Lincoln Electric SVM187-A service manual Schematic Complete Machine Code 11199 G4924

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G-8			ELECTRICAL DIAGRAMS						G-8
SCHEMATIC - COMPLETE MACHINE - CODE 11199 (G4924)
G4924	ENGINEERING CONTROLLED CHANGE DETAIL: Revised		POLARITY
	MANUFACTURER: No		SWITCH	(SHOWN IN NEGATIVE POISTION)		GENERATOR SHUNT	TO D1
							AC
			4		22	FIELD CIRCUIT	POST
				R					AUXILIARY POWER
	N	215	2					AC POSTS
									CIRCUIT
					35A	203		TO D1
	located behind upper	500 OHMS	1		800V
	control panel on reactor box			B	+ D2	-
		50W

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EN-170

U

214

3

CENTER OFF =NO WELD OUTPUT

top right of

GENERgeneratorATframeO

R

LEAD

BRUSH POSITION SHOWN AS

BLOCK

VIEWED FROMCONTROL PANEL

E

F

ARMATURE

2

& BRUSHES

MIN rheo=54vdc

SERIES FIELD

-

+

MAX rheo=140vdc

A

1

N

SHUNT

LOCAL / REMOTE

N

N

FIELD

SWITCH

+

-

38.2-40.6 ohms

N

(SHOWN IN LOCAL

@ 25C

POSITION)

POLES

located lower middle

of control panel

S

N

S S

N

S

WELDING

GENERATOR

TO PC BD

844-TERMINA

VARIABLE

WINDING SPEC'S & RESISTANCES

L

2 CR

REACTOR

WELD CIRCUIT

REED RELAY

located upper Rt

EXCITER

LOWER PANEL

located behind

hand side behind

WINDING

RESISTANCE

work stud

control panel

SPEC

GND SCREW

POWER

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

QUADRATURE

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

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

ROTOR (4-POLE) ALT-214-3A41.4+/-1.0 OHMS @ 25C

WOR

output studs located on right fuel tank

ELECTROD

DIAGRAM

M14262

rail (viewed from control panel end)

GENERATOR

K

E

(electrode closest to control panel)

INTERPOLE

S12261-25

N/A

CC WELD OUTPUT

SHUNT FIELD

FKL-5AJ

19.1-20.3 OHMS @ 25C

MIN TO MAX OCV 57-97VDC @ 1800 RPM

SERIES FIELD

FKL-420-U N/A

WELD RANGE 80-575 AMPS

ARMATURE

FKL-37.4N

N/A

MAX LOAD

400A @ 40V @ 100% D.C. (1725 RPM)

DIAGRAM

M5570

602

SAE400 INTERFACE WITH

OPTIONAL CV ADAPTER

CV ADAPTER

located inside CV

CVadapter box located on left fuel tank

CONTROL PCB

adapter box

S1 small switch

SHOWN FOR REFERENCE ONLY-

rail (viewed from control panel end)

OUTPUTS

(SCHEM. # L6922)

INPUTS

located on face of

NOT PART OF CV ADAPTER

CR1 CONTACTOR

CVadapter box

S1

J1-8

DRIVE INPUT

Ac

608

*140vdc

v

610

vv

+15VDC

(J1-8 toJ1-4)

Y

+140VDC

510

610

140vdc

140vdc (w/ rheo- statatmax)

CR1

CR1 CONTACTOR

POWER

510

500 OHMS

4

DRIVE CIRCUIT

J2-3(J2-3 toJ1-4)

50W

R

COI

606

J1-3

SUPPLY

L

BOARD

no

2

23-24vdc

POWER

CR1 located inside

600

U

203

TO D1AC

inCV

25V

*0vdc

CVadapter box

POST

J1-7

2 AMP

1

B

+

D2

-

605

J2-2

(J2-2 toJ1-4)

500

no

POLARITY

360-440 OHMS @ 25C

EXC. OVER-

SWITCH

3

35A

600

TO P8-2

CR1 located inside

n.c.

