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ELECTRICAL DIAGRAMS
G-6
POWER FEED 10M SINGLE/DUAL
SCHEMATIC - ENTIRE MACHINE - CODE 11086, 11216 (G4440)
G
4440
ENGINEERINGCONTROLLED
MANUFACTURER:
No
C
O
M
P
L
E
T
E
L
Y
R
E
V
I
S
E
D
E
THEINFORMATIONONTHIS
PRINTISFORREFERENCE
ONLY. COMPONENTSAND
CIRCUITRYMAYBE
DIFFERENT
FROMANACTUALMACHINE.
G4440
POWER FEED 10M SINGLE (BENCH)
MACHINESCHEMATIC
NONE
-
TJP
ZUCKER
DRAWNBY:
DESIGNINFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM22115-FX
1
PAGE___OF___
1
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
THISDOCUMENTCONTAINSPROPRIETARYINFORMATIONOWNEDBYLINCOLNGLOBAL,INC.ANDMAYNOTBEDUPLICATED,COMMUNICATED
TOOTHERPARTIESORUSEDFORANYPURPOSEWITHOUTTHEEXPRESSWRITTENPERMISSIONOFLINCOLNGLOBAL,INC.
PROPRIETARY& CONFIDENTIAL:
6/19/2006
J86
CAVITY NUMBERINGSEQUENCE
(COMPONENTSIDEOFP.C.BOARD)
J81,J82
6
5
10
1
3
4
1
2
J85,J87
9
8
16
1
4
6
1
3
J84,J810
5
4
8
1
J1,J83,J88
GENERALINFORMATION
ELECTRICALSYMBOLSPERE1537
COLORCODE
B- BLACK
W- WHITE
R- RED
U- BLUE
J2,J811
1
2
LEADCOLORCODE:
B-BLACK
R-RED
U-BLUE
W-WHITE
COMPONENTVALUEUNITS:
CAPACITOR:MFD/VOLTS
RESISTOR:OHMS/WATTS
CONNECTORPINNUMBERS:
VIEWOFCONNECTORONPCBOARD
1
6
712
LATCH
EX.12PINCONNECTOR
LABELS:
COMMON
FRAMEGROUND
P10
FEEDHEAD
P.C.BOARD
4J88
3
2
1
CURRENT
WFS
VOLTS
TRIM
PANELENCODERS
2STEP/4 STEP
SWITCH
-
+
DIODEBRIDGE
5-32VDC
1.8OHMS
13 SECONDAVERAGECURRENT
LIMIT= 6.3A
(LIMITIS SOFTWARE SET)
50-800/PMOR 75-1200PM
1 +15V
2+5V
3 /SS
4CS1
5CS2
6 CS3
7MISO
8SCK
9MOSI
10COM
FORALLFLEXAND
SHIELDEDCA BLE
PUSH-PULLGUN
DAUGHTER
P.C.BOARD
5K
7PIN
PUSH-PULL
GUN
CONNECTION
PROVIDES BRAKING
OF THE PUSH-PULL
GUN MOTORAND
CONDITIONS THE
SIGNAL FROMTHE
POTENTIOMETER.
2J811
TOPUSH-PULL
GUNMOTOR DRIVE
+40VDC SUPPLYFOR
PUSH-PULLGUNMOTOR
(NON-ISOLATED)
DISPLAYP. C. BOARD
(SCHEMATIC:L11756)
OPTIONALMEMORYP.C. BOARD
(SCHEMATIC:L11897)
FLEX
(OPTIONAL)
E
L1
TOROID
3J81
4J81
5PINARCLINK
CONNECTORTO
POWERSOURCE
{
TRIGGER
0VTO COMMONWHEN
SWITCH CLOSED
+15VDC
9J85
6J85
5J84
579A
COLD INCH/
GASPURGE SWITCH
COLD INCH
GASPURGE
579
586
535
ARCVOLTAGE
FEEDBACK
GAS
PERFORMSALL USER INTERFACE,
WIRE DRIVE, ANDGAS SOLENOID
CONTROL FUNCTIONS.
S9
MSP4P.C. BOARD
(SCHEMATIC:G4456)
LEDS
LEDDISPLAY
LEDDISPLAY
A-GUN-B
PUSHBUTTON
LED
1
2
O
N
SINGLE
HEAD
DUAL
HEAD
FEEDER
FUTURE
S9
SEE IM MANUAL FOR ERROR CODES
OR WWW.POWERWAVESOFTWARE.COM
OR SERVICE NAVIGATOR DIAGNOSTIC UTILITIES
MEMORY
PANEL
MSP4
PANEL
DISPLAY
PANEL
SET SWITCH 1"ON"
(SINGLEHEAD)AND
SWITCH 2"ON" (FEEDER)AS
SHOWN ONDIP SWITCHS9.
