Lincoln Electric SVM187-A Manual Do Utilizador
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ELECTRICAL DIAGRAMS
G-9
SAE-400 SEVERE DUTY
®
SCHEMATIC - COMPLETE MACHINE - CODE 11408 (G5827)
EN
-1
70
S
O
L
ID
E
D
G
E
G5827
SAE-400
MACHINE SCHEMATIC
NONE
-
DO NOT SCALE THIS DRAWING
EQUIPM
ENT TYPE:
SUBJECT:
SCALE:
NA
CRM38346
1
PAGE ___ OF ___
1
ENGINEERING CONTROLLED
MANUFACTURER:
MANUFACTURER:
No
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PRO
PRIETARY & CONFIDENTIAL:
t
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
ON A
LL ANGLES IS ± .5 OF A DEGREE
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
UNLESS OTHERWISE SPECIFIED TOLERANCE:
MANUFACTURING TOLERANCE PER E2056
Revised
CHANGE DETAIL:
REFERENCE:
MATERIAL
DISPOSITION:
DISPOSITION:
APPROVAL
DATE:
DATE:
PROJECT
NUMBER:
NUMBER:
DOCUMENT
NUMBER:
NUMBER:
DOCUMENT
REVISION:
REVISION:
IF PRINTED
@ A1 SIZE
UNITS:
INCH
1/1/2000
Maglietta
D. BENDER
-
DRAWN BY:
ENGINEER:
CLEVELAND
APPROVED:
CONTROL:
B
G582
7
Insight
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PC BOARD
1 2
6
7
12
EX. 12PIN CONNECTOR
LABELS
:
COMMON
FRAME
FRAME
GROUND
EARTH
GROUND
AUXILIARY
WINDINGS
WINDINGS
ALTERNATOR
ROTOR
R
EXCITER
WINDING
WINDING
15A
15A
20A
20A
B
B
B
B
B
W
B
R
W
B
B
G
G
G
UPPER PANEL
GND SCREW
UPPER PANEL
GND SCREW
B
R
POLARITY
SWITCH
1
4
2
3
214
215
600A
P8-2
600
Y-TERMINAL
R
Y
U
W-TERMINA
L
W
W
W
42
P8-3
42
A
602
P8-4
602
A
U
602
B
203
X-TERMINAL
X
B
n.c.
G-TERMINA
L
G
G
41
A
UPPER PANEL
GND SCREW
G
LO
CAL / REMOTE
SWITCH
(SHOWN IN LOCAL
POSITION)
OPTIONAL REMOTE
CONTROL BOX
TO D1
AC POSTS
TO D1
AC POST
D1
D2
-
-
+
+
SHUNT
FIELD
SERIES FIELD
BRUSH POSITION SHOWN AS
VIEWED FROMCONTROL PANEL
A
1
E
N
N
S
S
N
S
N
S
EL
ECTROD
E
WOR
K
2 CR
REED RELAY
N
U
B
R
POLARITY
SWITCH
U
Y
D2
ALTERNATOR
ROTOR
R
B
201
B
UPPER PANEL
GND SCREW
GND SCREW
D1
W
610
610
600
POWER
SUPPLY
SUPPLY
+15VDC
608
J1-8
EXC. OVER-
VOLTAGE
PROTECTION
605
J1-7
J1-3
J1-4
600
606
J2-3
510
500
J2-2
2 AMP
PWM
J1-1
667
+140VDC
25V
1/8 AMP
J1-5
J1-6
J1-9
J1-2
77
76
75
76
75
521
+140VDC
+15VDC
J2-1
J2-5
J2-6
501
503
509
INPUTS
OUTPUTS
vv
c
v
no
no
no
510
613
n.c.
S1
A
602
SHUNT FIELD
DRIVE CIRCUIT
10
K
HOUR
METER
METER
+ _
G
5
B
LOWER PANEL
GND SCREW
W
238
612
611
POSITIVE
VV
NEG.
C
V
NEG.
vv
c
v
567
vv
c
v
GENERATOR
666
622
R1
25,000uf 75v
x4
C1
C2
C3
C4
621
CR1
COI
L
CR1
CONTACTS
vv
c
v
GENERATOR
SHUNT FIELD
SHUNT FIELD
30OHMS
100W
602
J2-3
TO PC BD
J1-10
229
203
600
A
S1
B
S1C
500 OHMS
50W
500 OHMS
50W
S2
AUXILIARY POWER
CIRCUIT
WELDCIRCUIT
+
-
+
-
+
-
BOARD
POWER
CR1 CONTACTOR
DRIVE RETURN
ARC
VOLTAGE
FEEDBACK
WELD C
OMMON
POWER OUTPUT
TO SHUNT
FIELD
CV SWITCH FOR
SHUNT FIELD
FLYWHEEL
DIODE
CV ADAPTER
CONTROL PCB
(S
CHEM. # L6922)
+
-
N
N
ARMATURE
&
BRUSHES
-
-
+
+
1
2
3
3
4
5
6
6
1
2
3
3
4
5
6
6
J
2
8
9
9
CV ADAPTER
CONTROL PCB
TO D1
AC
POST
R
n.c
.
n.c
.
