

 

 

 

 

 

"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT

 

 

 

 

 

 

 

 

 

 

GEARBOX

A

U

555

 

 

 

 

 

 

 

OFF AND REVERSE LEAD CONNECTIONS AT CABLE

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

CONDUCTOR STRAP AND WORK STUD.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

B

206B

 

 

 

 

 

 

N.C. THERMOSTATS MOUNTED ON CHOKE COIL

 

 

 

 

 

 

 

 

 

 

 

 

B

 

539

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.B.

 

 

 

 

 

 

 

 

 

 

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO

 

 

 

 

206

207

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER TRANSFORMER.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

.

 

 

 

 

 

 

 

 

 

 

 

320

 

 

328

 

325A

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

N.C.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.D.

 

 

 

 

TO SINGLE PHASE

 

 

 

 

 

 

 

 

R.F. FILTER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THERMOSTAT

 

THERMOSTAT

 

 

SUPPLY LINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S3

 

S4

 

 

 

 

L1

 

 

 

 

 

 

 

 

 

 

 

 

 

X5

 

 

 

 

 

 

 

 

 

 

 

L2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

202

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X6

 

 

 

 

 

 

 

 

 

5

H5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

204A

 

 

 

 

 

 

 

 

GND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L1

L2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TO GROUND PER

 

 

 

 

 

 

 

 

 

 

 

 

 

X7

 

 

 

208

 

 

 

 

 

 

 

 

CAVITY NUMBERING SEQUENCE

 

 

 

 

 

T1

 

 

203

 

G1

 

 

 

4

2

H2

NATIONAL ELECTRICAL

 

 

 

 

 

 

 

X1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H1

 

 

 

 

 

 

SCR 1

 

 

 

 

 

 

CODE

 

 

(COMPONENT SIDE OF P.C. BOARD)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H2‰z·^ 63/64 ˆ

 

 

 

 

 

 

 

P2

 

 

 

 

 

 

250V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H2

 

 

 

 

204

 

470A

 

 

1

3

 

H4

 

 

 

 

 

 

 

 

L1

L2

 

 

H5

 

X2

 

 

 

 

SCR HEATSINK

 

 

J1

 

 

1

 

5

1

6

 

 

 

 

 

 

 

 

 

 

 

H3

1

4

 

 

 

 

 

H3

 

 

 

 

 

 

ASBLY

 

 

 

 

 

J4

 

 

J2

 

 

J3

 

 

 

 

 

 

X3

 

 

 

 

SCR 2

 

 

 

 

 

H1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

250V

 

 

RECONNECT PANEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X4

 

 

 

 

470A

 

GND.

(SHOWN CONNECTED

5

8

6

 

10

7

12

 

 

 

 

 

 

 

 

 

 

G2

 

 

 

 

FOR 230 VOLT.)

 

H1

H4

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

 

 

H4

 

 

 

 

 

209

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SHUNT

 

 

 

 

 

D1

 

 

 

 

 

 

 

 

 

1

 

7

1

8

 

 

 

POWER TRANSFORMER

 

 

 

 

 

 

 

 

 

N.C.

 

 

 

 

 

 

 

 

 

 

 

 

 

300V

 

 

 

 

 

 

 

 

 

J5

 

 

J6

 

 

 

H1

 

+

 

 

 

 

 

85A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P2

 

 

 

 

 

 

 

 

LINE

 

 

 

 

 

 

 

206

 

 

 

T1

 

 

T2

P1

P2

 

 

8

 

14

9

16

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S1

205

 

 

 

 

 

 

 

 

 

 

15 OHMS

 

FAN

 

 

S2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

MOTORS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C1 THRU C4

 

 

 

100 W

 

 

THERMOSTAT

 

 

1

2

1

3

 

 

 

206S

C1

C2

C3

C4

 

 

 

 

 

 

 

 

 

 

 

 

 

30,000 MFD

 

 

 

 

 

 

 

 

 

 

 

 

J7

 

J9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

+

+

+

50V

 

204

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J8

 

J10

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

 

R2

 

 

 

 

 

3

4

4

6

 

 

 

 

 

 

 

 

 

 

 

 

 

207

 

 

2.5K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.E.

10W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2-5-93

L9077

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

Image 97 Lincoln Electric SVM 117-A service manual Electrical Diagrams
Contents Safety Depends on You WIRE-MATICARC Welding can be hazardous SafetyCylinder may explode if damaged Iii Electric and MAG- Netic FieldsSûreté Pour Soudage a L’Arc Précautions DE SûretéWIRE-MATIC Table of Contents Table of Contents Installation Current Range Duty Cycle Amps Volts at Rated AmpsFuse Superlag Type 750C CopperSelect Proper Location Safety PrecautionsInput Connections StackingInput Power Connections and Ground Connections Fuse and Wire SizesConnect Shielding GAS Figure A.4 Input Air Supply Connections Reconnect ProcedureFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Install the Work Clamp InstallationConnect Output Components GUN Liner and Contact Output Polarity ConnectionGUN and Cable Installation Wire Size Conversion PartsWIRE-MATIC Operation General Description Safety InstructionsWELDING, Cutting Unit Features Design Features AdvantagesPower Source Features Recommended Processes and EquipmentMachine Capability Wire Feeder FeaturesLimitations Duty Cycle Amps VoltsFigure B.1 Operator Controls Controls and SettingsProcedure 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 Spool GUN Module Board InstallationReturn Return to Section TOC Spool GUN Connection BOX InstallationSpool GUN Preparation Spool GUN ConnectionMaking the Weld Making a Weld with the Spool GUN Adapter K607-1 InstalledTimer KIT K585-1 Aluminum Wire Sizes Steel Wire Sizes Part NumberDrive Roll Kits To Make Spot Plug WeldsMaintenance Perform the following daily Routine and Periodic MaintenanceMaintenance Cable Cleaning Contact TIP and GAS Nozzle InstallationDrive Rolls and Guide Tubes GUN Tubes and Nozzles DROP-IN Reel Spindle and ClipsFigure D.2 Liner maintenance Liner Removal ReplacementTo open up the handle GUN Handle DisassemblyDescription English Size Metric Size WIRE-MATIC Theory of Operation Transformer Input Line Voltage and MainFeedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal Protection Figure E.6 SCR Operation SCR OperationWIRE-MATIC Troubleshooting & Repair Recommended Course of Action HOW to USE Troubleshooting GuideElectric 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 Trolyte in these capacitors is Liquid elecPerform the Output Rectifier Test Description Main Transformer TestMaterials Needed ON/OFF Power Switch will be hot during these tests Main Transformer Test Test ProcedureMain Transformer Test Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads SCR connections Figure F.7 SCR Tester CircuitWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Feedback Voltage to the Control Board Test for Supply Voltage to TachometerNormal Open Circuit Voltage Waveform Scope SettingsTypical 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 Removal and Replacement Procedure Control PC Board Removal and ReplacementMaterials Needed Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Figure F.11 Wire Drive Assembly Removal Wire Drive Assembly Removal and Replacement ProcedureSCR Output Rectifier Removal & Replacement Disconnection Heat Sink Lead Right side heat sink See Figure F.14Capacitor Bank Removal and Replacement Components Bank Removal ReplacementMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement Figure F.16 Fan Motor and Fan Removal Components FAN Motor and FAN Removal and Replacement ProcedureTroubleshooting & Repair Open Circuit Voltage Wire Speed RangeInput 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