MOTORSWILL NOT
RUNIFDIODEIS
OPEN,REVERSED,
ORDISCONNECTED
MOTOR+
CAPACITOR
CAPACITORCONNECTS
FROMPIN 10OF SHIELDED
CABLETO FRAMEGROUND.
6J1
VOLTAGESENSE
SELECTP.C. BOARD
2J2
513
400F
1J1
2J1
3J1
4J1
J2
CASE
67A
514
2J81
1J81
4J82
3J82
2J82 1J82
14J85
13J85
+15V
OVWHEN"ON"
NOTE:WILLWORKWITH
LINKNETPOWERSOURCEBUT
WILLONLYSHOWANDHAVE
LINKNETFEATURES
A
B
D
E
541
542
67B
540
500
500B
INPUTELECTRODE
CABLECONNECTION
67A
FEEDPLATE
GENERA L
GMAW STD.CV 5
CV GMAW POWER MODE 40
FCAW STD. CV 6
STICK SOFT (7018) 1
STICK CRISP (6010) 2
CC TIG TOUCHSTART 3
GOUGE --- 9
ALUMINUM
0.035 3/64 1/16
GMAW Ar 148 71 73
4043 PULSE Ar 149 72 74
PULSEON PULSE Ar 98 99 100
5
00B
(SCHEMATICS24779)
+15VDC
+5VDC
SIGNAL
STEEL
0.030 0.035 0.045 0.052
GMAW CO2 --- 10 20 24
GMAW Ar(MIX) 94 11 21 25
PULSE(CRISP) Ar (MIX) 95 12 22 26
PULSE(SOFT) Ar(MIX) --- 14 19 28
STT (NOTAIL OUT) CO2 Ar/CO2 109 109 125 125
STTll CO2Ar/CO2 110 110 126 126
0.035 3/64 1/16
GMAW Ar 151 75 77
5356 PULSE Ar 152 76 78
PULSEON PULSE Ar 101 102 103
STAINLESS
0.030 0.035 0.045
GMAW Ar (MIX) 61 31 41
GMAW Ar/He/CO2 63 33 43
PULSE Ar/CO2 66 36 46
PULSE Ar/O2 62 32 42
PULSE Ar/He/CO2 --- 34 44
STT Ar/He/CO2 109 109 125
STTll Ar/He/CO2 110 110 126
METALCORE
0.045 0.052 1/16
GMAW Ar/CO2 81 83 85
PULSE Ar/CO2 82 84 86
WFS AMPS
VOLTS
TRIM
3
2
1
580
585B
585A
587
585
582
581
FLEX
(OPTIONAL)
FLEX
-OR-
SETUP LED
WELD MODE,WIRESIZE,
ERRORCODES,SEVEN
SEGMENTANDALPHA
NUMERICDISPLAY
INFRAREDTRANSCEIVER
(WIRELESS COMMUNICATION)
WELD MODELED
ARCCONTROL LED
SELECTPUSHBUTTON
SELECTPUSHBUTTON
ENDOPTIONS LED
START OPTIONSLED
16DETENT
ENCODER
67B
541
542
500
540
CAN
CAN
COM
+40VDC
8
7
6
5
4
3
2
1
SHIELDEDCABLE
6J810
4J810
3J810
2J810
8J810
1J810
5J810
526
548
6J84
6J85
8J84
1J88
518
PUSH-PULLGUN
BRAKESIGNAL
(0VOLT = MOTORBRAKE
0-5VPUSH-PULL GUN
POTENTIOMETERSIGNAL
REQUIRED FOR
4STEP MODE
16J85
15J85
B
W
RED/GREEN
STATUS LED
SEEERROR TABLE
INIM MANUAL
HIGH
OND
E
F
.
LOW
O
F
F
D
E
F
.
FEEDSPEEDGEAR
8
F
UNC
T
ION
7
6
5
4
3
2
DIP SWITCH S1 SETTING CHART
T
OG
GL
E
N
O
.