POLES
cw
64ohms +/- 6.4, 150
W
max
cc
w
64ohms +/- 6.4
150 W
25OHM
50W
x3
120 OHMS
2.5W
35A
800V
100 OHMS
50W
1A
1000V
max
cc
w
JOB
SELECTOR
R
HEOSTAT
VARIABLE
REACTOR
AUXILIARY OUTPUT
OCV
115/230 VAC + 10% @ 1800RPM
MAX LOAD
3KW @ 100% D.C.
120 OHMS
2.5W
1A
1000V
35A
800V
35A
800V
35A
800V
74hz
CENTER OFF =NO WELD OUTPUT
1
4
2
3
12.8ms
5.2ms
0v
50-250v
MAX POT/NO LOAD
0v
50-250v
12.8ms
.5ms
MIN POT/NO LOAD
VOLTAGE WAVEFORM : J2-6 to J2-1 INCV MODE
360-440 OHMS @ 25C
23-24vdc
in CV
*SEE WAVEFORM
(J2-6 toJ2-1)
(J2-6 toJ2-1)
140vdc
(J2-3 toJ1-4)
*140vdc
(J1-8 to J1-4)
(J1-8 to J1-4)
*12.9vdc
(J1-5 to J1-2)
(J1-5 to J1-2)
*3.1vdc
(J1-9 to J1-2)
*NOTE : measurementmade in CV mode.
*0vdc
(J2-2 to J1-4)
140vdc (w/rheo- statat max)
140vdc
38.2-40.6 ohms
@ 25C
@ 25C
41.5 ohms +/- 1.0 @ 25C
MIN rheo=54vdc
MAX rheo=140vdc
MAX rheo=140vdc
MIN rheo=86vac
MAX rheo=0vac
MAX rheo=0vac
located behind upper
control panel on
reactor box
control panel on
reactor box
located behind upper
control panel on
reactor box
control panel on
reactor box
alternator &rotor located at end of generator
diodes located behind
upper control panel
upper control panel
located behind upper
control panel on
reactor box
control panel on
reactor box
located behind upper
control panel on reactor box
control panel on reactor box
located behind
work stud
CVadapter box located on left fuel tank
rail (viewed from control panel end)
rail (viewed from control panel end)
positive stud located on
right fuel tank rail (viewed
from control panel end)
right fuel tank rail (viewed
from control panel end)
B
201
201A
-
CURRENT
SENSE
TOROID
ROTOR FIELDAND
FLASH CIRCUIT
WELDING
GENERATOR
2
REMOTE
RECEPTACLE
AND PLUG
(SHOWN IN POSITIVE POISTION)
flywheel
diode
diode
F
GENERATO
R
LE
AD
BLOCK
output studs located on right fuel tank
rail (viewed from control panel end)
(electrode closest to control panel)
rail (viewed from control panel end)
(electrode closest to control panel)
D2
610
J2-3
+15VDC
no
CR1 CONTACTOR
DRIVE CIRCUIT
J2-3
S1D
CV VOLTAGE
CONTROL
POT
CR1 CONTACTOR
DRIVE INPUT
-
+
+
2
9
max
(NO AFFECT W/CV
ADAPTER HOOKED UP)
ADAPTER HOOKED UP)
VVneg stud located on
right fuel tank rail
(viewed from control
panel end)
right fuel tank rail
(viewed from control
panel end)
D2
J2-3
-
+
+
9
R3
D2
SAE400 INTERFACE WITH
OPTIONAL CV ADAPTER
-
+
+
NOTE!! : WHEN INSTALLING CV ADAPTER,
"ELECTRODE" STUD BECOMES VV
"NEGATIVE"
STUD,& "TO WORK" STUD BECOMES
"POSITIVE"
STUD.
CVneg stud located on
adapter box mounted on left
fuel tank rail (viewed from
control panel end)
adapter box mounted on left
fuel tank rail (viewed from
control panel end)
CV WELD OUTPUT
MIN TO MAX OCV
8-41vdc
WELD RANGE
15-35vdc
MAX LOAD
400A @ 35V @ 60% D.C.
