Electrical diagrams, K924-5 remote control (optional), G-18 – Lincoln Electric CLASSIC SVM194-A Manuel d'utilisation

Page 224: Idler / engine protection pc board, Dc exciter, Welding generator

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ELECTRICAL DIAGRAMS

G-18

CLASSIC® 300D & 300G

SCHEMATIC - COMPLETE MACHINE - (CODES 11411, 11412) (L13096)

L13096

CLASSIC 300D PERKINS 404C-22

MACHINE SCHEMATIC

L12561

Maglietta

D. BENDER

UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

ON ALL ANGLES IS ± .5 OF A DEGREE

WITH PUBLISHED STANDARDS.

MATERIAL TOLERANCE (" ") TO AGREE

DO NOT SCALE THIS DRAWING

DRAWN BY:

DESIGN INFORMATION

ENGINEER:

APPROVED:

REFERENCE:

EQUIPMENT TYPE:

SUBJECT:

SCALE:

L1309

MATERIAL
DISPOSITION:

APPROVAL
DATE:

PROJECT
NUMBER:

CRM37529

PAGE ___ OF ___

ENGINEERING CONTROLLED
MANUFACTURER:

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:

10/05/2006

New

CHANGE DETAIL:

COMPONENT VALUE UNITS:

CAPACITOR: MFD/VOLTS

RESISTOR: OHMS/WATTS

CONNECTOR PIN NUMBERS:

VIEW OF CONNECTOR ON PC BOARD

1 2

LATCH

EX. 12 PIN CONNECTOR

LEAD COLOR CODE:

B-BLACK OR GRAY
G-GREEN
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
N-BROWN

LABELS:

COMMON

FRAME GROUND

EARTH GROUND

OIL PRESSURE SWITCH / SENDER

TEMPERATURE SWITCH / SENDER

GLOW PLUG

SWITCH

IGNITION
SWITCH

OIL PRESSURE

GAUGE

AMMETER

+ -

IDLER / ENGINE PROTECTION PC BOARD

J1-2
J1-1

J1-3

J1-6

J1-7

J1-8

J1-9

J1-4

RED ENGINE
PROTECTION
LIGHT

J1-10

ALTERNATOR

TYPICAL CURRENT
DRAW IS 40 +/- 3 AMPS

TYPICAL CURRENT DRAW: 3.3A

HOUR METER

TYPICAL CURRENT DRAW AND
RESISTANCE:

HOLD COIL: 1A, 10-15 OHMS
PULL COIL: 40A, LESS THAN .1 OHM

SWITCH CLOSES
AT 6+/-2 PSI

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

+/-6

SENDER OPERATION:

140

F -> 134+/-13.5 OHMS

194

F -> 51.2+/-4.3 OHMS

212

F -> 38.5+/-3 OHMS

12 VOLT - NORMALLY OFF

SHOWN IN "OFF"

POSITION

51C

50A

51A

212D

212C

200

212A

212B

58H

844

DC EXCITER

-40 TO 40 AMPS

AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH

65 AMP / 12 VOLT

GLOW PLUGS

N.C.

N.O.

ENGINE
SHUTDOWN

ENGINE
RUNNING

12.6 VOLTS MIN
AT REST
14-14.5 VOLTS

WHILE RUNNING

IDLE

SOLENOID

CIRUITS

(SEE BELOW

FOR LOGIC)

INJECTION
PUMP

SOLENOID

FUEL PUMP

SCHEMATIC G4828-1

FLYBACK

DIODES

IDLE SOLENOID

LOCATED BEHIND UPPER PORTION OF CONTROL PANEL

SENDER IS APPROX.

500 OHMS AT 70

NEGATIVE OUTPUT

TERMINAL

POSITIVE OUTPUT

TERMINAL

GENERATOR LEAD BLOCK

SHOWN AS VIEWED WITH

ENGINE IN THIS DIRECTION

INTERPOLE

COILS

SHUNT

FIELD

SERIES FIELD

12 11 10 9 8 7 6 5 4 3 2 1

P10

FJW-5AP
COIL PAIR:
25.2 - 26.7
OHMS EACH

FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED

SHOWN IN LOCAL
POSITION

RHEOSTAT

REMOTE
RECEPTACLE

LOCAL / REMOTE
SWITCH

5 3

64+/-6.4 OHMS MAX

BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL

602B

602

SELECTOR SWITCH

90-MIN

130-80

190-120

240-160

220-MAX

WELDING
GENERATOR

CCW

JUMPER PLUG IS

WIRE-TIED UPBEHIND

LOCAL / REMOTE

SWITCH ON RIGHT

SIDEOF MACHINE

JUMPER PLUG IS FOR CONNECTION
TO WIRE FEED MODULE

TYPICAL OCV (WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT

44-54.5 VOLTS AT MIN RHEOSTAT

JUMPER PLUG ISWIRE-TIED UP

BEHIND LOCAL / REMOTE SWITCH ON

RIGHT SIDEOF MACHINE (ASVIEWED

FROM CONTROL PANEL)

