Lincoln Electric SVM187-A service manual Electrical Diagrams

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G-7

ELECTRICAL DIAGRAMS

G-7

SCHEMATIC - COMPLETE MACHINE - CODE 10856 (G5351)

G5351

ENGINEERING CONTROLLED

CHANGE DETAIL: Revised

(SHOWN IN

MANUFACTURER: Yes

POLARITY

GENERATOR SHUNT

NEGATIVE

SWITCH

POISTION)

FIELD CIRCUIT

TO D1

AC POST

4

R

N

Y

2

TO PC BD

FROM

AUXILIARY POWER

242

240

500 OHMS

35A

R-TERMINAL

HOUR MTR +

50W

800V

-

W

203

TO D1

CIRCUIT

COMPRESSORR

B

TERMINAL

located behind upper

1

B

+

D2

AC POSTS

U

control panel on reactor box

U

located behind upper

REMOTE RECEPTACLE

loacted lower

ENABLE

3

control panel on

AND PLUG located lower Lt hand

front panel

SWITCH

CENTER OFF =NO WELD OUTPUT

reactor box

X-TERMINAL

side of control panel

ROTOR FIELD AND

OCV

AUXILIARY OUTPUT

85

RELAY

R

n.c.

B

X

n.c.

FLASH CIRCUIT

EXCITER

115/230 VAC + 10% @ 1800RPM

Y

30

top right of

MAX LOAD

3KW @ 100% D.C.

FROMAM-

239

B

generator frame

600A

P8-1G-TERMINAL

WINDING

no

located behind

GENERATO

alternator &rotor located at

15A

230V

METER +

87a

lower control

R

P8-2

41A

41

G

G

diodes located behind

CB2

POST

B

87

panel

LEAD

BRUSH POSITION SHOWN AS

64ohms +/- 6.4

upper control panel

end of generator

RECEPTACLE

86

BLOCK

UPPER PANEL

41.5 ohms +/- 1.0

R

B

B

10A

VIEWED FROMCONTROL PANEL

600

150 W

UPPER PANEL

GND SCREW

@ 25C

FUSE

cc

GND SCREW

G

Y-TERMINAL

w

ALTERNATOR

UPPER PANEL

G

located behind

E

F

Y

U

ROTOR

lower control

LOWER PANEL

ARMATURE

R

max

GND SCREW

panel

B

GND SCREW

2

LOCAL/

R

n.c.

25OHM

AUXILIARY

& BRUSHES

R

243

MIN rheo=54vdc

REMOTE

W-TERMINA

50W

140vdc

WINDINGS

loacted lower

MAX rheo=140vdc

SWITCH

W

L

W

W

x3

-

PRESSURE

-

+

front panel

A

1

SERIES FIELD

N

SHUNT

(SHOWN IN

W

G

SWITCH

LOCAL

42

OPTIONAL REMOTE

D1

G

B

N

N

FIELD

POSITION)

