Lincoln Electric SVM 117-A service manual Wiring Diagram 208/230 Code

Page 99

G-4

ELECTRICAL DIAGRAMS

G-4

Wiring Diagram (208/230) Code 9800

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

+

254

 

B

539B

 

 

C

322

POWER-ON

 

(J13)

INDICATOR

 

D

321

-

255

 

E

325B

 

 

 

 

F

324B

 

 

 

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

2515

2566

} 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

12

13

14

 

 

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

 

 

 

 

 

 

 

(J6)

 

 

 

 

541

 

 

 

 

 

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

 

205

11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

 

 

 

 

 

 

 

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12

 

 

 

 

 

 

 

 

206S

13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

325A

14

 

 

 

 

 

32015

208 16

(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

515

325A

324A

206A

541A

495

542

543

L8828 1-31-92

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK

W - WHITE

R - RED

U - BLUE

*INDICATES CONNECTOR CAVITY NO.

Return to

Return to Section TOC

Return to Section TOC

Return to

Return to Master TOC

Return to Master TOC

OPTIONAL SPOOL

OR PULL GUN

RECEPTACLE

 

 

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

 

 

 

 

 

 

MOTOR/

P.M.

T

R

 

 

 

 

 

GEARBOX

A

U

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

B

 

 

 

 

 

 

 

B

 

 

 

 

 

206

 

207

 

N.B.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

320

 

 

 

 

 

 

 

 

 

 

N.C.

 

R.F. FILTER

 

 

 

 

 

 

 

 

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S3

 

 

 

 

 

 

X5

 

202

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X6

204A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T1

 

X7

 

203

 

208

 

 

 

 

 

X1

 

 

G1

 

 

 

 

 

 

 

 

 

 

 

 

 

H1

 

 

 

 

 

SCR 1

 

 

 

 

P2

 

 

 

 

 

250V

 

 

 

 

H2

 

 

 

 

204

470A

L1

L2

 

 

H5

 

X2

 

 

 

SCR HEATSINK

 

 

 

 

H3

 

 

 

 

 

ASBLY

 

 

 

 

 

X3

 

 

 

SCR 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

250V

 

 

 

 

 

 

X4

 

 

 

470A

 

 

 

 

 

 

 

 

 

G2

H1

H4

 

 

 

 

 

 

 

 

 

 

H4

 

 

 

 

 

209

 

 

SHUNT

 

 

 

 

 

 

 

 

 

POWER TRANSFORMER

 

 

 

D1

 

 

 

 

 

 

 

 

 

 

300V

 

H1

 

+

 

 

 

 

 

 

85A

 

 

-

 

 

 

 

 

 

 

 

LINE

 

 

 

 

 

 

 

 

206

 

SWITCH

 

 

 

 

 

 

 

 

 

 

S1

205

 

 

 

 

 

 

 

 

 

 

206S

C1

C2

C3

C4

 

C1 THRU C4

 

R1

 

 

 

 

 

 

 

 

30,000 MFD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

+

 

+

+

50V

 

204

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

 

 

 

 

 

 

 

 

207

541

515B

555

206B

539

328

325A

 

 

 

 

 

 

N.D.

 

 

 

 

 

TO SINGLE PHASE

THERMOSTAT

 

 

 

 

SUPPLY LINE

S4

 

 

 

 

 

 

L1

 

 

 

 

 

 

 

L2

 

 

5

H5

 

 

 

 

 

 

 

 

 

 

GND

L1

L2

 

 

 

 

 

 

 

 

 

TO GROUND PER

 

 

 

 

 

 

 

4

2

H2

 

NATIONAL ELECTRICAL

 

 

 

 

CODE

 

 

 

 

 

 

 

 

 

 

H2 21/32

31/32

61/64

1/2

63/64 ð

 

1

3

H4

 

 

 

 

 

 

 

H3

 

 

 

 

 

 

 

H1

 

 

 

 

GND.

RECONNECT PANEL

(SHOWN CONNECTED

 

 

 

 

FOR 230 VOLT.)

 

 

G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.C.

 

 

 

 

 

 

 

 

P2

 

 

 

T1

 

T2

P1

P2

 

 

 

 

 

 

 

 

 

15 OHMS

FAN

S2

 

 

 

MOTORS

 

 

 

100 W

THERMOSTAT

 

 

 

 

 

 

 

 

 

R2

 

 

 

 

 

 

 

2.5K

 

 

 

 

 

N.E.

10W

 

 

 

 

 

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)

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 98 Page 100
Image 99
Page 98 Page 100
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 Type 750C Copper Duty Cycle Amps Volts at Rated AmpsCurrent Range Fuse SuperlagStacking Safety PrecautionsSelect Proper Location Input ConnectionsInput 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 Output Polarity Connection InstallationInstall the Work Clamp Connect Output Components GUN Liner and ContactGUN and Cable Installation Wire Size Conversion PartsWIRE-MATIC Operation Safety Instructions General DescriptionWELDING, Cutting Recommended Processes and Equipment Design Features AdvantagesUnit Features Power Source FeaturesDuty Cycle Amps Volts Wire Feeder FeaturesMachine Capability LimitationsFigure B.1 Operator Controls Controls and SettingsUsing the Wire Drive Roll Procedure for Changing Drive RollLoading the Wire Reel Proper Wire Feeding Feeding ElectrodeTo mount 10 to 30 lb. spools 8 and 12 diameter Setting Idle Roll Pressure Operating StepsStarting the Welder Making a Weld WIRE-MATIC Accessories OPTIONS/ACCESSORIES Installing the K607-1 Spool GUN Adapter KITK607-1 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 To Make Spot Plug Welds Steel Wire Sizes Part NumberAluminum Wire Sizes Drive Roll KitsMaintenance Perform the following daily Routine and Periodic MaintenanceMaintenance DROP-IN Reel Spindle and Clips Contact TIP and GAS Nozzle InstallationCable Cleaning Drive Rolls and Guide Tubes GUN Tubes and NozzlesFigure 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 GuidePC Board Troubleshooting Procedures Electric Shock can killBoard 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 Main Transformer Test Test DescriptionMaterials 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 Control PC Board Removal and Replacement Removal and Replacement ProcedureMaterials 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 230/60 375 Wire Speed RangeOpen Circuit Voltage Input Volts/HertzWIRE-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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