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ELECTRICAL DIAGRAMS
G-6
POWER MIG 300
SCHEMATIC - COMPLETE MACHINE - CODE 10958 AND 11000 ONLY
EN-170
S
O
L
ID
E
D
G
E
G4315
ENGINEERING CONTROLLED
MANUFACTURER:
No
CHANGE DETAIL: VARIOUS CORRECTIONS.
G4315
POWER MIG 300
MACHINE SCHEMATIC
NONE
cstuble
J. SKERBEC
Approve
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
3-26-2003
MATERIA L
DI SP OS I TI ON:
AP PR O VAL
DAT E :
PROJECT
NUMBE R :
NA
CRM22115-EE
1
PAGE ___ OF ___
1
DOCUMEN T
NUMBE R :
DOC U ME N T
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:
B
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONE NTS AND
CIRCUITRY MAY BE
DIF F E R E NT
FROM AN ACTUAL MACHINE.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNE CTOR ON PC BOARD
1
6
712
LATCH
EX. 12 PIN CONNE C T OR
LABE LS:
COMMON
FRAME GROUND
EARTH GROUND
J1,J86
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
J81,J82
6
5
10
1
3
4
1
2
J85,J87
9
8
16
1
4
6
1
3
J2,J84
5
4
8
1
J83,J88
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE
B - BLACK
W - WHITE
R - RED
U - BLUE
6J 83
2J 41
1J 41
1J 42
2J 42
3J 42
5J 42
472 412
471 411
408
410
+15VDC CONT ROL BD SUPPLY
-15VDC CONTROL BD SUPPLY
+5VDC CONTROL BD SUPPLY
CONTROL BD SUPPLY COMMON
DIGITAL POWER
SUPPLY P.C. BOARD
(SCHEMATIC G3631)
LOCATED AT BOTTOM OF
P.C. BOARD COMPARTMENT
PLACED AT A 45∫ ANGL E
ILLUMINATED LED
INDICATES VOLTAGES ARE
BEING SUPPLIED TO J43
LED2
RED
LED1
RED
4J 99
1J 99
431
437
PWM = 20KHZ 12V
CHOPPER P.C. BOARD
(SCHEMATIC M19 792 -1)
LOCATED AT
MAC HINE ' S B AS E
(WIRE DRIVE SIDE)
B8
B7
607
615
121K
G
EC
3J 2
4J 2
2
J
8
4
J
8
1
J
8
6
J
8
253
8
0
2
254
8
0
4
8
0
1
8
0
6
+
1
5
V
D
C
L
E
M
S
U
P
P
L
Y
L
E
M
C
O
M
M
O
N
-
V
A
R
IA
B
L
E
V
O
L
T
A
G
E
F
E
E
B
A
C
K
C
O
M
M
O
N
CONTROL
P.C. BOARD
(SCHEMATIC G3789)
LOCATED IN P.C. BOARD
COMPARTMENT
(LEFT FRONT SIDE)
VOLTAGE BETWEEN
801 AND 806 VARIES
DEPENDING ON
CURRENT THROUGH
LEM 500A = -4V
LED2
GREEN
LED1
LED7
RED
GREEN
LED3
GREEN
LED4
GREEN
LED6
GREEN
LED5
GREEN
L
E
D
8
G
R
E
E
N
RED LED's ARE SOLID AT
POWER UP THEN BLANK
GREEN LED's REMAIN
SOLID GREEN
4J 6
10J6
604
15J7
16J7
715
716
1J 11
2J 11
1J 2
251
3
J
9
1
J
9
9
0
3
9
0
1
-
S
T
U
D
+
S
T
U
D
V
O
L
T
A
G
E
F
E
E
D
B
A
C
K
1
5
J
6
7
J
6
6
1
5
6
0
7
P
W
M
C
O
M
M
O
N
+
P
W
M
S
I
G
N
A
L
2
J
5
3
J
5
5
0
2
5
0
3
L
E
D
1
0
R
E
D
L
E
D
9
G
R
E
E
N
RED LED's ARE SOLID AT
POWER UP THEN BLANK
SWITCHES MUST BE
IN OFF POSITION
DIP SWITCHE S
JUMPER ARE SO THE
CONTROL BOARD
RECOGNIZES
THAT IT IS IN A
PM300
THIS LED WILL BE
BLINKING IF THERE IS
AN ERROR
CAN COMMUNICATION
CAN COMMUNICATION
+ 6VDC
COM
+ 10VDC
COM
+ 10VDC
23 7
LOCATED ON TOP
OF P.C. BOARD
COMPARTMENT
FOR WELD FILE
DOWNL O ADS
R232
CONNECTOR
1
2
3
4
503A
2J 83
3J 83
832
833
FEEDHEAD
P.C. BOARD
(SCHEMATIC G3883)
5J 85
12J85
855
8512
8
J
8
5
1
1
J
8
5
4J 83
834
SWITCHES MUST BE
IN OFF POS ITION
DIP SWIT CHE S
MOTOR -
GAS S OLENOID +
GAS SOLE NOID -
2J 82
1J 82
LOCATED IN LEFT SIDE OF
P.C. BOARD COMPARTMENT
1
0
J
8
5
9
J
8
5
7
J
8
5
8
5
8
8
5
1
1
8
5
1
0
8
5
9
8
5
7
312321
WF S/AMPS V O LTS/TRIM
PANEL ENCODERS
FOR CODE 10952
AND HIGHE R
8
5
5
A
1J 83
831
MOT OR +
1J 85
2J 85
851
852
7J 84
4J 84
847
844
1J 84
841
5VDC TACH SUPPLY
TACH SIGNAL
TACH COM
GUN TRIGGER SUPPLY
GUN TRIGGER INPUT
+15 V D C
0V
LOCATED TO THE RIGHT
OF WIR E DRIVE AS SEMBLY
ON CENTER PANEL
LOCATED ABOVE WIRE
DR IVE AS SEMBL Y ON
CENTER PANEL
LOCATED BEHIND THE
INSULATING WIRE DRIVE
PANEL. REMOVE THE
WIRE DRIVE AS SE MBLY
TO GAIN ACCESS.
