Lincoln Electric 655/R Welder User Manual


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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
ELECTRICAL DIAGRAMS
G-24
PC BOARD ASSEMBLY - SWITCH PC BOARD
EN-170
G350
1-
1
INVERTER WELDERS
SWITCH P.C
.
BD
.
AS'BLY
1:1
-
lw
imb
ley
TK
-
UNLESS OTHERWISE SPECIFIED TOLERANCE
M
ANUF
ACTURING TO
L
ER
ANC
E
P
ER
E
2056
O
N
2
P
LAC
E
DE
CIM
AL
S I
S
± .
02
ON 3
P
LA
CE
DEC
IMA
LS IS
±
.002
O
N
ALL
A
NGLE
S I
S
± .
5
O
F
A
DEGREE
WI
T
H
PUBL
IS
HE
D
STA
ND
A
RD
S.
MATE
RI
AL
T
OLERA
NC
E
(" ") T
O
AGREE
t
DO NO
T
SC
AL
E
T
HIS DR
A
WING
D
RAWN
BY:
DESIG
N
I
NFO
RMATI
ON
ENG
I
NEER:
AP
PRO
VED
:
REFERENCE:
EQ
UIP
M
ENT
TYPE:
SUBJECT:
SCA
L
E:
G3501-1
MATERIAL
DISPOS
IT
ION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
C
RM35906
1
PAGE ___ OF
___
1
E
NGI
N
EE
RI
NG
CO
NT
RO
LLE
D
MA
NU
FA
CT
URE
R:
No
DO
C
UM
E
NT
N
UM
BE
R:
DOCUMENT
REVISION:
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBA
L, INC.
AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
TO O
THER PARTIES OR US
ED FOR
AN
Y
PURPOS
E WITHOU
T
THE EXPRES
S WRIT
TEN PERMISSION
OF LINCOLN GLOBAL, INC.
PRO
PRIETARY & C
ONFIDENTIAL:
B
3/10/200
5
R
EM
OVE
D MF
G
OPER
ATI
O
N
AN
D
W/
C T
A
BL
E
CHA
NGE
D
ETAIL:
S
O
L
ID
E
D
G
E
STRP
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. SEE E2454 BEFORE HANDLING.
N.B. PC BOARD AND MODULE MOUNTING HOLES TO BE FREE OF ENCAPSULANT MATERIAL
FOR A CENTERED 0.50” MIN. DIA. AND 0.55” MAX. DIA. (8 H
OLES). MASK PER
APPROPRIATE MANUFACTURING WORK INSTRUCTIONS. TO BE CENTERED WITHIN 0.100”
(DO NOT GET ON MATING SURFACES).
N.C. MOLEX CAVITIES AND
AREA AROUND LOCKING TAB TO BE FREE OF ENCAPSULANT
MATERIAL. MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
N.D. FEMALE EYELET TO BE AGAINST THE OPPOSITE COMPONENT
SIDE AS SHOWN. EYELET MUST NOT SPIN AFTER CLINCHING.
N.E. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND
ALL AROUND EYELET
ON OPPOSITE COMPONENT SIDE ONLY. NO
ICICLES OR SOLDER BLOBS PERMITTED.
N.F. BAR MUST BE FREE OF ENCAPSULATION MATERIAL ON BOTH
SURFACES AROUND MOUNTING HOLES AND ENTIRE LENGTH OF
MOUNTING SURFACES. ENCAPSULATION MATERIAL MUST NOT
EXTEND BEYOND THE MOUNTING SURFACE PLANE (4 PLACES).
N.G. DO NOT COAT THE TOP SURFACES OR THREADS WITH ENCAPSULANT MATERIAL
(4 TERMINALS). MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
EYELET DETAIL
.285
.275
R
.045
.116
MA
X.
C
RIM
P
H
EI
G
HT
OPPO
SIT
E
C
OM
PONE
NT
SI
DE
3
4
N.D.
N.J.
(4 PL
ACE
S)
N.
E.,
N.M.
(4 PL
ACE
S)
N.F.
2
MA
K
E
PE
R
E1911
P
OT
PE
R
E1911-
E
TE
ST
PE
R
E3826-
SW
MA
N
UF
A
CT
URE
D
A
S:
ID
E
NTIFI
C
ATI
O
N
CODE
G3501-1F0
CAPA
CIT
OR
S
= MFD/
V
OLT
S
RE
SI
ST
OR
S
=
O
HM
S
N.
B.
1
5
N.H. ELECTRONIC MODULES TO BE ASSEMBLED, SOLDERED, AND SEALED TO
PC BOARD PER E3875.
N.J. THESE SURFACES MUST BE MAINTAINED CO-PLANAR WITHIN .010”
THROUGH ENTIRE SOLDERING AND SEALING PROCESS (4 PLACES).
N.K. INSPECT POWER TERMINAL PER E1880.
