Lincoln Electric Power MIG 300, Service Manual, Page: 107 / 126

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ELECTRICAL DIAGRAMS
G-6
POWER MIG 300
SCHEMATIC - COMPLETE MACHINE - CODE 10958 AND 11000 ONLY
EN
-1
70
SO
LID
E
DG
E
G431 5
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
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
NA
CRM22115-EE
1
PAGE ___ OF ___
1
DOCUMENT
NUMBER:
DOCUMENT
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. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
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 CONNECTOR ON PC BOARD
1 6
7 12
LATCH
EX. 12 PIN CONNECTOR
LABELS:
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
2J41
1J41
1J42
2J42
3J42
5J42
472 412
471 411
408
410
+15VDC CONTROL 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
∫ ANGLE
ILLUMINATED LED
INDICATES VOLTAGES ARE
BEING SUPPLIED TO J43
LED2
RED
LED1
RED
4J
99
1J
99
43
1
43
7
PWM = 20KHZ 12V
CHOPPER P.C. BOARD
(SCHEMATIC M19792-1)
LOCATED AT
MACHINE'S BASE
(WIRE DRIVE SIDE) B8 B7
60
7
61
5
121K
G
E C
3J2
4J2
2J
8
4J
8
1J
8
6J
8
253
80
2
254
80
4
80
1
80
6
+1
5V
DC
L
EM
S
UP
PL
Y
LE
M
C
OM
M
ON
-
VA
RI
AB
LE
V
OL
TA
GE
FE
EB
AC
K
CO
M
M
ON
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
LE
D8
GR
EE
N
RED LED's ARE SOLID AT
POWER UP THEN BLANK
GREEN LED's REMAIN
SOLID GREEN
4J6
10J6 604
15J7
16J7
715
716
1J11
2J11
1J2 251
3J
9
1J
9
90
3
90
1
-
ST
UD
+S
TU
D
V
OL
TA
GE
F
EE
DB
AC
K
15
J6
7J
6
61
5
60
7
PW
M
C
OM
M
ON
+P
W
M
S
IG
NA
L
2J
5
3J
5
50
2
50
3
LE
D1
0
RE
D
LE
D9
GR
EE
N
RED LED's ARE SOLID AT
POWER UP THEN BLANK
SWITCHES MUST BE
IN OFF POSITION
DIP SWITCHES
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
2 3 7
LOCATED ON TOP
OF P.C. BOARD
COMPARTMENT
FOR WELD FILE
DOWNLOADS
R232
CONNECTOR
1 2 3 4
503A
2J83
3J83
832
833
FEEDHEAD
P.C. BOARD
(SCHEMATIC G3883)
5J85
12J85
855
8512
8J
85
11
J8
5
4J83 834
SWITCHES MUST BE
IN OFF POSITION
DIP SWITCHES
MOTOR -
GAS SO
GAS SOLENOID -
2J82
1J82
LOCATED IN LEFT SIDE OF
P.C. BOARD COMPARTMENT
10
J8
5
9J
85
7J
85
85
8
85
11
85
10
85
9
85
7
3 1 2 3 2 1
WFS/AMPS VOLTS/TRIM
PANEL ENCODERS
FOR CODE 10952
AND HIGHER
85
5A
1J83
831
MOTOR +
1J85
2J85
851
852
7J84
4J84
847
844
1J84 841
5VDC TACH SUPPLY
TACH SIGNAL
TACH COM
GUN TRIGGER SUPPLY
GUN TRIGGER INPUT
+15VDC
0V
LOCATED TO THE RIGHT
OF WIRE DRIVE ASSEMBLY
ON CENTER PANEL
LOCATED ABOVE WIRE
DRIVE ASSEMBLY ON
CENTER PANEL
LOCATED BEHIND THE
INSULATING WIRE DRIVE
PANEL. REMOVE THE
WIRE DRIVE ASSEMBLY
TO GAIN ACCESS.