1
POLARITY
NEG
SPARE
POS
10J86
9J86
8J86
7J86
6J86
5J86
4J86
3J86
2J86
1J86
10P86
9P86
8P86
7P86
6P86
5P86
4P86
3P86
2P86
1P86
(SCHEMATICL12008)
O
N
O
F
F
S
1
S
E
E
S
1
S
E
T
T
I
N
G
C
H
A
R
T
(SCHEMATICG3883)
1J811
5J83
5J83
554
640A
5J88
595
640
SETUP MENU
To access, pressthe rightand leftpush buttons
onthe MSP4panel simultaneously
Setupfeaturenumbersmay vary betweensoftware
versions. Mustreadsmalldisplayto findyour
specificfeatureyouwant. TheseP numbers listed
arefor reference.
SET UP MENU FEATURES
P.0= On/Off enterexitset upmode
P1= WFS English/metric
P2= Leftdisplay amps/wfs
P4= Trigger memoryrecall
P5= Trigger procedure change
P6= Stall factor
P7= Push pullgunoffset
P8= NewTIG solenoidfeature
P80-89= Senses from studs onS25629-09
P99= Showtest mode 200.201
P100= Viewdiagnostics
P102= Fatallog
P103= Viewsoftware
P104= Hardwareversion
P105= Weldingsoftware
P200= CCtest 25-600
P201= CVtest 10-35
P202= CCtest 10A
P203= CCtest 355A
P204= CCtest 455A
P205 =CC test 550A
P206 =CV test 10V to 30 V
P207 =1/0 test 25-600
P208 =STT test170A
P209 =1 curve 0-600A
P210 =Step resp background
P211 =V curve 0-70V 10-70V
P212 =OCVtest
P215 =Touch sense
P255 =Show weldfile
10J85
7J85
5J85
12J85
11J85
580
587
585
582
581
S4
S2
1J83
2J83
3J83
4J83
DUAL
PROCEDURE
A
C
SCHEMATICM19487
PROCEDURE
A= OPEN
B= CLOSED
1J84
7J84
4J84
2J85
1J85
3J85
4J85
532B
570C
543
MOTORGEARBOX TACH
1
2
3
4
R
U
B
R
U
B
5VDCTACH SUPPLY
TACHSIGNAL
TACHCOM
B
W
ACCESSTHIS
CONNECTOR BYREMOVING
THEWIREDRIVE
ASSEMBLYACCESSDOOR
550
551
553
554
PWM CONTROLLED
6.5VDC WHEN GASIS
FLOWING. COIL
MEASURES21 OHMS.
12 VDCCOIL
L2
TOROID
MOTOR+
MOTOR-
GASSOLENOID +
GASSOLENOID -
531
537
534
TRIGGER
SUPPLYFORTRIGGER ANDDUAL
DUALPROCEDURE
0VDC@ 50IN/MIN
24VDC@ 700IN/MIN
OPTIONAL6 PIN
REMOTEFOOT
AMPTROLCONNECTION
(WIREDRIVEBOXREAR)
570E
532E
77E
76E
75E
45
6
3
2
1
DA
C
B
F
B
A
M
E
F
C
DG
75
76
77
MOTOR-
570A
570
532A
570B
P13
P14
3218
3214
3218
3214
76
75
77
(WIREDRIVEREARLOW)
(WIREDRIVEREAR)
P11
(WIREDRIVEFRONT)
PUSH-PULLGUNWIRE
FEEDSPEED CONTROL
PUSH-PULL
GUNTRIGGER
AMPHENOL
(LOWER REAR)
SHUTDOWN INPUT(DISCONNECT
FORFLOW SWITCHCONNECTION)
(INSIDE WRAPAROUND)
+40
AC
(WIREDRIVEFRONT)
(WIREDRIVEFRONT)
PCTAND RESISTORS
PROTECTEDON
DAUGHTERBOARD
J87NOT USED
CLEANROOMUSE
P15
P16
L3
4
2
1
REARACCESS
PANEL
(DRIVE MOTOR
PANEL DIVIDER)
(FRONTBASE)
CONTROL B OX
FRONT AND
REAR
(DIVIDERPANELREAR
ACCESS DOOR SIDE)
532
570D
543
D
E
B
{
3
P9
SPARE
SPARE
SPARE
SPARE
SPARE
(DIVIDERPANEL)
FILTERP.C. BD.
SPOOLGUN/PUSH-PULLMOTOR
C
67
LED
A-GUN-B
MEMORYIS STOREDON
U/IFEED BOARD
Gridload testinguse
}
WELD MODESELECTIONS(POWER SOURCEWELD FILE DEPENDENT
AVG.= 2V
50/IPM= 125 HZ.
400/IPM= 985HZ.
800/IPM= 1.970KHZ.
}
TYPICALCURRENT:
DRAW @600/PM =1.6AMPS
@800/PM = 1.85AMPS
G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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