Lincoln Electric SVM178-B Welding System User Manual


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ELEcTricaL DiaGramS
G-10
vaNTaGE® 500
SchEmaTic - cOmpLETE machiNE - G4848 (cODES 11180, 11415 & 11468 DEuTz) paGE 1
G4848
VA
NTA
GE 500
DE
UT
Z
MAC
HI
N
E SC
HEM
ATIC
NONE
G4487
B.
M
UTER
N.S.
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
:
EQ
UIP
M
ENT
TYPE:
SUBJECT:
SCA
L
E:
UF
CRM36466
1
PAGE ___ OF
___
2
E
NGI
N
EE
RI
NG
CO
NT
RO
LLE
D
MA
NU
FA
CT
URE
R:
No
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:
A
08/03/2004
t
MAT
ERI
A
L TO
L
ER
ANC
E ("
"
) TO A
GR
EE
WITH
PU
B
LI
SH
ED
ST
ANDARD
S.
ON A
LL
AN
GL
E
S I
S ± .5 OF
A D
E
GR
EE
ON
3
PLACE
D
E
CIM
ALS
IS
± .
002
ON 2
PL
AC
E D
ECIM
AL
S I
S ± .02
UNLESS OTHERWISE SPECIFIED TOLERANCE:
M
ANUF
ACTURING TO
L
ER
ANC
E
P
ER
E
2056
R
ele
ased A.01 from
X
CHAN
GE
D
ET
AIL:
REFER
ENCE:
MA
T
ERI
AL
DIS
PO
SI
T
ION:
AP
PRO
VA
L
DA
T
E:
PROJ
EC
T
NUMBER:
DOCUMEN
T
NUMBER:
DOCUMEN
T
REV
ISI
ON:
G4848
TH
RE
E
PHASE
RE
CTIFI
ER
3200uf
300vdc
SHUNT
50
M
V=400
AM
PS
206S
204S
LEFT CHOKE
CURRE
NT L
EV
EL
FE
E
D
BAC
K
SI
GN
AL
POSITI VE
OUTPUT
TERMINAL
NEGATI VE
OUTPUT
TERMINAL
B
Y-
PASS
P
C
BOA RD
206B
208
5A
A
C
AU
X.
POWER
42 V
OLT
AC
WI
R
E F
EEDER
POWER
41
42
FO
U
R
P
OL
E 1800
R
PM
ALT
ERN
AT
OR
120 V
OLT
AC
POWE
R F
OR
R
OT
O
R FI
EL
DCI
RC
UIT
12 V
OLT
B
ATT
ERY
EN
GI
NE
ST
A
RT
ER
S
OL
EN
OI
D
ST
A
RT
B
UTT
O
N
S
WIT
CH
RU
N-STOP SWIT
CH
SHOWN I
N RUN
POS.
FR
AM
E
GROUND
W2
W2
W3
W3
W5
W4
W5
W4
W1
W1
W6
W6
3
5
6A
PERIPHERAL
PCBOARD
PULLCOIL
PCBOARD
(J31-9)
5T
229
(J31-4)
232F
405 (J31
-11)
(J32-6)
234
(J31-6)
262A
270 (J31
-8)
271 (J32
-7)
SENDER
SENDER
S
WIT
CH
TEM
PER
AT
URE
OIL
PRESSURE
S
WIT
CH
EN
G.
PRO
T.
FU
EL
TEM
P.
241
228
405 (J43
-5)
271 (J43
-4)
200 (J43
-3)
227 (B1)
IDL
E
S
OL.
P
ULL
C
OIL
5S (
B4)
232N (
B2)
SH
UT
DOW
N
C
OIL
+12
V
OLT
S
RUN
EN
GI
NE
ST
A
RT
ER
+12
V
OLT
S
RUN
+12
V
OLT
S
RUN
201
200
200A
HOUR
MET
ER
+
21
WI
R
EF
EEDER
V
OLTM
ET
ER
P
OL
A
RIT
Y
S
WIT
CH
206A
208A
231
238A
+
160 V
DC
6
5H
270 (J43
-6)
_
+
236B
232H
232D
C
B 15
A
238B
236A
C
E
LEFT
CHOPPE
R
P
C
BOARD
G
AT
E SI
GN
AL
IG
BT (8)
B7
B8
B6
B3
B5
B2
B4
B1
+CO
M
FLY
BACK
DI
ODE
S (6)
FILTE
R
CAPA
CIT
OR
S (4)
+
10,000u
F x4
p/n L118
45-1
C
E
RI
G
HT
CHOPPPPE
R
P
C
BOA RD
G
AT
E SI
GN
AL
IG
BT (8)
B7
B8
B6
B3
B5
B2
B4
B1
+CO
M
FLY
BACK
DI
ODE
S (6)
FILTE
R
CAPA
CIT
OR
S (4)
+
10,000u
F x4
p/n L118
45-1
RIGHT
C
HOKE
D
C
BU
S
V
OLT
AGE
90+/-10V
D
C
@
HI I
DL
E
AR
C
V
OLT
AG
E F
EEDBAC
K SI
GN
AL
R1
O
UT
P
UT
CO
NT
R
OL 10
K
77 (J7-
1)
76 (J7-
4)
75 (J7-
5)
R2
ARC
CO
NT
R
OL 10
K
279 (J7
-6)
278 (J7
-7)
277 (J7
-8)
(J3-14)
257
(J3-7)
256
IDL
E
R
S
WIT
CH
(J1-4)
2
(J1-3)
4
W
EL
D T
E
RM.