613

C R1

(NO AFFECT W/CV

800V

A

VOLTAGE

229

TO PC BD

CVadapter box

PROTECTION

CR1 CONTACTOR

no

CONTACTS

ADAPTER HOOKEDUP)

+ _

J1-10

J1-4

DRIVE RETURN

5

602

600

612

238

W

G

+140VDC

POWER OUTPUT

ARC

HOUR

B

GENERATOR

TO SHUNT

J1-1

VOLTAGE

611

METER

LOWER PANEL

FIELD

509

J2-6

+15VDC

FEEDBACK

667

W

GND SCREW

SHUNT FIELD

*SEE WAVEFORM

c

(J2-6 toJ2-1)

flywheel

74hz

+15VDC

v

UPPER PANEL

diode

vv

S1 small switch

GNDSCREW

FLYWHEEL

PWM

*12.9vdc

1A

S1C

vv

DIODE

J2-5

J1-5

(J1-5 toJ1-2)

S1D

located on face of

1000V

S1 small switch

c

503

77

max

CVadapter box

-

R

R3

10

located on face of

v

501

J2-1

J1-6

76

CV VOLTAGE

567

120 OHMS

35A

CVadapter box

30OHMS

J1-9

cw K

CONTROL

2.5W

800V

100W

CV SWITCH FOR

SHUNT FIELD

75

located on face of

POT

D1

SHUNT FIELD

DRIVE CIRCUIT

*3.1vdc

B

(J1-9 toJ1-2)

CVadapter box

201

B

S1

+

1/8 AMP

J1-2

WELD COMMON

521

Bc

ALTERNATOR

v

ROTOR

vv

S1 small switch

S2

*NOTE : measurementmade inCV mode.

located on face of

CVadapter box

S2 large switch located on

CV ADAPTER

face of CVadapter box

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

CONTROL PCB

POSITIVE

12.8ms

12.8ms

1

4

1

4

7

621

positive stud located on

25,000uf

50-250v

50-250v

right fuel

tank rail (viewed

5.2ms

.5ms

2

5

2

5

8

from control panel end)

75v

x4

3

6

3

6

9

666

0v

0v

J

MAX POT/NO LOAD

MIN POT/NO LOAD

2

-

+

R1

C1

C2

C3

C4

622

-

100 OHMS

Capacitor bank and bleeder

+

50W

resistor located inside CV

CV MODE – POWER UP SEQUENCE

VV MODE – POWER UP SEQUENCE

adapter box

Exciter rotor is flashed from 12v battery supply at

Exciter rotor is flashed from 12v battery supply at

machine power up, exciter winding builds up power.

machine power up, exciter winding builds up power.

GENERATOR

Exciter winding powers D2 bridge and CR1 contactor

CR1 contactor and PC board DO NOT power up.

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

Shunt fields receive power thru PC board.

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

Rheostat controls current thru the shunts.

VVneg stud located on

& 3

and disconnecting flashing circuit.

CVneg stud located on

right fuel

tank rail

PC Board PWM circuit regulates output voltage by

adapter box mounted on left

(viewed from control

VV

using voltage feedback from J1 pin 1 and control pot

fuel tank rail

(viewed from CV

panel end)

at J1 pin 6 to control current thru the shunt fields.

control panel

end)

NEG.

NEG.

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

CV WELD OUTPUT

NOTE!! : WHEN INSTALLING CV ADAPTER,

MIN TO MAX OCV 8-41vdc

WELD RANGE

15-35vdc

"ELECTRODE" STUD BECOMES VV "NEGATIVE"

MAX LOAD

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

STUD,& "TO WORK" STUD BECOMES "POSITIVE"

STUD.

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

REMOTE

ROTOR FIELD AND

AUXILIARY OUTPUT

located behind upper

RECEPTACLE

located lower center

OCV

control panel on

AND PLUG

FLASH CIRCUIT

EXCITER 602C

115/230 VAC + 10% @ 1800RPM

reactor box

X-TERMINAL

of control panel

203A

MAX LOAD

3KW @ 100% D.C.

n.c

B

X

n.c.