ACCESS THIS CONNE C T OR
BY REMOVING THE WIRE
DRIVE ASS EMBLY
6 PIN FOOT AMP TR O L
LOCATED IN P.C. BOARD
COMPARTMENT
SPOOL GUN/
PUSH-PULL
SWITCH
-
+
USED ONLY FOR
EXTERNAL DIODE
(USED FOR MOTOR
BRAKING)
RECTIFIER BRIDGE
5
J
8
3
8
3
6
8
3
5
15VDC WHEN IN THE SPOOL GUN POSITION
0VDC WHEN IN THE PUSH-PULL POSITION
1
2
3
4
R
U
B
R
U
B
LOCATED ON
CASEFRONT
TACHMOTOR / GEAR BOX
2.6 VDC @ 50 IN/MIN
27.4 VDC @ 700 IN/MIN
8 SECOND AVERAGE CURRENT
LIMIT = 3.5A
(LIMIT IS SOFTWARE SET)
ME AS UR E B T O U
120 Hz @ 50 IN/MIN
1.6 kHz@ 700 IN/MIN
LOCATED ON
CASE BACK
PWM CONTROLLED
6.5 VDC WHEN GAS
FLOWING COIL
ME AS UR E S 21 OHMS
12 VDC COIL
1
2
BW
SPI DISPLAY
L11757-1
YELLOW
REDRED
RED
RED
B
R
DUAL
ENCODER
L11559-
2
C1
J36
A1 A2
C9
D1
J361
TP
1
TP
4
TP
3
TP
2
X1
C2
C3
C4
C5
C6
C7
C8
R1
R16
R14
R3 R4 R5 R6 R8 R9
R13
R12 R11
R10
R15
X2
DUAL E NCODE R PRE SENT
ON CODE 10562 ONLY
FOR MECHANICAL ENCODERS,
AVAILABLE ON CODE 10952 AND
ABOVE , REFER TO J85 ON FEEDHEAD
P.C. BOARD. THE DISPLAY BOARD
CONNECTS DIRECTLY TO THE MSP3
OPTION PANEL.
1+15V
2+5V
3/SS
4CS1
5CS2
6CS3
7MISO
8SCK
9MOSI
10 GRD
FOR ALL FLEX AND
SHIELDED CABLE
SHIELDED
CABLE
FLEX
4J 11
3J 11
CAN COMMUNICATION SUPPLY +5V
0V
1J 43
431
7J 43
437
3J 43
403
6J 43
402
12J43
401
4J 43
406
9J 43
405
5J 43
1104
+5V
10J43
1103
COMMON
+5V
COMMON
+15V
COMMON
+5V
+20V D C
COMMON
12J4
11J4
412
411
8J 4
408
+ 15VDC
-15VDC
+ 5VDC
1J 3
2J 3
10J3
+ 15VDC
+5V DC
+0V DC
3J 4
2J 4
403
402
1J 4
401
+ 5VDC
SPI SUPPLY +15VDC
COM
6J 4
5J 4
406
405
10J4
410
RS232 SUPPLY + 5VDC
COM
COM
1104
1103
1101
1102
2J 86
10J86
1J 86
+15 V D C
+5VD C
SHIELDED CABLE COMMON
3J 82
4J 82
3243
3244
COMMON
TO POWER FEEDHEAD BOAR D +42VDC
2J 32
10J 32
1J 32
3J 324
4J 324
3243
3244
2J 321
7J 321
1J 321
3J 321
6J 321
4
2
75
77
76
REMOTE
TRIGGER
REMOTE
TRIGGER
REMOTE
LOCATED AT BOTTOM OF
P.C. BOARD COMPARTMENT
SPOOL GUN
P.C. BOARD
(SCHEMATIC G3997-1)
D
F
E
A
C
B
2A
4A
77A
76A
75A
ALL LED's
LIGHT
BRIEFLY
A DASH "-" SCROLLS
ALONG DISPLAY BOARD
(TAKES ABOUT 10 SECONDS)
MAC HINE DISP LAYS
SETTINGS OF LAST
WELD MODE OPERAT ION
AMP LE D ILLUMINATES
WITH CORR ESPONDING VALUE.