COMPRESSOR

+

-

38.2-40.6 ohms

located lower middle

602

CONTROL BOX

35A

CURRENT

W

N

of control panel

P8-3

located behind upper

+

800V

SENSE

CIRCUIT LAMP

POLES

@ 25C

P8-4MIN rheo=86vac

42

control panel

on

B

TOROID

20A

CB4

115V

B ON=ACTIVE

COMPRESSOR

MAX rheo=0vac

reactor box

RECEPTACLE

A

B

B

CLUTCH

241

located upper Lt

602

W hand side behind

20A

LOWER PANEL

S

N

S

S

N S

max

control panel

B

CB3

GNDSCREW

WELDING

A

JOB

cc

SELECTOR

TO PCB

B

G

GENERATOR

64RHEOohmsST+/-AT

TO PC BD

w

201

J2

6.4

TO D1

G

UPPER PANEL

R-TERMINAL

602

150 W

B

15A

UPPER PANEL

GND SCREW

WELD'N AIR - AIR COMPRESSOR CIRCUIT

2 CR

WINDING SPEC'S & RESISTANCES

U

AC POST

GND SCREW

WELD CIRCUIT

B

CB1

REEDRELAY

VARIABLE

EXCITER

B

located behind

W

B

WINDING

SPEC

RESISTANCE

COMPRESSOR OUTPUT

work stud

REACTOR

POWER

ALT-214-3C .230 OHMS @ 25C

LOWER PANEL

located upper Rt

DELIVERY

35CFM @ 100PSI @ 60% D.C.@ 1400RPM

GND SCREW

hand side behind

QUADRATURE

ALT-214-3B .560 OHMS @ 25C

MAX PRESSURE

150 PSI (11 GALLON TANK)

control panel

AUXILIARY (TAIL) ALT-214-3D .424 OHMS @ 25C

ROTOR (4-POLE) ALT-214-3A 41.4+/-1.0 OHMS @ 25C

OPERATING PRESSURE LOADS @ 90 PSI

output studs located on right fuel tank

DIAGRAM

M14262

UNLOADS @ 130 PSI

WOR

ELECTROD

GENERATOR

120 OHMS

rail (viewed from control panel end)

located behind upper

2.5W

K

(electrode closest to control panel)

E

INTERPOLE

S12261-25

N/A

control panel on

IDLER/ENGINE

located behind lower

CC WELD OUTPUT

SHUNT FIELD

FKL-5AJ

19.1-20.3 OHMS @ 25C

reactor box

SHUTDOWN PCB control panel

SERIES FIELD

FKL-420-U

N/A

1A

INPUTS

MIN TO MAX OCV 57-97VDC @ 1800 RPM

OUTPUTS

(SCHEM. # L11006-2C1)

ARMATURE

FKL-37.4M

N/A

1000V

WELD RANGE

80-575 AMPS

MAX LOAD

400A @ 40V @ 60% D.C. (1725 RPM)

DIAGRAM

M5570

30 SEC TIMER

+10v

238

TO EXC TERMINAL

(LOCKS OUT ENGINE

+10V

Vbatt

SENSORS AND TIMES ALT

602

SAE400 INTERFACE WITH

ON ENGINE ALT

FLASH AT POWER-UP)

reset

reset

OIL PRESS

mounted on engine block

OPTIONAL CV ADAPTER

SHOWN FOR REFER ENCE

ENGINE ALT

hi

lo

*10vdc =normal operation

belowfuel pump

CV ADAPTER

ONLY - NOT ACTUALLY PART OF

W

J1-

*0vdc

=shutdown

SWITCH

located inside CV

CV ADAPTER

CV adapter box located on left fuel tank

224 FLASH & SENSE

reset

t

SWITCH OPENS @ 15+/-3 PSI

located engine starter side

CONTROL PCB

located on

*11.5-12.9vdc

J1-

7

B

223

adapter box

S1 small switch

rail (viewed from control panel end)

ENGINE PROTECTION

at air intake manifold

OUTPUTS

(SCHEM. # L6922)

INPUTS

front panel

W

3

1.0-2.0 ohms

located on face of

HOUR

SENSE CIRCUIT

TEMP

micro switch located

THERMOSTART

CVadapter box

J1-1

J1-

*10vdc =normal operation

THERMOSTART

CR1 CONTACTOR

S1

METER

*11-13vdc

+

*0vdc

=shutdown

SWITCH

in temp guage

IGNITER

J1-8

DRIVE INPUT

Ac

5

G

_ +

B

229

0

-

6

B

TRIP POINT SET AT 220F +/- 4%

608

221

G

B

233

FROM

*140vdc

v

610

B

+10v

*10vdc =noweldcurrent

LOWER PANEL

PC BD

(J1-8 toJ1-4)

vv

LOWER PANEL

FUEL SOLENOID

GND SCREW

+15VDC

+140VDC

Y

*0vdc =weldcurrent, pick up

J1-3

610

140vdc (w/ rheo-

GNDSCREW

located engine left side

DRIVE CIRCUIT

2 CR REED

510

R

to hiidle

CR1

CR1 CONTACTOR

140vdc

510

500 OHMS

statatmax)

FUEL INJ PUMP (viewed from control panel end)

R

RELAY

POWER

J2-3

(J2-3 toJ1-4)

4

R

WELD

located behind

DRIVE CIRCUIT

50W

B

Vbatt

COIL

606

J1-3

SUPPLY

no

2

SEC

WELD & AUX CURRENT

CURRENT

CURRENT

work stud

LOWER PANEL

224

BOARD

ENGINE TEMP B

SENSE CIRCUIT

SENSE INPUT

located behind

GNDSCREW

23-24vdc

J1-7

25V

POWER

CR1 located inside

600

U

1

203

TO D1AC

24ohms

*11-13vdc

P-CHNL

J2-

W

SENSE

control panel

B

W

inCV

2 AMP

*0vdc

CVadapter box

+

-

POST

4 ohms SWITCH

J1-9

RECTI-

3

TOROID

605

J2-2

(J2-2 toJ1-4)

no

POLARITY

B

D2

G

B

227

J2-

B

TO P8-2

PRI

FIER

4

AUXILIARYW

B

237

360-440 OHMS

EXC. OVER-

500

SWITCH

3

35A

600

FUEL INJ PUMP COILS G

+12v

+

@ 25C

CR1 located inside

VOLTAGE

n.c.