S
W.
MO
DE
S
WIT
CH
CC
CV
PI
PE
TIG
(J7-9)
214
(J7-14)
218
(J7-15)
220
(J7-16) 222
260 (J3
-4)
261 (J3
-3)
TO
R
OI
D-
SENSE
S
AC
POWE
R T
O
A
CTI
V
AT
E
IDL
ER
WE L DC ON T RO L
PCBOARD
(J2-5) 2
26
(J2-4) 4
04
204S (J6-1)
206S (J6-2)
208B (J3-15)
23(J3-10)
25(J3-9)
5G (J2-3)
R
EM
OT
E
CO
NT
R
OL 10
K
77A (J1-11)
76A (J1-14)
75A (J1-10)
10 V
0-10 V
0 V
10 V
-15 V (
W/
O
P
OT.)
0 V
0 V
15 V
15 V
0 V
TWI
ST
ED
P
AI
R
(TO
AM
PHEN
OL)
(TO
AM
PHEN
OL)
2A
4A
(TO
AM
PHEN
OL)
31
32
41A
A
B
C
D
E
F
77A
21
42A
75A
GN
D-
A
4A
2A
76A
77B
76B
75B
GROU
ND
AMPHEN
OL
IN
P
UT T
O
AM
PHEN
OL
115V
AC
CO
NT
AC
T
OR
W
OR
K
RE
MOTE
CO
NT
RO
L
42V
AC
GROU
ND
AMPHEN
OL
J
A
D
C
H
B
K
E
F
G
I
77B
76B
75B
GN
D-
B
4B
2B
4B
2B
13(J3-8)
14(J3-16)
(J1-5) 5
00
(J1-13)
500
500 I.D. J
UM
PE
R (
Part
of amphe
nol plug a
nd
lead asse
mbly.)
+15
V
@ L
O
W I
DL
E T
O
P
ULL
C
OIL
BOARD
LO
W I
DL
E
S
OL
EN
OI
D
H
OL
D
C
OIL (0
V
@ L
O
W I
DL
E)
TWI
ST
ED
P
AI
R
TWI
ST
ED
P
AI
R
R
OT
O
R FL
AS
HI
NG
Located o
n back of
control pa
nel.
P/
N
G4107-1
Located o
n wiring behind
receptacle
s.
Open
Circuit
Volts:
CC
Max
Min
5858
58
58
58
26
12
12
CV
P
ipe
Tig
Control board com
mon is
at welder positive outp
ut
and shunt
Control board circuits
associated with J2 are
part
of engine
electrical syst
em and a
re comm
on to
frame g
round (
negative b
attery te
rminal.
Rotor Flashing: +12 volts
@ 0.5 amps
until gene
rator buil
ds up
then +160 volts @ 0 am
ps.
S
wich closed for high idle.
W
EL
D
AMM
ET
ER
W
EL
D
V
OLTM
ET
ER
(J4-1 to
10)
(J5-1 to
10)
Meters dis
play setpoin
t volts or a
mps when not welding.
Meters dis
play actual v
olts and a
mps when
welding.
Hold function displays act
ual volts an
d amps fo
r
approxim
ately 5 seco
nds after welding stop
s.
During this hold display t
he right
most deci
mal point will blink.
23A(J3-12)
25A(J3-11)
14A
13A
14
13
TWI
ST
ED
P
AI
R
(J2-6) 2
32D
+12
V F
R
OM
RU
N/
ST
O
P
S
WIT
CH
R4
50
OH
M
100 W
R4 is located on top of
chopper
power module
assembly.
5J
1
1
1
4
4
4
404 (J43
-8)
IDL
E
S
OL.
