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:

12/10/2004

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

LATCH

EX. 12 PIN CONNECTOR

LABELS:

COMMON

FRAME GROUND

EARTH GROUND

J1,J86

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

J81,J82

J85,J87

J2,J84

J83,J88

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

B -

BLACK

W -

WHITE

R -

RED

U -

BLUE

6J83

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)

ILLUMINATED LED

INDICATES VOLTAGES ARE

BEING SUPPLIED TO J43

LED2

RED

LED1

RED

4J9

PWM = 20KHZ 12V

CHOPPER P.C. BOARD

(SCHEMATIC M19792-1)

LOCATED AT
MACHINE'S BASE
(WIRE DRIVE SIDE)

121K

3J2
4J2

253

254

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

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

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

+ 15VDC

COM

+ 10VDC

COM

+ 10VDC

2 3

LOCATED ON TOP
OF P.C. BOARD
COMPARTMENT

FOR WELD FILE
DOWNLOADS

R232

CONNECTOR

503A

2J83
3J83

832:W

833

FEEDHEAD

P.C. BOARD

(SCHEMATIC G3883)

5J85

12J85

855

8512

8J85

11J85

4J83

834

SWITCHES MUST BE
IN OFF POSITION

DIP SWITCHES

MOTOR -

GAS SOLENOID +

GAS SOLENOID -

2J82
1J82

LOCATED IN LEFT SIDE OF
P.C. BOARD COMPARTMENT

10J85

9J85

7J85

858

8511

8510

859

857

3 1 2

3 2 1

WFS/AMPS

VOLTS/TRIM

PANEL ENCODERS

1J83

831:B

MOTOR +

1J85

2J85

851

852

7J84
4J84

847:U
844:B

1J84

841

5VDC TACH SUPPLY

TACH SIGNAL

TACH COM

GUN TRIGGER SUPPLY

GUN TRIGGER INPUT

+15VDC

COMMON

LOCATED TO THE RIGHT OF WIRE
DRIVE ASSEMBLY ON CENTER PANEL

LOCATED ABOVE WIRE
DRIVE ASSEMBLY ON
CENTER PANEL

LOCATED INSIDE THE
P.C. BOARD
COMPARTMENT
PLUGGED ONTO THE
FEED HEAD BOARD.

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

5J83

836

835

15VDC WHEN IN THE SPOOL GUN
POSITION 0VDC WHEN IN THE
PUSH-PULL POSITION

1
2
3
4

R
U
B

LOCATED ON
CASEFRONT

TACH

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

SPI DISPLAY

L11757-1

YELLOW

RED

+15V

+5V

/SS

CS1

CS2

CS3

MISO

SCK

MOSI

GRD

FOR ALL FLEX AND
SHIELDED CABLE

SHIELDED
CABLE

4J11
3J11

CAN COMMUNICATION SUPPLY +5V

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

1104
1103
1101
1102

3J82
4J82

3233
3234

COMMON

TO POWER FEEDHEAD BOARD +42VDC

75
77

REMOTE

TRIGGER

REMOTE

TRIGGER

REMOTE

LOCATED AT BOTTOM OF
P.C. BOARD COMPARTMENT

SPOOL GUN

P.C. BOARD

(SCHEMATIC L12008-2)

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

3214
3218

C D G

MOTOR

SPOOL GUN/PUSH-PULL MOTOR

0VDC @ 50 IN/MIN

24VDC@700 IN/MIN

7 PIN AMPTROL

SPOOL/PUSH-PULL GUN

CURRENT

TRANSDUCER

OUTPUT

CHOKE

tts

2520

2530

2400/100

57 VAC

DIODE RECTIFIER

80 VDC

INPUT

RECTIFIER

MAIN

TRANSFORMER

6800/75

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

TOROID

LOCATED ON
DIVIDER
PANEL IN THE
WIRE DRIVE
COMPARTMENT

TOROID

LOCATED ON
TRANSFORMER
BAFFLE

TOROID

+ 42VDC

LOCATED ON FRONT
OF MACHINE'S BASE

LOCATED ON
MACHINE'S BASE
(STORAGE
COMPARTMENT SIDE)

(SHOWN
CONNECTED
FOR 230V)

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.

15 V

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

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 SELECTION OF DIFFERENT WELD
MODES AND PROCESSES.

PI FLEX/SHIELDED

CABLE SUPPLY

RS232 SUPPLY

CAN COMMUNICATION
SUPPLY

14J85

8514

3J810
2J810

1J810

5J810

6J810
4J810

8J810

3218

3214

8514

846A

6J84

846

4J85

3J85

853

DUAL PROCEDURE SUPPLY

DUAL PROCEDURE INPUT

851A

2J811

1J811

8115

8111

5J88

8115

FLEX

TO SPOOL/PUSH-PULL
GUN MOTOR DRIVE

+40V DC SUPPLY FOR

SPOOL/PUSH-PULL GUN MOTOR

0-5V SIGNAL VARIES WITH
REMOTE POT WIPER

SPOOL/PUSH-PULL GUN

BRAKE SIGNAL

(0 VOLT= MOTOR BRAKE)

CIRCUIT

BREAKER

15A

1205

115V

LOCATED ON
CASE BACK

1203

1204

MOTOR / GEARBOX

STANDARD MAGNUM

SPOOL GUN

2J812
3J812

8123

4J812

8124

GAS SOLENOID +
GAS SOLENOID -

1J812

LOCATED ON
CASE BACK

PWM CONTROLLED
6.5 VDC WHEN GAS
FLOWING COIL
MEASURES 21 OHMS
12 VDC COIL

SPOOL GUN/TIG

SOLENOID

G-3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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