613

CR1

(NO AFFECT W/CV

800V

A

TO PC BD

DO NOTHAVE OVER-

ENGINE FAULT LAMP located on

CURRENT

B

ALTERNATOR

CVadapter box

PROTECTION

CR1 CONTACTOR

no

ADAPTER HOOKED UP)

229

CURRENT PROTECTION

LAMP

rst

SENSE INPUT

DRIVE RETURN 600

CONTACTS

+ _

J1-10

front panel

IDLER

55AMP MAX DRAW

602

+140VDC

J1-4

612

238

W

G

5

5C

G

R

U

*12-14vdc J1-4

DRIVE CKT

12 SEC

IGNITION

located engine right side

POWER OUTPUT

ARC VOLTAGE

B

226

TIMER

+10v

Vbatt

SWITCH (SHOWN IN

(viewfrom control panel end)

GENERATOR

HOUR

LOWER PANEL

IDLE DRIVE

reset

reset

out

AUTO IDLE

SWITCH

TO SHUNT

611

LOWER PANEL

located engine left side

J1-

START BUTTON

+15VDC

J1-1

FEEDBACK

METER

GNDSCREW

CIRCUIT

hi

lo

*12-14vdc

POSITION)

SHUNT FIELD

FIELD

J2-6

667

GNDSCREW

(viewed from control panel end)

J1-8

reset

t

POWER

1

220

B

B

B

SWITCH

509

*8.6-42vdc

W

B

225

SUPPLY

B

236

+

-

*SEE WAVEFORM

c

J1-

BOARD

(J2-6 toJ2-1)

flywheel

+15VDC

(J1-1 toJ1-2)

v

UPPER PANEL

10.5-12.5vdc

N-CHNL

POWER

AMMETER

S1C

diode

74hz

PWM

vv

S1 small switch

1A

GND SCREW

8.8 OHMS +/- .88 @25C

OVERCURRENT

5

G

5

FLYWHEEL

*12.9vdc

J1-

B

vv

DIODE

J2-5

J1-5

(J1-5 toJ1-2)

S1D

located on face of

1000V

IDLER

FLYWHEEL

PROT. CKT

A

S1 small switch

c

503

77

max

CVadapter box

-

R

SOLENOID

DIODE

2

LOWER PANEL

B

R3

J2-1

J1-6

10

CV VOLTAGE

120 OHMS

35A

PULL TO LOWIDLE

located on face of

v

501

76

567

HI IDLE =1800RPM

GND SCREW

CVadapter box

30 OHMS

cw

K

CONTROL POT

2.5W

800V

235

CV SWITCH FOR

SHUNT FIELD

J1-9

75

LOW IDLE =1100RPM

100W

located on face of

D1

U

222

SHUNT FIELD

DRIVE CIRCUIT

*3.1vdc

B

(J1-9 toJ1-2)

CVadapter box

201

B

+

B

234

+

+

1/8 AMP

J1-2

WELD COMMON

S1B

521

c

ALTERNATOR

12 VOLT

v

*NOTE : measurementmade with respecttoframeground.

BATTERY

ENGINE

located engine right side

vv

ROTOR

IDLER/ENGINE SHUTDOWN

located generator

STARTER (viewfrom control panel end)

S1 small switch

S2

end of machine

*NOTE : measurementmade inCV mode.

located on face of

CIRCUIT

CVadapter box

S2 large switch located on

FRAME

ENGINE BLOCK

FRAME

CV ADAPTER

face of CVadapter box

VOLTAGE WAVEFORM : J2-6 to J2-1 IN CV MODE

CONTROL PCB

IDLER/ENGINE SHUTDOWN PC BOARD

POSITIVE

12.8ms

12.8ms

1

4

1

4

7

621

POWER UP SEQUENCE

positive stud located on right fuel tank

50-250v

50-250v

Upon receiving power, circuit to flash alternator is closed and

2

5

2

5

8

rail (viewed from control panel end)

5.2ms

engine protection is bypassed. After time delay, alternator

.5ms

3

6

3

6

9

666

flashing circuit opens up and engine protection is enabled.