500A @ 35V @ 35% D.C.
500A @ 35V @ 35% D.C.
CC WELD OUTPUT
MIN TO MAX OCV 57-97VDC @ 1800 RPM
WELD RANGE
WELD RANGE
80-575 AMPS
MAX LOAD
400A @ 40V @ 100% D.C. (1725 RPM)
CV MODE – POWER UP SEQUENCE
Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
Exciter winding powers D2 bridge and CR1 contactor
drive circuit on PC board at J1 pins 4 & 8.
CR1 closes, applying power to PC board at J2 pins 2
& 3 and disconnecting flashing circuit.
PC Board PWM circuit regulates output voltage by
using voltage feedback from J1 pin 1 and control pot
at J1 pin 6 to control current thru the shunt fields.
Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
Exciter winding powers D2 bridge and CR1 contactor
drive circuit on PC board at J1 pins 4 & 8.
CR1 closes, applying power to PC board at J2 pins 2
& 3 and disconnecting flashing circuit.
PC Board PWM circuit regulates output voltage by
using voltage feedback from J1 pin 1 and control pot
at J1 pin 6 to control current thru the shunt fields.
Note!!: Rheostat Must be set to max for CV operation.
VV MODE – POWER UP SEQUENCE
Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
CR1 contactor and PC board
Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
CR1 contactor and PC board
DO NOT power up.
Shunt fields receive power thru PC board.
Rheostat controls current thru the shunts.
Rheostat controls current thru the shunts.
TO D1AC
POST
TO P8-2
S2 large switch located on
face of CVadapter box
face of CVadapter box
Capacitor bank and bleeder
resistor located inside CV
adapter box
resistor located inside CV
adapter box
located inside CV
adapter box
adapter box
S1 small switch
located on face of
CVadapter box
located on face of
CVadapter box
CR1 located inside
CVadapter box
CVadapter box
TO PC BD
844-TERMINA
L
LOWER PANEL
GND SCREW
top right of
generator frame
located upper Rt
hand side behind
control panel
located upper Lt
hand side behind
control panel
hand side behind
control panel
CR1 located inside
CVadapter box
S1 small switch
located on face of
CVadapter box
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
located on face of
CVadapter box
located on face of
CVadapter box
CVadapter box
located lower center
of control panel
of control panel
located lower middle
of control panel
of control panel
OIL PRESSURE SWITCH /SENDER
TEMPERATURE SWITCH /SENDER
IDLER /ENGINE PROTECTION PC BOARD
J31-2
J31-1
J31-1
J31-3
J31-6
J31-7
J31-8
J31-9
J31-5
J31-4
RED ENGINE PROTECTION LIGHT
J32-1
J32-2
J32-3
J32-4
J32-2
J32-3
J32-4
J31-10
ALTERNATOR
TY
PICAL
CURRENT
DRAW IS
40 +/- 3
AMPS
TY
PICAL CURRENT DRAW: 3A
+
HOUR METER
TY
PICAL CURRENT DRAW:
HOLD COIL - 1.1A
PULL COIL - 46A
SWITCH OPENS
AT 6
+/-2PSI
SENDER OPERATION:
0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
SHOWN IN "AUTO
IDLE" POSITION
SWITCH CLOSES
AT 230
AT 230
v+/-6vF
SENDER OPERATION:
140
140
vF -> 134+/-13.5 OHMS
194
vF -> 51.2+/-4.3 OHMS
212
vF -> 38.5+/-3 OHMS
12 VOLT - NORMALLY OFF
SHOWN IN
"OFF" POSITION
53
50B
B
51
51A
59
57
212D
212C
43
200
54
44
212A
212B
61
58
58H
238A
844A
-40 TO 40 AMPS
AMMETER SHOWS FULL
DI
SCHARGE WHILE PRESSING
GL
OW PLUG SWITCH
65AMP / 12VOLT
B
+
D+
GL
OW PLUGS
N.C.
N.O.
ENGINE
SHUTDOWN
ENGINE
RUNNING
CR1
CR1
ENGINE PROTECTION AND ALTERNATOR FLASHING DELAY TIMER LOGIC
UPON RECIEVEING POWER, CIRCUIT TO FLASH ALTERNATOR IS OPENED
AND ENGINE PROTECTION IS BYPASSED. AFTER TIME DELAY, ALTERNATOR
FLASHING CIRCUIT IS CLOSED AND ENGINE PORECTION IS ENABLED. NOTE:
AFTER TIME DELAY WHEN ENGINE PROTECTION IS ENABLED, IF THE ENGINE
IS NOT STARTED THE OIL PRESSURE WILL BE LOW AND THE MACHINE WILL
SHUT DOWN BECAUSE OF THE ENGINE PROTECTION CIRCUIT.