610A

215

810

820

SLIP RINGS

214

GND-E

CB1

20A

11A

11C

EXCITER STATOR
(ALTERNATOR)

11B

230 VOLT

RECEPTACLE

POSITIVE SLIP RING
IS NEAREST TO IRON

EXCITER REVOLVING

FIELD (ROTOR)

400E

400D

15A

610

600B

600A

600

602A

INTERPOLE

COILS

FUSE

WINDING SPEC: ALT-241-3A
40.5 - 42.5 OHMS AT 25C

EXCITER CIRCUIT
LEAD 21A TO 21B
WINDING SPEC: ALT-214-2B
.488 OHMS MAX AT 25C

115 VOLT CIRCUIT
LEAD 810 TO 820

WINDING SPEC: ALT-214-2C
.230 OHMS MAX AT 25C

115 VOLT CIRCUIT
LEAD 820 TO 830
WINDING SPEC: ALT-214-2D
.424 OHMS MAX AT 25C

THIS CIRCUIT USES THE
RESIDUAL MAGNETISM OF
THE GENERATOR TO FLASH
THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE

GENERATOR

600C

LOWER, RIGHT SIDEOF CONTROL PANEL

DIODE

LOWER,

RIGHT OF

CONTROL

PANEL

UNDER LEFT DOOR

115 VOLT GFCI

RECEPTACLE

HOT LINE

HOT LOAD

WHITE LINE

WHITE LOAD

400F

GND-S

844A

SWITCH CLOSES
WITH FLOW OF

WELDING CURRENT

GND-A

HOLD COIL

PULL COIL

CB4

10A

GND-B

IN-LINE BOLTED CONNECTION

BEHIND CONTROL PANEL

THE P10 PLUG IS ONLY ON UNITS WITHOUT

THE WIRE FEED MODULE. THE WIRE FEED

MODULE HAS A HARNESS THAT PLUGS

DIRECTLY INTO J5.

GND-T

REED SWITCH

BACK, BOTTOM

OF MACHINE

BACK, LEFT SIDEOF ENGINE

BACK, TOPOF ENGINE

BACK, LEFT SIDEOF ENGINE

LOWER LEFT OF

CONTROL PANEL

LOWER LEFT OF

CONTROL PANEL

TEMPERATURE

GAUGE

WHITE

BLACK

RED

CENTER OF

CONTROL PANEL

CENTER OF CONTROL PANEL

J2-1
J2-2

60C

RIGHT SIDEOF ENGINE

BY INJECTION PUMP

GND-C

RIGHT SIDEOF ENGINE

BY OIL FILLER

LOWER LEFT OF

CONTROL PANEL

START
SWITCH

212E

BACK OF OUTPUT STUD

THIS LEAD PROVIDES FLASH

FOR ALTERNATOR AND

SENSES ALTERNATOR OUTPUT

TYPICAL CURRENT DRAW: 3A

APPROXIMATE

RESISTANCE: 3-4 OHMS

APPROXIMATE

RESISTANCE: 3.3 OHMS

BACK, RIGHT SIDEOF ENGINE

BATTERY

STARTER
MOTOR

STARTER
SOLENOID

MOUNTED TO NEGATIVE

BRUSH HOLDER

DIODE AND MOV ASSEMBLY

TOP, RIGHT PORTION

OF CONTROL PANEL

TOP, LEFT PORTION

OF CONTROL PANEL

B4
B5
B6

UNUSED

J2-4

J2-3

1. UPON RECIEVING POWER FROM THE
IGNITION SWITCH, THE FUEL SOLENOID,
FUEL PUMP AND HOUR METER ARE
ENERGIZED.

2. ENGINE PROTECTION IS BYPASSED
FOR ONE MINUTE TO ALLOW OIL
PRESSURE BUILDUP. ENGINE MUST BE
STARTED WITHIN ONE MINUTE OF

TURNING IGNITION SWITCH ON OR THE
FUEL SOLENOID, FUEL PUMP AND HOUR
METER WILL TURN OFF. AFTER ONE
MINUTE, THE IGNITION SWITCH MUST BE
CYCLED OFF AND BACK ON TO START
ENGINE.

3. AFTER ENGINE STARTS, FLASHING
CURRENT IS SUPPLIED TO THE ENGINE
ALTERNATOR.

4. AFTER ONE MINUTE, TIMER IS TIMED
OUT. IF OIL PRESSURE IS LOW,
COOLANT TEMPERATURE IS HIGH OR
ALTERNATOR IS NOT CHARGING, THE
ENGINE WILL SHUT DOWN AND THE
ENGINE PROTECTION LIGHT WILL COME

ON.

IDLER SWITCH

WELD LOAD SENSING

AUX LOAD SENSING

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.

3. IF AN AUXILIARY CURRENT DRAW OR WELD
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED.

ENGINE PROTECTION CIRCUIT LOGIC

IDLE SOLENOID CIRUIT LOGIC

J1-5

60A

REVERSE VOLTAGE
PROTECTION DIODE

ENGINE

PROTECTION

CIRCUITS (SEE

BELOW FOR

LOGIC)

D+