IDLER/ENGINE SHUTDOWN PCB

LEAD COLOR CODE:

COMPONENT VALUE UNITS:

0v

0v

J

J

25,000

Note!!: After time delay when engine protection is enabled, if

B-BLACK OR GRAY

CAPACITOR: MFD/VOLTS

MAX POT/NO LOAD

MIN POT/NO LOAD

2

1

R1

the engine is not started, oil pressure will be low, the fuel

1

5

1

2

-

+

uf

G-GREEN

solenoid will drop out, and the engine fault light will turn on

RESISTOR: OHMS/WATTS

C1 C2

C3 C4 75vx

O-ORANGE

because of the engine protection circuit.

GENERATOR

622

4

R-RED OR PINK

CONNECTOR PIN NUMBERS:

-

100 OHMS

Capacitor bank and bleeder resistor

CODE

MACHINE DESPCRIPTION

U-BLUE

+

50W

located inside CVadapter box

6

10

3

4

W-WHITE

EX. 12PIN CONNECTOR

10601

SAE400 PERKINS 1004.42 DIESEL

J

J

Y-YELLOW

1 2

6

CV MODE – POWER UP SEQUENCE

VV MODE – POWER UP SEQUENCE

10602

SAE400 WELD -N- AIR PERKINS 1004.42 DIESEL

1

2

LABELS

Exciter rotor is flashed from 12v battery supply at

10856

SAE400 SEVERE DUTY

:

machine power up, exciter winding builds up power.

Exciter rotor is flashed from 12v battery supply at

10884

SAE400 PERKINS (DOMESTIC)

COMMON

Exciter winding powers D2 bridge and CR1 contactor

machine power up, exciter winding builds up power.

10885

SAE400 WELD -N- AIR PERKINS (CANADIAN)

FRAME

7

12

drive circuit on PC board at J1 pins 4 & 8.

CR1 contactor and PC board do not power up.

GROUND

LATCH

CR1 closes, applying power to PC board at J2 pins 2 & 3

Shunt fields receive power thru PC board.

CVneg stud located on

EARTH

VIEW OF CONNECTOR ON PC BOARD

and disconnecting flashing circuit.

Rheostat controls current thru the shunts.

adapter box mounted on left

CV

VVneg stud located on right fuel tank

GROUND

PC Board PWM circuit regulates output voltage by using

fuel tank rail (viewed from

VV rail (viewed from control panel end)

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

voltage feedback from J1 pin 1 and control pot at J1 pin 6

control panel

end)

NEG.

NEG.

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

CV WELD OUTPUT

MANUFACTURING TOLERANCE PER E2056

CONTROL:

CLEVELAND

SCALE:

EQUIPMENT TYPE:

SAE-400

PAGE 1

OF 1

to control current thru the shunt fields.

NOTE!! : WHEN INSTALLING CV ADAPTER,

UNLESS OTHERWISE SPECIFIED TOLERANCE:

SOLIDEDGE

Note!!: Rheostat must be set to max for CV operation.

MIN TO MAX OCV

8-41vdc

ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)

NONE

"ELECTRODE" STUD BECOMES VV "NEGATIVE"

ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)

DRAWN BY:

FEI

SUBJECT:

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

EN-170

WELD RANGE

15-35vdc

STUD,& "TO WORK" STUD BECOMES

ON ALL ANGLES IS ± .5 OF A DEGREE

IF PRINTED

NUMBER:

REVISION:

MAX LOAD

400A @ 35V @ 60% D.C.

"POSITIVE"

MATERIAL TOLERANCE (" t ") TO AGREE

ENGINEER:

D. BENDER

@ A1 SIZE

APPROVAL

WITH PUBLISHED STANDARDS.

UNITS:

MATERIAL

PROJECT

REFERENCE:

G5351

B

500A @ 35V @ 35% D.C.

STUD.

DO NOT SCALE THIS DRAWING

APPROVED:

-

INCH

DISPOSITION:

NA

DATE:

1/1/2000

NUMBER:

CRM38346

-

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

®

SAE-400 SEVERE DUTY