12.6 VOLT
S MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
ENGINE
PROTECTION
AND
ALTERNATOR
FLASHING
DELAY TIMER
(S
EE BELOW
FO
R LOGIC)
IDLER DELAY TIMER CIRUITS
Q2ON FOR HIGH IDLE
FUEL SHUTDOWN SOLENOID
FUEL PUMP
UNUSED
USED FOR TOROID IN AC
AUXILIARY MACHINES
P. C. BD. L12400-2
SCHEMATIC G4828-2
FLYBACK
DI
ODE
Q2
IDLE
SOLENOID
RIGHT SIDE OF ENGINE (AS VIEWED
FROM CONTROL PANEL)
FROM CONTROL PANEL)
LOCATED BEHIND LOWER PORTION OF CONTROL PANEL
SENDER IS APPROX.
500 OHMS AT 70
500 OHMS AT 70
vF
B2
HOLD COIL
PULL COIL
B3
55
CB5
10A
56
B1
212E
844
TO REED RELAY
TO HOUR
METER (+)
METER (+)
238
IDLE SOLENOID CIRCUIT LOGIC
1. WHEN THE ENGINE IS RUNNING IN HIGH IDLE OR UNDER LOAD, THE SOLENOID IS NOT ENERGIZED.
2. IF NO AUXILIARY CURRENT DRAW OR WELD LOAD IS SENSED FOR 15 SECONDS AND THE IDLER SWITCH IS
OPEN (AUTO), THE PULL AND HOLD COIL OF THE IDLER SOLENOID ARE ENERGIZED. THE PULL COIL IS
DE-ENERGIZED AFTER HALF A SECOND.
DE-ENERGIZED AFTER HALF A SECOND.
3. IF AN AUXILIARY CURRENT DRAW OR WELD LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED (HIGH),
THE IDLE SOLENOID IS DE-ENERGIZED.
CENTER OF CONTROL PANEL
CENTER OF CONTROL PANEL
RIGHT SIDE OF ENGINE
BY INJECTION PUMP
BY INJECTION PUMP
TY
PICAL CURRENT DRAW: 0.9A
RIGHT SIDE OF ENGINE
ABOVE FUEL FILTER
ABOVE FUEL FILTER
APPROXIMATE RESISTANCE:
3-4 OHMS
APPROXIMATE RESISTANCE: 16 OHMS
WINDING SPEC'S & RESISTANCES
EXCITER
WINDING
SPEC
RESISTANCE
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-214-3A 41.4+/-1.0 OHMS @ 25C
DIAGRAM
ROTOR (4-POLE) ALT-214-3A 41.4+/-1.0 OHMS @ 25C
DIAGRAM
M14262
GENERATOR
INTERPOLE
S12261-25
N/A
SHUNT FIELD
FKL-5AJ
19.1-20.3 OHMS @ 25C
SERIES FIELD
FKL-420-U
N/A
ARMATURE
FKL-37.4N
N/A
DIAGRAM
M5570
G
I
S
TEMPERATURE
GAUGE
G
I
S
OIL PRESSURE
GAUGE
IGNITION
SWITCH
G
W
G
WK
IDLER SWITCH
GENERATOR SHUNT
FIELDCIRCUIT
7
-
+
AMMETER
LATCH
SHOWN FOR REFERENCE ONLY-
NOT PART OF CV ADAPTER
NOT PART OF CV ADAPTER
UPPER PANEL
GND SCREW
UPPER PANEL
GND SCREW
GL
OW PLUG
SWITCH
230V DUPLEX
RECEPTACLE
RECEPTACLE
115V DUPLEX
RECEPTACLE
RECEPTACLE
R
203A
602C
810
820
CB3
CB2
202
11B
11
11A
CB1
6A
7A
400F
212F
2C
R
INJ
ECTION PUMP
TIMING SOLENOID
ENGINE
TEMPERATURE
SENSOR
212F
16 OHMS
0.9 AMPS
RIGHT SIDE OF ENGINE
ON INJECTION PUMP
ON INJECTION PUMP
INJ
ECTION PUMP TIMING
SOLENOID TYP. CURRENT
DRAW 0.9A APPROX.
RESISTANCE 16 OHMS
MAY NOT APPEAR ON ALL MODELS
located generator
end of machine
end of machine
located engine right side
(viewfrom control panel end)
(viewfrom control panel end)
FRAME
FRAME
ENGINE BLOCK
+
+
ENGINE
STARTER
12 VOLT
BATTERY
235
ST
ART SWITCH
50A
G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.