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ELECTRICAL DIAGRAMS
G-3
PRECISION TIG 185
SCHEMATIC - ENTIRE MACHINE - (G4588)
EN-170
S
O
L
ID
E
D
G
E
ENGINEERING CONTROLLED
MANUFACTURER:
No
RELEASED FROM X A.02
G4588
Precision Tig 185
MACHINE SCHEMATIC
NONE
Reference
Jbarto
TNguyen
Approve
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM36191
1
PAGE ___ OF ___
1
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
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.
PROPRIETARY & CONFIDENTIAL:
A
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE
DIFFERENT
FROM AN ACTUAL MACHINE.
02/20/2004
CHANGE DETAIL:
G4588
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PC BOARD
1
2
6
712
LATCH
EX. 12 PIN CONNECTOR
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
SCR4
SCR3
SCR1
SCR2
MAIN SCR
RECTIFIER
D1
OUTPUT
INDUCTOR
AC
DC
DC
DC
DC
AC
AC
AC
++
-
-
POLARITY SWITCH
SHUNT
MAIN
TRANSFORMER
X1
X2
H1
H2
H3
L2
L1
+
-
250VAC
.0047/
400A/200mV
S2
C1
C2
L1
DC
+
DC
-
DC
+
DC
-
G1
G2
G3
G4
218
217
216
220
SCR3,SCR2 CATHODE
SCR1 CATHODE
SCR4 CATHODE
SCR1,SCR4 ANODE
SCR1 GATE
SCR2 GATE
SCR3 GATE
SCR4 GATE
216A
G4
G3
G2
G1
220
217
218
FREE WHEELING DIODE
POWER SWITCH
R 222(-)
W 221(+)
W 221
R 222
SHUNT (+)
SHUNT (-)
1J1
2J1
TOROID
LOW
HIGH
T1
BYPASS ASSEMBLY
R1
WORK
SV1
GAS
SOLENOID
FAN
X7
X8
HIGH FREQ.
TRANSFORMER
100/100
T2
S
F
C3
.0015/
12KV
SPARK
GAP .020
R3
200/100
C4
15/250
HIGH
VOLTAGE
TRANSFORMER
L2
L3
T3
ELECTRODE
HOLDING RESISTORS
231
231
231A
232
236B
237
238
239
236
HI-FREQ (115VAC)
GAS (115VAC)
FAN (115VAC)
235
260
314
313
THERMOSTAT INPUT
235
232
260
232
115VAC IN
4J4
1J4
2J4
3J4
X5
X6
X3
X4
18VAC
CONTROL BOARD SUPPLY
18VAC
TRIGGER CIRCUIT
209
210
201
204
AUX. WINDINGS OF
MAIN TRANSFORMER T1
CHOKE TSTAT
(SCHEMATIC S22530)
BYPASS/STABILIZER
PCB
115VAC
(115VAC)
115VAC
5.5 OHMS
TYP.
14.5 KOHMS
TYP.
12.5 OHM TYP.
12.5 OHM TYP.
T1
T1
HI-FREQ CIRCUIT
3 DIGIT
METER
CW
R1
CW
10K
RECEPTACLE
TM
OPTIONAL AMPTROL REMOTE
CONTROL AND ARC START SWITCH
A
B
C
D
E
F
U
N
R
B
W
10K
TOROID
C
A
B
OUTPUT CONTROL
(ENCODER)
+5Vref
+5Vref
CW
R2
CW
10K
+5Vref
CW
R3
CW
10K
+5Vref
BALANCE
PULSE FREQUENCY
POSTFLOW
+15V
MODE
STICK
(RED)
TIG
(GREEN)
MICRO-
PROCESSOR
AUT0BALANCE
(GREEN)
FREQUENCY
(GREEN)
THERMAL
(YELLOW)
SEE RATING PLATE FOR SPECIFIC VOLTAGES
230 o
r 400-415 or 575 VOLT CONNECTION
H1 and H3 (HIGH) TO POWER SWITCH.
208 o
r 380 or 460 VOLT CONNECTION
H1 and H2 (LOW) TO POWER SWITCH.
H3 NOT CONNECTED; INSULATE.
H2 NOT CONNECTED; INSULATE.
C1 AND C2 MUST ALWAYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES
VOLTAGE RECONNECTION
(AS SHOWN & AS SHIPPED FROM FACTORY)
R2
CLOSED
IN DC
311
312
311
312
MICRO SWITCH INPUT
5J3
6J3
N.C.
