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G5638
ENGINEERING CONTROLLED
RELEASED A.02 F ROM " X".
MANUFACTURER:
No
5 PIN ARCLINK
CONNECTOR TO
POWER SOURCE
NOTE: WILL WORK WITH LINKNET
POWER SOURCE BUT WILL
ONLY SHOW AND HAVE
LINKNET FEATURES
(BEHIND WIRE REEL COVER)
P11
(LOCATED AT REAR OF FEEDER)
A
1
541A
{
541
COMMUNICATION
B
542
2
542A
C
67
3
67A
P10
{
D
540
4
540A
40 VDC
(LEFT LOWER CASE FRONT)
(LEFT LOWER CASE FRONT)
E
500
5
500A
500B
500C
6
7
(BEHIND WIRE FEED MOTOR)
L6
8
TOROID
R3
520
ARC VOLTAGE
40 OHMS
FEEDBACK
10 WATTS
500D
W
8
B
7
INPUT ELECTRODE
67B
CABLE CONNECTION
P9
(BASE CONTROL
BD. AREA)
FEED PLATE
MOTOR FRAME
IS HOT TO
1
MOTOR GEARBOX
TACH
ELECTRODE
2
TYP: IPM
R
R
3
50 - 800/IPM NORMAL SPEED
U
U
4
30-400/IPM EXTRA TORQUE
B
B
5
5-32 VDC
6
3.1 OHMS
13 SEC. AVERAGE CURRENT
(ACCESS THIS
LIMIT = 3.5A
CONNECTOR BY REMOVING
THE WIRE DRIVE ASSEMBLY)
(LIMIT IS SOFTWARE SET)
0V TO COMMON WHEN
SWITCH CLOSED
(CASE FRONT)
P6
P4
L3 TOROID
A
532
532
1
532C
{
TRIGGER
C
570D
570D
2
570E
D
543
543
3
543A
DUAL
{
L1 TOROID
PROCEDURE
E
570G
532A
9
532D
PROCEDURE
B
570A
8
570C
A = OPEN
PUSH-PULL MOTOR
B = CLOSED
0VDC @ 50 IN/MIN
7 PIN
532A
24VDC @ 700 IN/MIN
PUSH-PULL
GUN
B
3214A
M
PUSH-PULL GUN WIRE
CONNECTION
A
3218A
FEED SPEED CONTROL
5K
L2 TOROID
P5
PUSH-PULL
E F C D G
GUN TRIGGER
570A
AMPHENOL
77B
(LOWER CASE FRONT)
570B
76B
532B
75B
77A
76A
3214A
3218A
75A
E
D A C B F
P3
L1 TOROID
6 PIN REMOTE FOOT
AMPTROL CONNECTION
(LOWER CASE FRONT)
GENERAL
STEEL
GMAW
STD. CV
5
0.030 0.035 0.045 0.052
CV
GMAW POWER MODE
40
GMAW
CO2
---
FCAW
STD. CV
6
GMAW
Ar (MIX)
94
PULSE (CRISP)
Ar (MIX)
95
STICK
SOFT (7018)
1
PULSE (SOFT)
Ar (MIX)
---
STICK
CRISP (6010)
2
STT (NO TAIL OUT) CO2 Ar/CO2
109
CC
TIG
TOUCH START
3
STTll
CO2 Ar/CO2
110
GOUGE
---
9
ALUMINUM
0.035
3/64
1/16
GMAW
Ar 148
71
73
GMAW
4043
PULSE
Ar 149
72
74
5356
PULSE
PULSE ON PULSE Ar
98
99
100
PULSE ON PULSE
J2
S1 POWER
540B
CONNECTS TO S4
400E
540B
R2
530
7P7
530A
540E
8P7
540D
S5 HEATER
HELPS KEEP MOISTURE
OFF OF WIRE
(ABOVE WIRE FEED MOTOR)
L5
TOROID
PWM CONTROLLED
6.5 VDC WHEN GAS IS
FLOWING. COIL
MEASURES 21 OHMS.
GAS
12 VDC COIL
3J81 4J81
2J81 1J81
(LOCATED AT REAR
OF FEEDER)
MOTOR +
550
1J83
MOTOR -
551
2J83
GAS SOLENOID +
553
3J83
GAS SOLENOID -
(BEHIND COVER AND
554
4J83
MOTOR AREA)
5VDC TACH SUPPLY
531
1J84
(SCHEMATIC G3883)
TACH SIGNAL
537
7J84
TACH COM
534
4J84
PERFORMS ALL USER
L4 TOROID
INTERFACE, WIRE DRIVE,
TRIGGER
AND GAS SOLENOID
532E
2J85
CONTROL FUNCTIONS.