N.L. ELECTRONIC MODULES ON A COMMON P.C. BOARD ASSEMBLY TO
HAVE VGE (TH) AND VCE (SAT) IN SAME SORT CODE (0.1 VSPAN) AND THE SAME
VENDOR CODE.
e.g. M16100-46 X XX XXX……
VENDO
R
CODE
VC
E (
S
AT)
VG
E (T
H)
N.M. DO NOT COAT WITH ENCAPSULATION MATERIAL. TOP AND BOTTOM, FOR 0.80” MIN. DIA. AND
0.85” MAX. DIA. MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
TO BE CENTERED WITHIN 0.100” (DO NOT GET ON THE MATINGSURFACES).
N.
K.
N.
G.
N.C.
N.
A.,
N.
H.,
N.L.
ITEM
QTY
PART NO.
DESCRIPTION
X1
1 M13552-3
IC, CONVERTER, V/F, 654
T1
1 S13000-46 TRANSFORMER,PCB;
C29
1 S13490-93 CAPACITOR, TAEL, 27, 35V, 10%
OC11
1 S15000-22 OPTOCOUPLER, PHOTO-Q, 70V, CNY17-3/VDE
X2
1 S15128-10 VOLTAGE REF, ADJ, PERCISION, 431I
R77
1 S16296-5 TRIMMER, MT, 1/2W, 10K, 10%, LINEAR
C30
1 S16668-5 CAPACITOR, CEMO, .022, 50V, 20%
C1,C2,C3,C4,C31
5 S16668-6 CAPACITOR, CEMO, 4700p, 50V, 10%
C32
1 S16668-11 CAPACITOR, CEMO, 0.1, 50V, 10%
R78
1 S19400-1000 RESISTOR, MF, 1/4W, 100, 1%
R2,R12,R22,R32
4 S19400-1001 RESISTOR, MF, 1/4W, 1.00K, 1%
R46,R74
2 S19400-1002 RESISTOR, MF, 1/4W, 10.0K, 1%
R70,R71,R72
3 S19400-1003 RESISTOR, MF, 1/4W, 100K, 1%
R47,R75
2 S19400-2001 RESISTOR, MF, 1/4W, 2.00K, 1%
R79
1 S19400-2213 RESISTOR, MF, 1/4W, 221K, 1%
R73
1 S19400-6191 RESISTOR, MF, 1/4W, 6.19K, 1%
R76
1 S19400-6811 RESISTOR, MF, 1/4W, 6.81K, 1%
C33
1 S20500-14 CAPACITOR, PPMF, .022, 100V, BOX, 5%
J40
1 S24020-6 CONNECTOR, MOLEX,MINI,PCB,6-PIN,TIN
T12218-15 CHOKE, RF,FERRITEBEAD,180OHM
DZ13
1 T12702-4 ZENER DIODE, 1W, 20V, 5% IN4747A
DZ1,DZ4,DZ7,DZ10 4 T12702-40 ZENER DIODE, 1W, 6.2V, 5% IN4735A
D1,D2,D3,D4
4 T12705-44 DIODE, AXLDS, 1A, 1000V, FR, 818
R1,R6,R7,R8,R9,R10,R11,R16,
R17,R18,R19,R20,R21,R26,
R27,R28,R29,R30,R31,R36,
R37,R38,R39,R40,R69
C5,C6,C7,C8,C9,C12,C13,C14,
C15,C16,C17,C18,C19,C20,
C21,C24,C25,C26,C27,C28
20
25
T12702-29 ZENER DIODE, 1W,15V, 5% IN4744A
S19400-10R0
S20500-1
RESISTOR, MF, 1/4W,10.0,1%
CAPACITOR, PPMF, 0.1, 1000V, 10%, BOX
L1,L2,L3,L4,L5,L6,L7,L8,L9,
L10,L11,L12,L13,L14,L15,L16,
L17,L18,L19,L20
20
DZ2,DZ3,DZ5,DZ6,DZ8,DZ9,
DZ11,DZ12
8
D7,D8,D9,D10,D11,D12,D13,
D14,D15,D16,D17,D18,D19,
D20,D21,D22,D23,D24,D25,D26
20
T12705-32 DIODE, T220, 15A, 600V, FR, MUR1560
R41,R42,R43,R44,R45,R63,
R64,R65,R66,67
10
T14648-9
RESISTOR, WW, 5W,2.5K,5%,SQ.
SCHEMATIC REFERENCE
:
L11016-1F0
BUY BLANK COMPLETE AS G3501-F
P.
C.
B
OAR
D
BLAN
K
REFERENC
E
IN
FO
RMA
TI
ON
(M
AKE
S
2
BOARD
S
PE
R
PANE
L,
SE
E
ELE
CT
RO
NIC
FIL
E
FO
R
AD
DI
TI
ONA
L I
NF
ORMA
TI
O
N)
PANE
L
SI
Z
E
PE
R
E
1911
FO
R
PA
RT
S
ORDER
S
O
R
SUB
SI
DI
AR
Y
ORDER
S:
IN
CL
UD
E (1)
S25254
P
RI
NT, (1)
S25191-1
P
RI
NT,
(1) T1
2837-1 A
N
D (4)
S25347-2.
C
OM
PONE
NT
SI
DE
ENCAPS
UL
ATI
ON
P.
C.
BOARD
OPPO
SIT
E
C
OM
PONE
NT
SI
D
E
ENCAPS
UL
ATI
ON
N.