R5
12/100 EACH
R4
220A
218A
ARC STARTER ASSEMBLY
1J3
2J3
7J3
8J3
4J3
3J3
100/100
284A
285A
285B
284B
284
285
MICRO SWITCH CLOSED IN DC
OPEN IN AC
W
B
G
INPUT PLUG
216
BACKGROUND RESISTORS
BACKGROUND AC INPUT
BACKGROUND ( - )
BACKGROUND ( + )
240
11J3
9J3
10J3
12J3
5J2
6J2
3J2
8J2
2J2
1J2
4J2
7J2
1J5
3J5
2J5
5J5
6J5
METER
INTERFACE
LED INTERFACE
J2
J3
J4
J5
J6
J1
+15V
(GREEN)
+5V
(GREEN)
+5Vref
(GREEN)
CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT
(VIEWED FROM COMPONENT SIDE)
AUTO LOCAL/REMOTE
STICK MODE: ALWAYS LOCAL
TIG MODE: REMOTE IF PLUGGED
LOCAL IF UNPLUGGED
2 PIN
6 PIN
8 PIN
12 PIN
4 PIN
4 PIN (WHITE)
PROGRAMMING
CONNECTOR
HI-FREQ BYPASS
CONNECTION
SCHEMATIC G4550-
ASSEMBLY G4551-
CONTROL PC BOARD
+5V
30 S
1 S
20 HZ
OFF
MAX. PENETRATION
AUTO
MAX. CLEANING
5 - 185A IN DC
7 - 185A IN AC
+5V
+5Vref
OUTPUT CONTROL &
MODE SETTINGS ARE
MEMORIZED AT POWER
- DOWN AND RECALLED
AT POWER - UP
SCR
GATING & SNUBBER
+15V
+5V
MICRO-START
CIRCUIT
+15V
OUTPUT REGULATOR
+15V
115V CIRCUIT
TRIAC & OPTO-TRIAC
DRIVER
+15V
(PCB AS'BLY L10121-1)
435 OHMS TYP.
12 OHMS TYP.
FAN RUNS FOR 5 S AT POWER-UP
STOPS AT IDLE 8 MINUTES
AFTER WELDING.
COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED
FROM FRONT OF MACHINE UNLESS STATED
OTHERWISE
G4
G3
G2
G1
IN-LINE CONNECTOR J7
4
3
2
1
In Front of main
transformer,
Attached to Base
Left side of Machine
near front
Rear Panel
Right Side
Right Side of SCR Bridge
Rectifier. Top of Machine
behind Choke.
Right side of Machine
above Choke Coil.
Right side of machine,
front of gas solenoid,
attached to Base
Attached to Power Switch
S1
Front Panel Left side
Front Panel Center
Front Panel Top
Inside hi-freq box on
right side of machine
near front
Rear of machine attached to
base, below fan
0.1 HZ
Right front side of
Main Transformer
Between SCR Bridge halves
behind choke.
Mounted to front side
of hi-freq box on
right side of machine
near front.
Lower left side of
Polarity Switch
Inside hi-freq box on
right side of machine
near front
BACKGROUND AC INPUT
245
244
216A
240
TWISTED PAIRS
BALANCE
POSTFLOW
FREQUENCY
(NORMALLY CLOSED
OPEN AT 135C TYP.)
Right rear side of Main
Transformer
80 VAC
On top of Main
Transformer
Inside sleeving at top left side of
Main Rectifier
DISPLAY PRESET AT IDLE
ACTUAL AMP WHEN WELDING
NO HOLD FUNCTION
(DISABLED IN STICK)
OUTPUT CONTROL
X1
SOFTWARE
VERSION LABEL
65V IN DC
75V IN AC
POWER-UP SEQUENCE
METER AND MODE DISPLAY THE PREVIOUS OUTPUT
CONTROL AND MODE SETTINGS. FAN RUNS FOR 5
SECONDS. IF MODE IS TIG, GAS FLOWS FOR A TIME
SET BY THE POSTFLOW KNOB. OUTPUT IS HOT IF
MODE IS STICK. IN TIG MODE OUTPUT IS COLD UNTIL
TRIGGER IS CLOSED
(DISP1)
A1
S1
METER, ENCODER, SWITCH, LEDs,
AND ALL POTENTIOMETERS ARE
MOUNTED ON PC BOARD
TYPICAL OCV
TOGGLE BETWEEN TIG &
STICK.