SUPPLY FOR TRIGGER AND DUAL
570F
1J85
DUAL PROCEDURE
543A
3J85
ON
1
2
OFF
J87 NOT USED
CLEAN ROOM USE
1J88
REQUIRED FOR
518
4 STEP MODE
8J84
PUSH-PULL GUN
BRAKE SIGNAL
(0 VOLT = MOTOR BRAKE
6J85
6J84
0-5V PUSH-PULL GUN
6J810
526
P6
POTENTIOMETER SIGNAL
548
4J810
5
3214
3214
3J810
4
3218
2J810
3218
76A
7
76
76
5J810
75A
10
75
75
8J810
77A
6
77
77
1J810
PUSH-PULL GUN
PCT AND RESISTORS
PROTECTED ON
DAUGHTER BOARD
(SCHEMATIC L12008)
P89
STAINLESS
0.030
0.035
0.045
10
20
24
GMAW Ar (MIX)
61
31
41
11
21
25
GMAW Ar/He/CO2
63
33
43
12
22
26
PULSE Ar/CO2
66
36
46
SPARE
1
14
19
28
PULSE Ar/O2
62
32
42
2
SPARE
109
125
125
PULSE Ar/He/CO2
---
34
44
110
126
126
STT
Ar/He/CO2 109
109
125
3
SPARE
STTll
Ar/He/CO2 110
110
126
SPARE
4
METAL CORE
5
SPARE
0.045
0.052
1/16
0.035
3/64
1/16
GMAW
Ar/CO2
81
83
85
Ar
151
75
77
6
SPARE
PULSE
Ar/CO2
82
84
86
Ar
152
76
78
7
POLARITY
Ar
101
102
103
8
FEED SPEED GEAR
This diagram is for reference only. It may not be accurate for all machines covered by this manual.
VOLTAGE SENSE
SELECT P.C. BOARD
(SCHEMATIC S24779)
(LOCATED BEHIND WIRE
REEL COVER)
J1
400
(CONTROL
BOX BOTTOM)
25 TO 35
NORMAL
BALL FLOAT
FLOW RATE
USE MIDDLE OF
BALL TO SET
ADJUST VALVE
FLOW METER
(OUTSIDE BACK OF CASE)
GOOD FOR Ar, CO2, CO2/Ar BLENDS
ARCLINK OPTION USE
1
2
4
3
4J82 3J82 2J82 1J82
14J85 13J85
5
7
15J85
1W
6
8
16J85
1B
FEED HEAD
P8
580A
10J85
P.C. BOARD
(BEHIND DISPLAY BOARD)
7J85
587A
5J85
585C
12J85
582A
COLD INCH
11J85
581A
+5VDC
5J84
535
3
535A
SIGNAL
6J85
586
4
586A
+15VDC
9J85
579
1
579A
400C
SEE DIPSWITCH S1
S2
579B
SETTING CHART
4J88
578
2
578A
579C
S1
3
2 STEP/4 STEP SWITCH
4
8J84
518
5
6
7
8
(WIRE DRIVE AREA FRONT TOP)
OPEN = 4 STEP: CLOSED = 2 STEP
1J88
518C
518D
6
518B
W
B
W
P7
J86 SPI USE
+40
MOTORS WILL NOT
5J83
554
WIRE
AC
RUN IF DIODE IS
MOTOR
OPEN, REVERSED,
5J83
640A
OR DISCONNECTED
USE
DIODE BRIDGE
5J88
(DIVIDER PANEL REAR
ACCESS DOOR SIDE)
2J811
595
TO PUSH-PULL
1J811
640
GUN MOTOR DRIVE
PROVIDES BRAKING
+40V DC SUPPLY FOR
OF THE PUSH-PULL
PUSH-PULL GUN MOTOR
GUN MOTOR AND
To access, press the right and left push buttons
(NON-ISOLATED)
CONDITIONS THE
on the MSP4 panel simultaneously
SIGNAL FROM THE
DAUGHTER
P.C. BOARD
POTENTIOMETER.
Setup feature numbers may vary between software
versions. Must read small display to find your
specific feature you want. These P numbers listed
are for reference.
