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ELECTRICAL DIAGRAMS
G-7
POWER MIG 300
SCHEMATIC - COMPLETE MACHINE - CODE 11097 AND 11098 ONLY
EN-170
S
O
L
ID
E
D
G
E
G4512
ENGINEERING CONTROLLED
MANUFACTURER:
No
CHANGE DETAIL: RELEASED A.01 FROM X.
G4512
POWER MI G 300
MACHINE SCHEMATIC
NONE
CDIEKMANN
JZUCKER
-
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
Name? :Creation Date
MATERIA L
DI SP OS I TI ON:
AP PR O VAL
DAT E :
PROJECT
NUMBE R :
NA
CRM32923-B
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:
A
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 SUPPL Y
CONTROL BD SUPPLY COMMON
DIGITAL POWER
SUPPLY P.C. BOARD
(SCHEMATIC G3631)
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
+ 15VDC
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: W
833
FEEDHEAD
P.C. BOARD
(SCHEMATIC G3883)
5J85
12J 85
855
8512
8J 85
11J 85
4J 83
834
SWITCHES MUST BE
IN OFF POSITION
DIP SWITC HES
MOTOR -
GAS S OLENOID +
GAS SOLE NOID -
2J 82
1J 82
LOCATED IN LEFT SIDE OF
P.C. BOARD COMPARTMENT
10J 85
9J 85
7J 85
858
8511
8510
859
857
312321
WF S/AMPS
VOLTS/TRIM
PANEL ENCODERS
8
5
5
A
1J 83
831:B
MOT OR +
1J 85
2J 85
851
852
7J 84
4J 84
847: U
844:B
1J 84
841
5VDC TACH SUPPLY
TACH SIGNAL
TACH COM
GUN TRIGGER SUPPLY
GUN TRIGGER INPUT
+15V DC
COMMON
LOCATED TO THE RIGHT OF WIRE
DRIVE ASSEMBLY ON CENTER PANEL
LOCATED ABOVE WIRE
DRIVE AS SEMBLY ON
CENTER PANEL
LOCATED INSIDE THE
P.C. BOARD
COMPARTMENT
PLUGGED ONTO THE
FEED HEAD BOARD.
ACCESS THIS CONNECTOR
BY REMOVING THE WIRE
DRIVE ASS EMBLY
6 PIN FOOT AMPTR OL
LOCATED IN P.C. BOARD
COMPARTMENT
SPOOL GUN/
PUSH-PULL
SWITCH
-
+
USED ONLY FOR
EXTERNAL DIODE
(USED FOR MOTOR
BRAKING)
RECTIFIER BRIDGE
5J 83
836
835
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 / GEARBOX
2.6 VDC @ 50 IN/MIN
27.4 VDC @ 700 IN/MIN
8 SECOND AVERAGE CURR ENT
LIMIT = 3.5A
(LIMIT IS SOFTWARE SET)
ME AS UR E B TO 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 U RE S 2 1 O HMS
12 VDC COIL
1
2
BW
SPI DISPLAY
L11757-1
YELLOW
REDRED
RED
RED
1+15V
2+5V
3/SS
4CS1
5CS2
6CS3
7MISO
8SCK
9MOSI
10 GRD
FOR ALL FLEX AND
SHIELDED CABLE
SHIELDED
CABLE
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
3J 82
4J 82
3233
3234
COMMON
TO POWER FEEDHEAD BOAR D +42VDC
4
2
75
77
76
REMOTE
TRIGGER
REMOTE
TRIGGER
REMOTE
LOCATED AT BOTTOM OF
P.C. BOARD COMPARTMENT
SPOOL GUN
P.C. BOARD
(SCHEMATIC L12008-1)
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 ILLUMINAT E WI T H
CORRESPONDING VALUES.
IF LAST MODE WAS CC IF LAST MODE WAS CV IF LAST MODE WAS SYNERGIC
3214
3218
F
ECDG
A
B
MOT OR +
MOT OR -
5K
SPOOL GUN/PUSH-PULL MOTOR
0VDC @ 50 IN/MIN
24V DC@700 IN/MIN
7 PIN AMP TR OL
SPOOL/PUSH-PULL GUN
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
-
+
DIODE RECTIFIER
80 VDC
INPUT
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
DI V ID E R
PANEL IN THE
WIR E DR IVE
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
DI VI DE R
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 CONTROL P .C . BOAR D
LED6: +5V FOR RS232 CONNECTOR
LED7: A FATAL ERROR HAS OCCURED
LED8: +5V FOR CAN COMMUNICATION
LED9 AND LED10: ERROR CODE. LED9 BLINKS ONCE
THEN LED10 BLINKS ERROR CODE.
15 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
PROVIDES BRAKING OF THE
SPOOL/PUSH-PULL GUN
MOTOR AND CONDITIONS
THE SIGNAL FROM 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
2
J
8
6
7
J
8
6
1
J
8
6
3
J
8
6
6
J
8
6
4
J
8
6
8
J
8
6
6
J
8
6
9
J
8
6
1
0
J
8
6
2
P
8
6
7
P
8
6
1
P
8
6
3
P
8
6
6
P
8
6
4
P
8
6
8
P
8
6
6
P
8
6
9
P
8
6
1
0
P
8
6
14J 85
8514
3J 810
2J 810
1J 810
5J 810
6J 810
4J 810
8J 810
77
3218
3214
8514
76
846A
75
6J 84
846
4J 85
3J 85
2B
853
DUAL PR OCEDURE SUPP LY
DUAL PR OCEDURE INPUT
1
2
3
4
851A
4
2
2J811
1J 811
8115
8111
5J 88
8115
FLEX
TO SPOOL/PUSH-PULL
GUN MOTOR DRIVE
+40V DC SUPPLY FOR
SPOOL/PUSH-PULL GUN MOTOR
0-5V SIGNAL VAR IES WITH
REMOTE POT WIPER
SPOOL/PUSH-PULL GUN
BRAKE SIGNAL
(0 VOLT= MOTOR BRAKE)
G-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.