RIGHT DISPLAY "OFF"
WFS AND VOLTAGE
LED's ILLUMINATE WITH
CORRESPONDING VALUES.
WFS AND TRIM
LED's ILLUMINATE WITH
CORRESPONDING VALUES.
IF LAST MODE WAS CC IF LAST MODE WAS CV IF LAST MODE WAS SYNERGIC
4J 324
8J 321
3214
3218
F
E
C
D
G
A
B
MOT OR +
MOTOR -
5K
SPOOL GUN/PUSH-PULL MOTOR
0VDC @ 50 IN/MIN
24VDC @ 700 IN/MI N
7 PIN
SPOOL GUN/PUSH-PULL
AMP TROL
3
J
3
2
3
4
J
3
2
3
3
2
3
3
3
2
3
4
C
O
M
+
4
2
V
D
C
CURRENT
TRANSDUCER
OUTPUT
CHOKE
5
0
w
a
t
t
s
5
0
0
o
h
m
s
2520
2530
R1
+
2400/100
+
-
57 VAC
-
+
CONTROL RECTIFIER
80 VDC
OUTPUT
RECTIFIER
MAIN
TRANSFORMER
+
6800/75
X6X5
X4X3
PWM: PULSE WIDTH
MO D U LATI O N
CHOPPER
SUPPLY
30 VAC115 VAC
LOCATED ON TOP OF
MAIN T RANS FOR MER
SCHEMATIC: L11108
MS P3 B OAR D
(SCHEMATIC: L11612)
LOCATED ON
SECONDARY
WI NDING S
LOCATED ON
CHOPPER BOARD
HE ATS I NK
FAN STAYS ON FOR 5 MIN AFTER
LAST GUN TRIGGER (WHEN 2/4
IS CLOSED)
CR1
FAN
FAN RELAY
11J6
12J6
611
45 206
TOROID
TOROID
TOROID
TOROID
LOCATED ON DIVIDER
PANEL IN THE WIRE DRIVE
COMPARTMENT
TOROID
LOCATED ON
TRANSFORMER
BAFFLE
LOCATED ON
TRANSFORMER
BAFFLE
TOROID
+ 42VDC
LOCATED ON FRONT
OF MACHINE'S BASE
LOCATED ON
MACHI N E ' S B AS E
(STORAGE
COMPARTMENT SIDE)
H1
H4
H1
(SHOWN
CONNECTED
FOR 230V)
H4
H3
H2H5
L2
L1
G
B
W
H1
L1
L2
H4
H1
H4
H3
H5
H2
H1
LINE
SWITCH
RECONNECT PANEL
LOCATED ON DIVIDER
PANEL IN THE WIRE DRIVE
COMPARTMENT
LOCATED NEXT TO
MAIN TR ANS FORME R
(ON WIRE DRIVE SIDE)
LOCATED ON
CHOPPER BOARD
ASSEMBLY
CONTROL P.C. BOARD LED LEGEND
LED1: +15V POWER TO CONTROL P.C. BOARD
LED2: -
15V P OWE R TO CONTROL P. C. BOAR D
LED3: +5V FOR SPI CABLE
LED4: +15V FOR SPI CABLE
LED5: +
5V POWE R TO CONT ROL P.C . BOAR D
LED6: +5V FOR RS232 CONNECTOR
LED7: A FATAL ERROR HAS OCCURED
LED8: +5V FOR CAN COMMUNICATION
LED9 AND LE D10: ERROR CODE . LED9 BLINKS ONCE
THEN LED10 BLINKS ERROR CODE.
6 V
N. C.
N. C.
ALL 3 LED'S ILLUMINATE
AT THERMAL TRIP.
SELECT
SWITCH
SET
SWITCH
ILLUMINATED LED
INDICATES VOLTAGES ARE
BEING SUPPLIED TO J42
ILLUMINATES WHEN
DIS PLAYING WFS
ILLUMINATES WHEN
DISPLAYING AMPS
ILLUMINATES WHEN
DIS PLAYING VOLTS
ILLUMINATES WHEN
DISPLAYING TR IM
CONTROLS THE SPEED
OF THE SPOOL /
PUSH-PULL GUNS BY
READING THE
POTENTIOMETER.
CONTROLS THE WIRE
DRIVE FUNCTIONS AND
THE GAS SOLENOID.
CONTROLS THE
FUNCTIONALITY OF
THE MACHINE.
ALLOWS THE S ELECTION OF DIFFERENT WELD
MODE S AND P ROCE SS E S .
1
J
3
4
2
J
3
4
1
0
J
3
4
SPI FLEX/SHIELDED
CABLE SUPPLY
RS232 SUPPLY
CAN COMMUNICATION
SUPPLY
G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.