WINDING

.

alternator &rotor located at

15A

diodes located behind

600A

end of generator

41

G-TERMINA

upper control panel

R 810

B 7A

B

G

L

G

G

P8-2

A

UPPER PANEL

ALTERNATOR

UPPER PANEL

64ohms +/- 6.4

230V DUPLEX

GND SCREW

ROTOR

G

600

GND SCREW

150 W

UPPER PANEL

RECEPTACLE

cc

41.5 ohms +/- 1.0 @ 25C

GNDSCREW

Y-TERMINAL

w

AUXILIARY

Y

U

max

202

WINDINGS

R

140vdc

-

R

R

n.c

25OHM

W

. W-TERMINA

50W

W

L

W

W

x3

D1

35A

800V

201A

CURRENT

located behind upper

42

OPTIONAL REMOTE

+

B

SENSE

20A

control panel on

115V DUPLEX

6A

TOROID

602

P8-3

CONTROL BOX

reactor box

201

B

CB4

B

4A

RECEPTACLE W

P8-4MIN rheo=86vac

42

11B

11

MAX rheo=0vac

A

B

20A

CB3

located upper Lt

B

400F

hand side behind

B

G

602

control panel

UPPER PANEL

UPPER PANEL

A

max

JOB

11A

GNDSCREW

G

GND SCREW

cc

SELECTOR

120 OHMS

B

15A

R HEOSTAT

w

located behind upper

2.5W

CB1

64ohms +/- 6.4, 150

602

W

TO D1

control panel on

B

AC POST

reactor box

U

B

1A

1000V

238

MAY NOT APPEAR ON ALL MODELS

TO HOUR

METER (+)

RIGHT SIDE OF ENGINE

INJECTION PUMP

ENGINE

ON INJECTION PUMP

TEMPERATURE

INJECTION PUMP TIMING

TIMING SOLENOID

SENSOR

212F

SOLENOID TYP. CURRENT

DRAW 0.9A APPROX.

16 OHMS

RESISTANCE 16 OHMS

0.9 AMPS

RIGHT SIDEOF ENGINE

(ASVIEWEDFROM CONTROL PANEL)

IDLER / ENGINE PROTECTION PC BOARD

LOCATEDBEHINDFUEL FILTER,

ALTERNATOR

AMMETER SHOWS FULL

LOCATEDBEHINDLOWERPORTIONOF CONTROL PANEL

65AMP / 12VOLT

GLOW PLUG

DISCHARGE WHILE PRESSING

LEFT SIDEOF ENGINE

J32-1

UNUSED

(ASVIEWEDFROM CONTROL PANEL)

SWITCH

GLOW PLUG SWITCH

J32-2

J31-3

59

D+

53

IDLE

J32-3

USED FOR TOROID IN AC

P. C. BD. L12400-2

TYPICAL CURRENT DRAW:

B

GLOW PLUGS

SOLENOID

50B

CENTEROF CONTROL PANEL

J32-4

AUXILIARY MACHINES

SCHEMATIC G4828-2

PULL COIL

HOLD COIL - 1.1A

+

TYPICAL

FLYBACK

B3

55

PULL COIL - 46A

-40 TO 40 AMPS

CURRENT DRAW

RED ENGINE

HOLD COIL

212E

IGNITION

IS 40 +/- 3 AMPS

PROTECTION

61

J31-

ENGINE

DIODE

J31-8

57

51

AMMETER

LIGHT

4

N.C. SHUTDOWN

SWITCH

-

START SWITCH

J31-2

212C

56

51A

50A

12 VOLT - NORMALLY OFF

+

CR1

J31-1

LOCATEDABOVEENGINE 212D

SHOWN IN

10A

RIGHT SIDEOF ENGINEBY

"OFF" POSITION

CB5

RIGHT SIDE OF

INJECTIONPUMP

J31-9

N.O. ENGINE

CR1

ALTERNATOR.

212F

212A

B

235 ENGINE (AS

58

RIGHT SIDEOF ENGINE

INJECTION PUMP

RUNNING

(ASVIEWEDFROM CONTROL PANEL)

S

I TEMPERATURE

STARTER

VIEWED FROM

SOLENOID

J31-6

43

CONTROL PANEL)

TYPICAL CURRENT DRAW:

58H

ENGINE

44

GAUGE

SOLENOID

3.3A

12 VOLT +

+

APPROXIMATE RESISTANCE:

PROTECTION

W

G

G

3.3 OHMS

AND

TEMPERATURE SWITCH /SENDER

BATTERY

ENGINE

located engine right side

RIGHT SIDEOF ENGINEBY

SWITCH CLOSES SENDER OPERATION:

OIL FILLER

ALTERNATOR

212Blocated generator

STARTER (viewfrom control panel end)

TYFUPIELCPALUMCURREP NT DRAW:

FLASHING

AT 230v+/-6vF

140vF -> 134+/-13.5 OHMS

end of machine

3A

DELAY TIMER

194vF -> 51.2+/-4.3 OHMS

SENDER IS APPROX.

