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G-6
cOmpacT WirE WElDErS
SchEmaTic - cOmplETE machiNE m21240
2
7
CONNE
CT
O
R
PI
N
N
UM
BER
S:
CAPA
CIT
O
R: MF
D/
V
OLT
S
12
C
OM
PONE
NT
V
AL
U
E
U
NIT
S:
LABELS:
FR
AM
E
GROUND
1
C
OMM
ON
LE
A
D
C
OL
O
R
COD
E:
VIEW
OF
CONNEC
TO
RONPCBOARD
RE
SI
ST
O
R:
O
HM
S/
W
ATT
S
6
EX.
12
PIN CONNEC
TO
R
B-
BL
ACK
G-
GREEN
O-
ORANGE
R-
RED
U-
BL
UE
W-
W
HIT
E
Y-
Y
ELL
OW
LA
TCH
EA
RT
H
GROUND
EN-170
S
O
L
I
D
E
D
G
E
M2
1240
SM
ALL
W
IRE FEE
DE
R
W
ELDE
RS
MAC
HI
N
E SC
HEM
ATIC
NONE
-
DO NO
T
SC
AL
E
T
HIS DR
A
WING
EQ
UIP
M
ENT
TYPE:
SUBJECT:
SCA
L
E:
NA
CRM39439
1
PAGE ___ OF
___
1
E
NGI
N
EE
RI
NG
CO
NT
RO
LLE
D
MA
NU
FA
CT
URE
R:
No
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBA
L, INC.
AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
TO O
THER PARTIES OR US
ED FOR
AN
Y
PURPOS
E WITHOU
T
THE EXPRES
S WRIT
TEN PERMISSION
OF LINCOLN GLOBAL, INC.
PR
OP
R
IETA
R
Y &
CON
FI
DE
NTIAL:
t
MAT
ERI
A
L TO
L
ER
ANC
E ("
"
) TO A
GR
EE
WITH
PU
B
LI
SH
ED
ST
ANDARD
S.
ON A
LL
AN
GL
E
S I
S ± .5 OF
A D
E
GR
EE
ON
3
PLACE
D
E
CIM
ALS
IS
± .
00
2 i
n.
(
±
0.
0
5
mm)
ON 2
PL
AC
E D
ECIM
AL
S I
S ± .02 in. (
±
0.5 mm)
UNLESS OTHERWISE SPECIFIED TOLERANCE:
M
ANUF
ACTURING TO
L
ER
ANC
E
P
ER
E
2056
UPD
ATED FO
R
C
E MAC
HI
N
E.
CHAN
GE
D
ET
AIL:
REFER
ENCE:
MA
T
ERI
AL
DIS
PO
SI
T
ION:
AP
PRO
VA
L
DA
T
E:
PROJ
EC
T
NUMBER:
DOCUMEN
T
NUMBER:
DOCUMEN
T
REV
ISI
ON:
IF PR
IN
T
ED
@ A
1
SIZ
E
UNI
T
S:
IN
CH
6/6/
2008
cst
u
bl
e
B. ST
ELLE
R
.
DRAWN BY:
ENGINEER:
CL
EV
EL
AND
APPROVED:
CONTROL:
D
M21 240
Insight
C
B1
S1
Two v
er
sions of INPUTS
180A un
it
s:208/230v
r
eta
il
and
i
ndus
tri
al
(
NEMA
)
6-
50 plug, 20 amps n
or
ma
l (
use 40 sup
er
l
a
g)
125A and 140A un
it
s: 120v
r
eta
il
and
i
ndus
tri
al
(
NEMA
)
5-
15plug,20amps
208/230v
r
eta
il
and
i
ndus
tri
al
r
equ
ir
eno
r
econnect of
i
nput.
But, at 208v
i
nput, the output
i
sd
er
ated to 17.6vdc
r
ated
loading.
D
if
f
er
ent case
fr
ont and nameplate
fr
om
r
eta
il
to
i
ndus
tri
a
l
v
er
sions.
Indus
tri
a
l
v
er
sionhasalu
mi
num ex
tr
uded
lifti
nghandleanda
plas
ti
c case back attached to the
r
e
ar
sheet meta
l
back.