ACCESS THIS CONNECTOR
BY REMOVING THE WIRE
DRIVE ASSEMBLY
6 PIN FOOT AMPTROL
LOCATED IN P.C. BOARD
COMPARTMENT
SPOOL GUN/
PUSH-PULL
SWITCH
-
+
USED ONLY FOR
EXTERNAL DIODE
(USED FOR MOTOR
BRAKING)
RECTIFIER BRIDGE
5J
83
83
6
83
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
TACH MOTOR / GEARBOX
2.6 VDC @ 50 IN/MIN
27.4 VDC @ 700 IN/MIN
8 SECOND AVERAGE CURRENT
LIMIT = 3.5A
(LIMIT IS SOFTWARE SET)
MEASURE 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
MEASURES 21 OHMS
12 VDC COIL
1
2
B W
SPI DISPLAY L11757-1
YELLOW
RED RED
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
R1
6
R1
4
R3 R4 R5 R6 R8 R9
R13
R12 R11
R10
R1
5
X2
DUAL ENCODER PRESENT
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
4 CS1
5 CS2
6 CS3
7 MISO
8 SCK
9 MOSI
10 GRD
FOR ALL FLEX AND
SHIELDED CABLE
SHIELDED
CABLE
FLEX
4J11
3J11
CAN COMMUNICATION SUPPLY +5V
0V
1J43 431
7J43 437
3J43 403
6J43 402
12J43 401
4J43 406
9J43 405
5J43 1104
+5V
10J43
1103
COMMON
+5V
COMMON
+15V
COMMON
+5V
+20VDC
COMMON
12J4
11J4
412
411
8J4 408
+ 15VDC
-15VDC
+ 5VDC
1J3
2J3
10J3
+ 15VDC
+5VDC
+0VDC
3J4
2J4
403
402
1J4 401
+ 5VDC
SPI SUPPLY +15VDC
COM
6J4
5J4
406
405
10J4 410
RS232 SUPPLY + 5VDC
COM
COM
1104
1103
1101
1102 2J86
10J86
1J86
+15VDC
+5VDC
SHIELDED CABLE COMMON
3J82
4J82
3243
3244
COMMON
TO POWER FEEDHEAD BOARD +42VDC
2J32
10J32
1J32
3J324
4J324
3243
3244
2J321
7J321
1J321
3J321
6J321
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)
MACHINE DISPLAYS
SETTINGS OF LAST
WELD MODE OPERATION
AMP LED ILLUMINATES
WITH CORRESPONDING 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
4J324
8J321
3214
3218
F E C D G
A
B
MO
TO
R +
MO
TO
R -
5K
SPOOL GUN/PUSH-PULL MOTOR
0VDC @ 50 IN/MIN
24VDC@700 IN/MIN
7 PIN
SPOOL GUN/PUSH-PULL
AMPTROL
3J
32
3
4J
32
3
32
33
32
34
CO
M
+
42
VD
C
CURRENT
TRANSDUCER
OUTPUT
CHOKE
50
wa
tts
50
0 o
hm
s
2520
2530
R1
+
2400/100
+
-
57 VAC
-
+
CONTROL RECTIFIER
80 VDC
OUTPUT
RECTIFIER
MAIN
TRANSFORMER
+
6800/75
X6 X5
X4 X3
PWM: PULSE WIDTH
MODULATION
CHOPPER
SUPPLY
30 VAC 115 VAC
LOCATED ON TOP OF
MAIN TRANSFORMER
SCHEMATIC: L11108
MSP3 BOARD
(SCHEMATIC: L11612)
LOCATED ON
SECONDARY
WINDINGS LOCATED ON
CHOPPER BOARD
HEATSINK
FAN STAYS ON FOR 5 MIN AFTER
LAST GUN TRIGGER (WHEN 2/4
IS CLOSED)
CR1
FAN
FAN RELAY
11J6
12J6 611
4 5 20 6
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
MACHINE'S BASE
(STORAGE
COMPARTMENT SIDE)
H1
H4
H1
(SHOWN
CONNECTED
FOR 230V)
H4 H3 H2 H5
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 TRANSFORMER
(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 POWER TO CONTROL P.C. BOARD
LED3: +5V FOR SPI CABLE
LED4: +15V FOR SPI CABLE
LED5: +5V POWER TO CONTROL P.C. BOARD
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.
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
DISPLAYING WFS
ILLUMINATES WHEN
DISPLAYING AMPS
ILLUMINATES WHEN
DISPLAYING VOLTS
ILLUMINATES WHEN
DISPLAYING TRIM
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 SELECTION OF DIFFERENT WELD
MODES AND PROCESSES.
1J
34
2J
34
10
J3
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.