DIP SWITCH S1 SETTING CHART
SERIAL NUMBER AND
CODE NUMBER LOCATED
BELOW WIRE FEED
DRIVE ROLL AREA
POS
NEG
LOW SPEED
NORMAL
EXTRA TORQUE
SPEED
LEAD COLOR CODE:
COM PONENT VALUE UNIT S:
B- BLACK
CAPACIT OR: MF D/ VOLTS
CAVITY NUMBERING SEQUENCE
R- RED
(COMPONENT SIDE OF P.C. BOARD)
RESI STOR: OHM S/ W ATTS
U- BLUE
W-W HIT E
CONNECTOR PI N NUM BERS:
1
1
2
1
3
J2,J811
J81,J82
J1,J83,J88
J84,J810
EX. 12PI N CONNECTOR
2
3
4
6
4
1
6
LABELS:
1
5
1
8
J86
COMM ON
J85,J87
7
12
6
10
9
16
FRAM E GROUND
LATCH
VI EW OF CONNECTOR ON PC BOARD
SEE ERROR TABLE
LED DISPLAY
IN IM MANUAL
LEDS
RED/GREEN
STATUS LED
(TOP FRONT)
W
B
WFS
AMPS
VOLTS
DISPLAY P. C. BOARD
(SCHEMATIC: L11756)
(TOP FRONT)
(BEHIND FRONT PULL DOWN DOOR)
PANEL ENCODERS
CURRENT
WFS
1
2
3
1
2
P1
580
587
585
582
581
SINGLE
SET SWITCH 1 "ON" (SINGLE HEAD)
HEAD
AND SWITCH 2 "ON" (FEEDER)
AS SHOWN ON DIP SWITCH S9.
DUAL
(WIRE DRIVE FRONT TOP)
(LOCATED ON BACK
HEAD
SIDE OF BOARD)
COLD INCH/
LEDS
GAS PURGE SWITCH
A-GUN-B
(CONTROL
PUSHBUTTON
BOX TOP)
S3
400F
400G
GAS PURGE
MEMORY P.C. BOARD
400D
(SCHEMATIC: L11897)
(BEHIND CASE FRONT)
S4
(ON PULL DOWN DOOR FRONT)
LIGHT LED SWITCH
(USED IN DARK AREAS)
(BEHIND PULL DOWN DOOR FRONT)
(ABOVE WIRE FEED MOTOR TOP)
590
INFRARED TRANSCEIVER
(WIRELESS COMMUNICATION)
MSP4 P.C. BOARD
WELD MODE, WIRE SIZE,
(SCHEMATIC: G4456)
400B
ERROR CODES, SEVEN
SEGMENTAND ALPHA
NUMERIC DISPLAY
(CONTROL BOX TOP)
WELD MODE LED
16 DETENT
B
R1
ARC CONTROL LED
ENCODER
475 OHMS
SELECT
SELECT PUSHBUTTON
(BACK OF WIRE DRIVE
PUSHBUTTON
PANEL - SOLDER
SEE IM MANUAL FOR ERROR CODES
ON BRACKET)
OR WWW.POWERWAVESOFTWARE.COM
OR SERVICE NAVIGATOR DIAGNOSTIC UTILITIES
SHIELDED CABLE
SET UP MENU
SET UP MENU FEATURES
P.0 = On/Off enter exit set up mode
P205 = CC test 550A
P1 = WFS English/metric
P206 = CV test 10V to 30 V
P2 = Left display amps/wfs
P207 = 1/0 test 25-600
P4 = Trigger memory recall
P208 = STT test 170A
P5 = Trigger procedure change
P209 = 1 curve 0-600A
P6 = Stall factor
P210 = Step resp background
P7 = Push pull gun offset
P211 = V curve 0-70V 10-70V
SEE IM MANUAL
P8 = New TIG solenoid feature
P212 = OCV test
FOR MORE
P80-89 = Senses from studs on S25629-09
P215 = Touch sense
DETAILS
P99 = Show test mode 200.201
P255 = Show weld file
P100 = View diagnostics
P102 = Fatal log
P103 = View software
P104 = Hardware version
P105 = Welding software
P200 = CC test 25-600
P201 = CV test 10-35
P202 = CC test 10A
P203 = CC test 355A
P204 = CC test 455A
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
THE I NFOR MA TIO N ON THIS
DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
POW ER FEED 25M
PRINT IS FOR RE FERENC E
DRAWN BY:
JIMJ/KJ
G4440
SUBJECT:
MACHI NE SCHEMATI C
ON LY. C O MP ON ENTS AND
ENGINEER:
SCALE:
CIRCUITRY MA Y BE
ENYEDY
DIFFERENT
MATERI AL
APPROVAL
PROJ ECT
FRO M AN ACTUAL M ACHINE.
NA
9/13/200 6
CRM38268
APPROVED:
NO NE
DI SPOSIT I ON:
DATE:
NUMBER:
1
4
5
8
LED DISPLAY
TRIM
FLEX
VOLTS
TRIM
3
P2
ADAPTER
DIP SWITCH S9
FLEX
1
FEEDER
O
2
N
FUTURE
SET UP
LED
CAPACITOR
400H
(BEHIND CASE
FRONT)
START OPTIONS LED
END OPTIONS LED
CAPACITOR CONNECTS
FROM PIN 10 OF SHIELDED
CABLE TO FRAME GROUND.
L7
TOROID
1
PAGE ___ OF ___
1
DO CUM ENT
DOCUMENT
NUM BER:
REVI SI ON:
G5638
A
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