D
if
f
er
ent c
or
dandplugf
or
both vo
lt
ages
120 and 230
i
nput = 25A / 250VAC
Same sw
it
chf
or
a
ll
machines
Fro
nt Cent
er
TopRe
ar
DutyCycle
(re
ta
il
&
i
ndus
tri
a
l):
180amp un
it
:
3
0% d
uty 130 amps @ 20 v
30 to 180 amps
OCV = 33 vdc
1
40 amp un
it
:
2
0% d
uty 90 amps @ 19.5v
30 to 140 amps
OCV = 33 vdc
1
25 amp un
it
:
2
0% d
uty 90 amps @ 19vdc
30 to 125 amps
OCV = 32 vdc
Too
ll
ess
Dr
ive Ro
ll
Change Ov
er
T
wist
l
ock type
dr
ive
r
o
ll
r
etain
er
c
li
p.
i
nn
er
/out
er
w
ir
es
li
de guide
Comes w
it
hun
it
:.025smooth
.035 smooth
.030/.045 kn
ur
led
Vo
lt
age Con
tr
ol
Con
ti
nuous Con
tr
o
l
=10K~2to5vdca
cr
oss pot.
(i
ndus
tri
a
l
v
er
sions onl
y)
T
APCon
tr
o
l
5 pos
it
ions D to A =6.6v
( r
eta
il
v
er
sions onl
y)
B=7.6v
C=8.7v
F
= 9.8 v
G =14.2v
open= 15v
Ri gh t
Fr
ont
fi
xed
b
urn-
back
con
tr
ol
Vo
lt
age Con
tr
ol
c
irc
u
it
Tri
gg
er
C
irc
u
it
s
PWM
Con
tr
ol
Amp
li
fi
er
SCR Con
tr
ol
WFS Con
tr
ol
FET
Mot
or
Ov
er
load
and
F
eedback
FE
T
Con
tr
o
ll
er
bleed
er
r
esist
or
t
ur
ns on aft
er
tri
gg
er
r
elease
f
or
a
fi
xed
ti
me
.Thr
ee 5W,
51ohm
r
esist
or
s
i
n p
ar
a
ll
e
l.
Indus
tri
a
l
& Reta
il
v
er
sion:
has a potted
tr
ay
R
eta
il
e
ar
ly v
er
sion :
ar
e hu
mi-
sealed bo
ar
d
Same blank ,d
if
f
er
ent
vo
lt
age con
tr
o
l
p
ar
ts.
Tri
gg
er
St at us
CO
NT
R
OL
S
ARE
BOAR
D M
OU
NT
ED
WF
S 10
K ohms .7v to 9.1v
continuous
control (
no tap co
ntrol)
Left
Fr
ont
Top
Fr
ont
(l
ays
fl
a
t)
A
ll
meas
ur
ements made w
it
h
re
spect to Bo
ar
d Common
203 at
4-
J5
or1-
J3
open circui
t
typically equ
als
board inp
ut volts
Top Re
ar
GAS
SOLENOID
12vdc
r
ated 22 ohms
P
ul
l =12vdc,H
old
=6vdc
ov
er
load
pr
otected by PC bo
ar
d.
Shut off
i
sap
pr
ox. 1.25A of c
urr
ent
dr
aw
S
olenoidnot found
i
n 125A
r
eta
il
un
it
s.
Must
or
d
er
k
it
and
i
nsta
ll
.
15vdc
re
gulat
or
and
i
sol
+15vdc
203
Common
FAN
A
ir flow is back to front
(all versions
of all units
)
D
if
f
er
ent fan f
or
120
and 230
i
nput
Fan
r
uns a
ll
the
ti
me
Can not change plug to
make w
or
k w
it
h d
if
f
er
ent
input pow
er
l
evels
i
nthe
fi
eld
(f
act
or
yuseonl
y)
PCBpow
er
use
120V use
120V use
230V use
N.C.
19
-
30 VDC to
r
un
solenoid and one WFS
mot
or
at a
ti
me
203
Wo u nd
i
nside of
mai n
tr
ansf
or
m
er
(n
o
n-r
eplaceabl
e)
same th
er
mostat on a
ll
machines
D1
MAI
N
BRI
DG
E
Copp
er
f
or
the 180, and
alu
mi
num f
or
the 125 and 140.
T1
Base
Fr
ont below choke
3
"
stack f
or
125A v
er
sion
4" stack for 1
40 and 180
A
versions
C1
ri
ght out
er
plate
left and
ri
ght side
rear ar
ea
d
if
f
er
ent
br
idge f
or
230v
i
nput v
er
sions
left out
er
plate
ACAC
Use
Do
w
Corning
joint comp
ound
(T1283
7) to
reconnect
cap
BO
ARD
PO
WER
OUT
P
UT
CAP
base
r
e
ar
59,000mf/50vdc f
pr
120v
i
nput weld
er
s
120,000
mf/5
0vdc fpr 23
0v inpu
t
w
elders
C
HO
KE
below pc bo
ar
d
(a
lu
mi
nu
m)
ELE
CT
RO
DE
WO
RK
ri
ght
fr
ont
(for
w
ar
dstu
d)
ri
ght
fr
ont
(re
ar
stu
d)
Spool-
gun/
standar
d gun
s
wi
tch
(option
)
S26766
harness pl
ug
(timmer
option)
J6
low
er
case
fr
ont
4
2
543A
544A
Spool-
gun option K2532
-1
Magn
um 100 SG
Same motor control
circuits, but
for a small
er
motor
Reta
il
v
er
sion has a plas
ti
c
ge
ar
fr
ont housing.