H
OL
D
C
OIL
405A (J31-12)
247 (J32
-1)
+12
V
OLT
S
RUN
FIEL
D FL
AS
HI
N
G
ALT
ERN
AT
OR
IG
BT'
S, FL
YBAC
K
DI
ODE
S
AND
FILTE
R
CAPA
CIT
OR
S
AR
E I
NT
EGR
AL
TO
CHOPPE
R M
OD
UL
E
S
AN
D
N
OT
INDI
VI
DU
ALL
Y
RE
PL
ACEA
BL
E.
STAT
OR
W
EL
D
WI
N
DI
NGS
R
OT
O
R FI
EL
D
SLI
P
RI
NGS
RE
MOT E
CO
NT
RO
L
OIL
PRES
S.
FU
EL L
VL.
SENSOR
Chokes are mounted
on
power module assem
bly
behind ou
tput ter
minal pan
el.
Po
wer
Supply
to Control
Board
P
WM
S
ignal to Chopper
15 volt @ 20 kHz
Chopper modules a
re located
on power
module as
sembly be
hind outp
ut termin
al
panel.
Rectifier is located on p
ower module
assembly b
ehind out
put contr
ol panel.
Shunt on back of positiv
e
output te
rminal
Located o
n back of
output pa
nel
between terminals
60 TO 65 V
A
C
PHAS
E T
O
PHASE
AT
HI
G
H IDL
E
REV
OL
VI
N
G FI
EL
D
RE
SI
ST
ANC
E
APPRO
X.
25 O
HM
S
@ 75F
Field capa
citor and
diode brid
ge
located on
lower rear of fan b
affle
on right si
de of mac
hine.
Battery voltage:
12.6 volts
at rest
14 volts en
gine
running
Located o
n lower left
side of con
trol
compart
ment
Located o
n rear
of control
panel
left side.
0.2 O
HM
11 O
HM
S
3.5 O
HM
S
Oil
Pressure
S
witch
closes on low
oil pressur
e.
Temper
ature S
witch
closes on hi
gh
tempera
ture.
Engine protection
circuit. La
mp test
and 30sec
ond
delay one
ngine
start.
+20
Volts from pull
coil board
+10
Volts
Voltage
Regulators
+10
Volts
+20
Volts
YEL
LO
W
LED
230 O
HM
S
EM
PT
Y
30 O
HM
S F
ULL
10 O
HM
S
@ 0
P
SI
100 O
HM
S
@ 75
P
S1
500-600
O
HM
S
C
OL
D
50-100 OHM
S
H
OT
(S
E
E
SHE
ET 2 F
OR
SIMPLIFI
ED
CO
NT
R
OL
BOARD
SCH
EM
ATI
C)
(SIM
PLIFI
E
D
BOARD
SCH
EM
ATI
C)
(SIM
PLIFI
ED
BOARD
SCH
EM
ATI
C)
250 (J3
-5)
250 (J3
-1)
Jumper
required
for outp
ut.
Low oil
pressure
or
high
tempera
ture
shutdown
4
3 TO 5 - 120 V
A
C 1
PHASE
6A T
O 5 -120
VA
C 1
PHASE
3 TO 6
A - 240
VA
C 1
PHASE
3, 4 A
N
D 6
A - 240
VA
C 3
PHASE
LO
CKO
UT
S
WIT
CH
6
5H
Located in
top of fu
el tank
Located o
n front p
anel
Located in
engine bl
ock
Right side, rear
Located in
engine th
ermostat
housing
Located o
n front p
anel
Located in
side engin
e blower housing
Solenoids located on rig
ht front
of engine
J55-3
J55-4
J54-1
J55-2
J54-2
281 (J43
-2)
AL
T.
YEL
LO
W
LED
243 (J32
-4)
239 (J32
-8)
W
B-
B+
D+
ALT
ERN
AT
OR
3/4 Second Timer
LE
A
D
C
OL
O
R
COD
E:
B-
BL
AC
K
O
R
GRAY
G-
GREEN
O-
ORANGE
R-
RE
D
O
R
PI
NK
U-
BL
UE
W-
W
HIT
E
Y-
Y
ELL
OW
C
OM
PONE
NT
V
AL
U
E
U
NIT
S:
CAPA
CIT
O
R: MF
D/
V
OLT
S
RE
SI
ST
O
R:
O
HM
S/
W
ATT
S
CONNE
CT
O
R
PI
N
N
UM
BER
S:
VI EW
OF
CONNEC
TO
RONPCBOARD
1
2
6
7
12
LA
TCH
EX.
12
PI N CONNEC
TO
R
LABELS:
C
OMM
ON
FR
AM
E
GROUND
EA
RT
H
GROUND
G-10
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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