N.
ENCAPS
ULAT
E
C
OM
PONE
NT
SI
D
E
OF
P.
C.
BOAR
D T
O
A T
HI
CKNES
S
OF .30 +.12/-.00 IN
ARE
A
SHOW
N.
N.
P.
ENCAPS
ULAT
E
OPPO
SIT
E
C
OM
PONE
NT
SI
D
E
OF
P.
C.
BOAR
D T
O
A T
HI
CKNES
S
OF .25 +.12/-.00.
N.
R.
ENCAPS
UL
ATI
O
N M
AT
E
RI
AL M
U
ST
E
XT
EN
D
BEYON
D
EDGE
S
OF
P.
C.
BOAR
D .12
+.12/-.00.
N.
S.
ENCAPS
ULAT
E
OPPO
SIT
E
C
OM
PONE
NT
SI
D
E
OF
P.
C.
BOAR
D I
N
AREA
S
SHOW
N T
O
A M
A
XIM
UM
THI
CKNES
S
OF .20.
2.70
±.12
1.32
+.
12
-.
00
1.36
+.
12
-.
00
N.
S.
N.
N.,
N.
P.,
N.R.
2.50 5.90
N.
S.
N.
S.
(4 LAYER BOARD PER E3281)
8
7
ITEM
QTY PART NO.
DESCRIPTION
11
SEE ABOVE
P.C. BOARD BLANK
2 4 M16100-46 ELECTRONIC MODULE (A1,A2,A3,A4) (SS)
3 4 T9147-15 EYELETS (MALE)(B2,B3,B6,B7)
4 4 T9147-11 EYELETS (FEMALE)
54
S23006
POWERTERMINAL (B1,B4,B5,B8)
6
430g
E2527
EPOXY ENCAPSULATING RESIN
7 1 S24869-1
PC BOARD SHIELD
8 1 S24869-2
PC BOARD SHIELD
C
5
C
6
C
7
C
8
C
9
C
12
C
13
C
14
C
15
C
16
C
17
C
18
C
19
C
20
C
21
C
24
C
25
C
26
C
27
C
28
L6 L7 L8 L9 L10
L16 L17 L18 L19 L20
L1L2L3L4L5
L11L12L13L14L15
R6R7R8R9R10
R16 R17 R18 R19 R20
R26R27R28R29R30
R36 R37 R38 R39 R40
R
41
R
42
R43
R
63
R
64
R
65
R
66
R
67
R44 R45
R
1
R
2
R11
R12
R
46
R
47
C
1
C2
C
29
C
3
C
4
R
21
R
22
R
31
R
32
T
1
X2
D1
D2
D3
D4
C30
C
32
C31
OCI1
R70
R
71
R
72
R73
R
74
R75
R76
R
69
R79
R
78
X1
B7B6B3B2
J40
C
33
R
77
S
H1
B4 B5
B8B1
DZ7
DZ1
0
DZ4
DZ1
DZ1
2
DZ1
1
DZ9
DZ8
DZ6
DZ5
DZ3
DZ2
DZ1
3
A1
A2
A3
A4
D8
D7
D26
D25
D24
D23
D22
D21
D20
D19
D18
D17
D16
D15
D14
D13
D12
D11
D10
D9
SH
1
14
OR
17
11
OR
16
J40/
J5
0
B
A
D
C
R41
C3
3
C2
9
R45
T1
J40/
J5
0
R77
D
C
B
A
D1
6
D1
5
D1
4
D1
3
D1
2
D1
1
D1
0
D
9
D
8
D
7
C
5
C
6
C
7
C
8
C
9
C1
2
C1
3
C1
4
C1
5
R44
C1
6
C1
7
C1
8
C1
9
C2
0
C2
1
C2
8
C2
7
C2
6
C2
5
C2
4
D1
7
D1
8
D1
9
D2
6
D2
5
D2
4
D2
3
D2
2
D2
0
D2
1
R67
R66R65
R64
R63
R42
R43
1
8
1
5
1
2
1
3
OR
OR
1
9
2
0
2
2
2
1
ELE
C
TR
ICAL
LY L
I
VE P
A
RT
S.
S
ERV
ICI
NG
.
D
O
N
OTTOUCH
I
NP
UT
C
APACIT
OR
S
BEF
ORE
DISC
ONNEC
TI
NP
UTPO
WER
A
ND
DISCHA
RGE
DO
N
OTO
PER
AT
E W
ITH PA
NEL
S
RE
M
OVE
D.
HIGH VOLTAGE CAN
KI
LL
DANG ER
FR
SW
ITCH
G
3501-
1
PW-655
1.15 2.25 2.25 2.25
0
10.75
±.04
0
9.00
±.04
N.T.
N.T.
N.T.
ITEM 8
MO
U
NT
S
AN
D
S
OL
DER
S T
O
S
AM
E
H
OL
E
S
AS
ITEM 7
.
ITEM 8
IS M
OU
NT
E
D
ON
N
O
N-
C
OM
PONE
NT
SI
D
E
OF
P.
C.
BOAR
D.
1.32
+.
12
-.
00
B
G-24
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