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ELECTRICAL DIAGRAMS
G-14
RANGER 305D
SCHEMATIC - ENTIRE MACHINE - CODE 11121 (L12212) PAGE 2 OF 2
EN -168
S
O
L
ID
E
D
G
E
L12212
RANGER 305D
MACHINE SCHEMATIC
NONE
L11946
DEO
BAM
-
UNLESS OTHERW ISE SPEC IF IED TOLERAN CE
MANUFAC TURIN G TOLERANCE PER E205 6
ON 2 PLAC E DECIMA LS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANG LES IS ± .5 OF A DEGREE
WITH PUB LISHED S TANDARDS.
MA TERIA L TOL ERANCE (" ") TO AGREE
t
DO NOT SCALE THIS DRAWING
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPRO VED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
MATERIAL
DI SPOSI TI ON:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM35573
2
PA GE ___ O F ___
2
ENGINEERING CONTROLLED
MANUFACTURER:
No
DOCUMENT
NUMBER:
DOCUMENT
REVI SI ON:
THIS D O CUME NT C O NTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D FO R ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
A
12/11/2003
RELEASED "A.02" FROM "X"
CHANGE DETAIL:
L12212
LEAD COLOR CODE:
B- BLACK
G-GREEN
O- ORANGE
R-RED
U- BLUE
W- WH IT E
Y- YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PCBOARD
1
2
6
712
LATCH
EX. 12 PIN CONNECTOR
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
J7-1
J7-4
J7-5
+10V
+10V
J1- 10
J1-14
J1-11
TIG MODE
ALL OTHER MODES
ARC
CONTROL
CIRC UITRY
CONTROL
POINT
SELECT
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
LOCAL
REMOTE
TOUCH START
OCV
J7-6
J7-7
J7-8
x80
G4109
(ONLY)
G4107
(ONLY)
47.5 ohms
J3- 15
J6-2
J6-1
VOLTAGE FEEDBACK
CURRENT FEEDBACK
J5-10
J5-9
J5-8
J5-7
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-10
J4-9
J4-8
J4-7
J4-6
J4-5
J4-4
J4-3
J4-2
J4-1
MACHINE /
MODE
LOGIC
(CPU)
HOLD (+5V=HOLD)
ON / OFF (+5V=ON)
ON/OFF (+5V=ON)
HOLD(+5V=HOLD)
J7-16
J7-9
J7- 10
J7- 11
J7- 12
J7- 13
J7-14
J7-15
TIG MODE
PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/ A
N/A
N/ A
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
CV MOD E
+15V
J1-5
J1-6
J1-7
J1-8
J1-13
+15V
J1-12
MACH SEL 4
MACH SEL 3
MACH SEL 2
MACH SEL 1
PRESET
CURRENT FEEDBACK
VOLTAGE
FEEDBACK
AMMETER
DISPLAY
VOLTMETER
DISPLAY
SELECT CONTROL POINT
FIXED HOT START
J3- 14
IDLE SWITCH SENSE
+15V
J3-7
J1-3
J1-4
+15V
(4)
(2)
2-4 SENSE
J3-4
J3-3
REG ULATING
AMPLIFIER
PWM
CHOPPER
CONTROL
CIRCUIT
CURRENT
LIMITS,
AVERAGE,
ABSOLUTE,
& FOLDBACK
THERMALSHUTDOWN
THERMAL SHUTDOWN (if used)
CURRENT FEEDBACK
CONTROL POINT
J3-12
J3-10
J3-11
J3-9
47.5 ohm
TRANSF ORMER
+15V
+3.3V
-15V
+5V
J3-16
J3-8
-
+
40-100VDC
INPUT
FRAME
+15V
IDLE CONTROL
IDLE CONTROL
+15V COM
FRAME
V-BATTERY
J2-6
J2-4
J2-5
IDLE HOLD COIL
TO IDLE PULL COIL BOARD
HI GH = PULL TO LOW IDLE
FRAME
+15V COM
V-BATTERY
J2-1
FRAME
J2-8
J2-9
J2-10
RANGER OIL PRESSURE
STARTER BUTTON
FUEL SHUTDOWN
FRAME
V- BATTERY
FRAME
J2-7
J2-3
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
-STUD
+ STUD
AUXILLARY
CURRENT
SENSE
-
+
10K
POT
10K
POT
10K
POT
AUXI LI ARY
SENSE
TOROID
MACHINE IDENTITY TABLE:
PINS JUMPERED TO SELECT MACHINE
1
2
3
4
A
TIG
PI PE
CC
CV
MODE
SELECTOR
SWI TCH
(AUSTRAIL IAN
VANTAGE 575 USES A
3POSITI ON TOGGLE
SWI TCH)
(77)
(76)
(75)
(77B)
(76B)
(75B)
(277)
(278)
(279)
OUTPUT
CONTROL
REMOTE
CONTROL
ARC CONTROL
+ STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD
+STUD +STUD
+STUD
+STUD
+STUD
(206S)
(204S)
+
-
(208B)
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
+
BATTERY POSITIVE
1
2
3
4
HOLD
COI L
PULL
COI L
IDLE
SOLENOID
BLK
RED
WHT
-
BATTERY NEGATIVE
PULL COIL
BOARD
FOR AUX USE: CONNECT
TO FRAME FOR HIGH IDLE
J2-12
J1-5 J1-6 J1-7 J1-8 MACHINE
RANGER 250 G&D
J1-13 RANGER 305 G&D
J1-13 VANTAGE 500
J1-13 VANTAGE 575
J1-13 AIR VANTAGE 500
#1
CHOPPER
BOARD
#2
CHOPPER
BOARD
47.5 ohm
47.5 ohm
47.5 ohm
(ALL MACHINES)
(VANTAGE ONLY)
50mV = 400 AMPS
SHUNT
+
-
ROTOR
POS I T IV E
BRUSH
NEGATI VE
BRUSH
+
-
CONTROL BOARD
POWER FROM
CHOPPER BOARD
FEEDBACK
CURRENT LIMITS
REGULATION MODE
METER (-) INPUT
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
BLINK (PULLED LOW AND HIGH
INLOOKBACK TO FLASH
DECIMAL POINT)
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine
isnot ON. +40V or more when the machine is running.
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V
when not energized. "HIGH IDLE"
+12V Battery Supply to
the Idle Hold Solenoid
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted
the PTC will change to high impedance
PWM SIGNAL (+12V ON MULTIMETER)
PWMCOMMON
PWM SIGNAL (+12V)
PWM COMMON
PTC
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
PRESET
PRESET
DISPLAY WELD AMPS
DISPLAY WELD VOLTS
DI SPLA Y
PRESET
VALUE
+5V
+5V+5V
DIODE ONLY ON -E
VERSION AND ABOVE
THE TOP END OFTHE REMOTE POT I N
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOT E
POT WI LL SET MACHINE TO MAX OUTPUT.
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
V-BATTERY
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
+15V
J7-2
WELDING
TERMI NAL
CONTROL
SWI TCH
SHOWN IN "ALWAYS
ON" POSITION
IDLE R
CONT ROL
SHOWN I N "HIGH" POSITION
G-14
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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