HI-FREQ, GAS, BALANCE
CONTROL, PULSE
FREQUENCY, &
MICRO-START CIRCUIT
ARE DISABLED IN STICK
LED 1
LED 3
LED 4
LED 5
LED 2
THERMAL
(YELLOW)
LED 6
NEXT TO MODE SWITCH
NEXT TO BALANCE POT.
NEXT TO PULSE
FREQUENCY POT.
NEXT TO METER
NEXT TO METER
NEXT TO MODE SWITCH
OFF IN STICK AND DC TIG
OFF IN STICK, BLINKS AT
FREQUENCY RATE
TWO THERMAL LEDs TO
LIGHT THROUGH
BACK-LIT THERMAL
SYMBOL
MODE
MICRO-PROCESSOR
1J6
2J6
3J6
4J6
+5Vref
DATA
SCLK
XRES
PROGRAMMING CONNECTOR
FOR SOFTWARE UPGRADE
HI-FREQ BYPASS CONNECTION
FROM BOTTOM LEFT
MOUNTING HOLE TO SHEET
METAL
Left front
SCR4
SCR2
SCR1
SCR3
G4
216
G3
2
1
8
G
2
G
1
2
1
7
A
C
D1
+
( )
( )
_
2
1
6
A
X
2
2
2
0
2
1
8
A
P
O
S
S
H
U
N
T
2
2
0
A
D
C
2
1
6
A
R 222R 222
W 222
TO0 COPPER BAR
BOTTOM
COPPER
BAR
6 GA. FLEX LEADS
7 GA. FLEX LEAD
ALUMINUM BAR
FARTHEST LEFT
SCR (VIEWED
FROM FRONT)
FARTHEST RIGHT SCR
(VIEWED FROM
FRONT)
SCR
HEATSINK
SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL
240
P
O
S
DC
285
2
8
4
OUTPUT INDUCTOR
X1
MOUNTING HOLE
Gang D
Gang A
gang B
Gang C
Rear gang G
Rear gang H
Gang F
Gang E
GANG LOCATIONS ARE
VIEWED FROM REAR OF
SWITCH
POLARITY SWITCH
MICRO SWITCH
A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H
OPEN
CLOSED
CLOSED
AC
DC+
DC-
311
312
MICRO SWITCH
UNUSED TERMINAL
RECONNECT IS DONE AT
POWER SWITCH
Center of machine
Top rear
SEE CONNECTION DETAIL
SETPOINT
PHASE_FIRE
INTERFACE
INTERFACE
AC/DC
THERMOSTAT
DETERMINE IF HI-FREQ IS
CONTINUOUS OR START
ONLY, MIN. CURRENT, AND
BALANCE CONTROL
DISABLE OUTPUT & HI-FREQ
IF THERMOSTAT OPEN
CURRENT FEEDBACK
Iarc
PHASE
DETECTOR
POWER SUPPLY
+15V
+5V
+5Vref
-15V
PHASE
TO MICRO PROCESSOR
AND SCR GATING
PHASE
PHASE
AUTO
LOCAL/
REMOTE
CONTROL
DET_REM
REM_SENSE
REM_POT
TO MICRO
PROCESSSOR
DET_REM
REM_SENSE
REM_POT
From Auto Loc/Rem
Polling signal
Hi = Local
Remote control
TRIGGER
INTERFACE
TRIGGER
TRIGGER
TO MICRO
PROCESSOR
DO NOT REVERSE LEADS
209 & 210, USED FOR SCR
PHASE TIMING
115V
5000V
HI-FREQ OFF IN STICK
START ONLY IN DC TIG
CONTINUOUS IN AC TIG
Right front
Center front
TYP. RPM:
1600 RPM 60Hz
1340 RPM 50Hz
15 - 20 OHM
GATE-CATHODE
RESISTANCE TYP.
FIRE_SCR
BG
-15V
RF
CHOKES
+15V
-15V
+5V
+24V
+5V
+24V
+5Vref
+24V
+5Vref
+24V
DC
AC
P
O
S
Gang D
Gang A
Gang C
Gang G
Gang B
Gang H
Gang E
Gang F
CBW
CBW
CBW
CBW
CBW
CBW
CBW
CBW
CBW = CONNECTED
BY SWITC H
THESE CONNECTIONS
ARE MASE BY POLARITY
SWITCH, THEY ARE NOT
PHYSICAL LEADS
CBW
SEE CONNECTION DETAIL
BALANCE CONTROL IS
DISABLED IN STICK AND
DC TIG
PULSE FREQUENCY IS
DISABLED IN STICK
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.