APPROXIMATE RESISTANCE:

(SEE BELOW

212vF -> 38.5+/-3 OHMS

500 OHMS AT 70vF FRAME

FRAME

3-4 OHMS

+ 238A

J31-1

FOR LOGIC)

S

I

ENGINE BLOCK

CENTEROF CONTROL

J31-7

54

200

PANEL

0

WK

G

G

OIL PRESSURE

HOUR METER

J31-5

GAUGE

OIL PRESSURE SWITCH /SENDER

Q2

LEFT SIDEOF ENGINE

IDLER DELAY TIMER CIRUITS

(ASVIEWEDFROM CONTROL PANEL)

Q2 ON FOR HIGH IDLE

SENDER OPERATION:

B2

B1

SWITCH OPENS

0 PSI -> 10+/-5OHMS

AT 6+/-2PSI

40PSI -> 105+/-5OHMS

SHOWN IN "AUTO

80 PSI -> 187+/-5OHMS

TO REED RELAY

844

844A

IDLE" POSITION

IDLER SWITCH

ENGINE PROTECTION AND ALTERNATOR FLASHING DELAY TIMER LOGIC

IDLE SOLENOID CIRCUIT LOGIC

LEAD COLOR CODE:

COMPONENT VALUE UNITS:

B-BLACK OR GRAY

CAPACITOR: MFD/VOLTS

UPON RECIEVEING POWER, CIRCUIT TO FLASH ALTERNATOR IS OPENED

1. WHEN THE ENGINE IS RUNNING IN HIGH IDLE OR UNDER LOAD, THE SOLENOID IS NOT ENERGIZED.

G-GREEN

RESISTOR: OHMS/WATTS

O-ORANGE

AND ENGINE PROTECTION IS BYPASSED. AFTER TIME DELAY, ALTERNATOR

2. IF NO AUXILIARY CURRENT DRAW OR WELD LOAD IS SENSED FOR 15 SECONDS AND THE IDLER SWITCH IS

R-RED OR PINK

CONNECTOR PIN NUMBERS:

FLASHING CIRCUIT IS CLOSED AND ENGINE PORECTION IS ENABLED. NOTE:

U-BLUE

AFTER TIME DELAY WHEN ENGINE PROTECTION IS ENABLED, IF THE ENGINE

OPEN (AUTO), THE PULL AND HOLD COIL OF THE IDLER SOLENOID ARE ENERGIZED. THE PULL COIL IS

W-WHITE

EX. 12 PIN CONNECTOR

IS NOT STARTED THE OIL PRESSURE WILL BE LOW AND THE MACHINE WILL

DE-ENERGIZED AFTER HALF A SECOND.

Y-YELLOW

1 2

6

SHUT DOWN BECAUSE OF THE ENGINE PROTECTION CIRCUIT.

3. IF AN AUXILIARY CURRENT DRAW OR WELD LOAD IS SENSED OR THE IDLER S WITCH IS CLOSED (HIGH),

LABELS

:

THE IDLE SOLENOID IS DE-ENERGIZED.

COMMON

FRAME

7

12

GROUND

LATCH

EARTH

VIEW OF CONNECTOR ON PC BOARD

GROUND

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

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

MANUFACTURING TOLERANCE PER E2056

CONTROL: CLEVELAND

SCALE:

EQUIPMENT TYPE:

SAE-400

1

1

UNLESS OTHERWISE SPECIFIED TOLERANCE:

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

DRAWN BY:

Maglietta

NONE

PAGE ___ OF ___

EDGE

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

IF PRINTED

SUBJECT:

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

ON ALL ANGLES IS ± .5 OF A DEGREE

ENGINEER:

D. BENDER

@ A1 SIZE

NUMBER:

REVISION:

MATERIAL TOLERANCE (" t ") TO AGREE

G4924

D

SOLID

WITH PUBLISHED STANDARDS.

UNITS:

MATERIAL

APPROVAL

PROJECT

REFERENCE:

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