Indus
tri
a
l
v
er
sion has a metal
housing
(
s
il
v
er
i
ncol
or).
Load com
pensated
type contr
ol for this
motor. Does not ten
d to stall if lin
er is
clogged like i
n older s
mall S
P
’s.
WFS Range :
50 to 500 +
i
pm
1.5 to 12.5 vdc
C
urr
ent L
im
it
to ap
pr
ox 2.5 amps
Gea
r Box
Feeder
Motor
ri
ght side
brass
bushing
MOT+
MOT-
TS1
FA
N
4
2
1
3
H2
H1
6
FA
N
TS2
1
TMP
TMP
opto
isola
ti
on
CO
NT
R
OL
P.
C.
BOARD
P
RIM
AR
Y SI
DE
CO
NT
R
OL
P.
C.
BOARD
SECONDAR
Y SI
DE
5
4
3B
1
21
5
B
2
2
B
3
2
0
3
B
4
5
4
4
B
5
4
B
6
4
C
2
C
2
1
5
B
20
3
B
4
B
2
B
5
4
3
B
1
2
2C
3
4
5
4
4
B
5
4
C
6
MOTOR
S
P
O
O
L
G
U
N
TRIGG
ER
+
-
O
PTI
ON
AL
SP
OT TIM
ER
P.
C.
BOARD
S
chematic
M20960
-1, -2 (C
E
VER
SI
O
N)
10
9
8
7
6
5
4
3
2
1
CAP-
CAP+
SOL
MOTB+
MOTB-
SOL
TMP
G
ND
TMP
CAP-
CAP+
SOL
MOTA+
MOTA-
SOL
TMP
GND
TMP
1
2
3
4
5
6
1
2
3
4
S
T
A
N
D
A
R
D
G
U
N
TRIGG
ER
19
-
30VDCto
r
un
solenoid and one WFS
mot
or
at a
ti
me
PWM Con
tr
ol
and Ov
er
load
P
ro
tec
ti
on
203
+15VDC
Control
Board
Trigger Circuit
OPE
N
= 0
V
CL
OSE
D
= 13.8
V
Trigger
from gu
n
when measuring fro
m
pin 2 to g
round
OPE
N
= 0
V
CL
OSE
D
= 9.8
V
when measuring
between pins 1 and 2
OPE
N
= 15
V
CL
OSE
D
= 0
V
J7
P3
10
98
7
6
54
3
2
1
J3
P7
J8
J9
P8
J5
P9
P4
J4
R
+15VDC
+
1
2
3
4
5
6
P5
stand
ar
d
use plu
g-
in
B
R
W
W
ti
m
er
op
ti
on
spoo
l
gun
op
ti
on
1
2
3
4
5
6
M21182
harness pl
ug
(spool gu
n option)
spoo
l
gun
op
ti
on
w
ir
e
r
ee
l
cent
er
pane
l
ar
ea
use one o
r the othe
r but
not both at the same time
w
ir
e
r
ee
l
cent
er
pane
l
ar
ea
Schema
ti
c: G4822
= spot
ti
m
er
op
ti
on&w
iri
ng
=spoo
l
gun op
ti
ons & w
iri
ng
=fact
or
yconnec
ti
ons to con
tr
o
l
bd.
s
ho
w
nin
std
.
gun p
os
itio
n
10
98
7
6
54
3
2
1
BACK O
F
OUTPU
T
STUD
(o
nCEv
er
siononl
y)
OC
V
RANGE
10 - 35V (IN
P
UT
V
OLT
AG
E
DEPENDE
NT)
1
2
3
4
5
6
7
8
+15VDC +15VDC
CW
CCW
P1
J1
B
W
Logic
Spot
T
im
e
Fu
ll
CCW
=O
FF
Adjusts
fr
om
200mS to 10S
TH
E
RM
AL L
ED
PM180
C (
C
E)
VER
SI
O
N
O
NL
Y
Upp
er
l
eftc
or
n
er
of
Cas e
Fr
ont
65
FILTE
R
P.
C.
BD
O
N
C
E M
AC
HI
NES
O
NL
Y
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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