Lincoln Electric LN-25 PRO DUAL POWER Service Manual page 95

G-3
SchEmaTic - cOmplETE machiNE - (G6333) pG1
ENGINEERING CONTROLLED
MANUFACTURER:
For Work Clip Lead
667D
Input See Page 2
621 21D
767
TO
821
PRESET
721
P.C.
67
BOARD
667B
see 41B
page 2 621B
42B
MOTOR FILTER P.C.
BOARD SCHEMATIC=
S27592 BEFORE 6/15/2009
S27505 AFTER 6/15/2009
J61-1
J61-2
J61-3
J61-4
621
J62-1
J62-2
USED TO DISCHARGE
POWER SUPPLY CAP
AFTER A HIGH VOLTAGE
TRANSIENT. LATER
RELOCATED TO THE
CONTROL BOARD.
NOT PRESENT
ON S27505
Located on
667
Case Front
621
GAS PURGE
PUSHBUTTON S4
SWITCH (N.O.)
13.5 VDC WHEN
NOT DEPRESSED
(OUTSIDE BACK
OF CASE)
25 TO 35
NORMAL
FLOW
RATE
BALL FLOAT
USE MIDDLE OF
BALL TO SET
ADJUST VALVE
FLOW METER
GOOD FOR Ar, CO2,
CO2/Ar BLENDS
Model Ranger 8,9
K2614-1 Recommended
K2614-2 all CV
operation.
CHANGE DETAIL: MISC. UPDATES PER SERVICE DEPARTMENT REQUEST AND ADDED BYPASS CAPACITOR ASSEMBLY
No
P7 = 16 PIN
P17 = 6 PIN (Both are lo cat ed on lower front)
P17
3
667C 667A
1 of 2
6
21E
621A
5
821B
531
21D 4
P17
537
767
2 of 2
534
821A 1
67B
67C
821
Located on
IN HARNESS
721 Sheet Panel
D1 CENTER
front
SEE PAGE TWO FOR BASE AREA
BYPASS CAPACITOR
BOTTOM
ASSEMBLY SCHEMATIC
67
667A
42
667B 41
TOP
P18
41B
J
621A D2
L
I 41A 9
24-42VAC 10 10
K 42A
621A
41
77D
E 5
42B Located on REMOTE
4
Case Back VOLTAGE F 76D
CONTROL G 75D 3
J12
1
SENSE N 67E
667D
14 PIN
21F 6 21E
21F H
AMPHEN OL
2
M
OUTPUT C 2 7
USED FOR FILTERING
CONTROL 8
D 4
INVERTER NOISE
J15
Values for CV305. Others may be different.
0 VDC @ 0 = 5.8 Arc Volts
667E 6.6 VDC @ 10 = 40 ArcVolts
10K/2W
75
R2 76
B2
77
75B
77B 75 10 75C
B1 REMOTE CONTROL
76B
VOLTAGE
76 11 76C
POTENTIOMETER
77 12 77C
TO PRESET
Connector
P7
P.C. BOARD
located behind
4 of 4
see page 2
case front
575A 6 575
576A 7 576
577A 8 577
J4-11 J4-12 J4-6
MOTOR
100K +5V
10K/2W
SUPPLY
ohm
575A
J5-1
576A
R1
+15V
COM
577A
+15V SPI
+5V SPI
WIRE FEED SPEED
POWER -15V
0 VDC MIN. WFS
CONTROL
SUPPLY
5 VDC MAX. WFS +15V ISO
POTENTIOMETER
+5VDC
LED
ISO 35VDC
B1
B2
C1
C2
OVER POWER
VOLTAGE SUPPLY
PROTECTION
B1
610
612
B2
C1
(LOCATED AT
OUTSIDE REAR
C2
OF FEEDER)
621
J5-8
COM
+35V
+15V
22 O COIL
610 J6-7
0 VDC OPEN
612 J6-1
4 VDC CLOSED
12 VDC COIL
PWM CONTROLLED
GAS
SOLENOID J4-3
J4-4
690
COM
(LOCATED INSIDEOF
691
CONTROL BOX)
(LOCATED AT REAR
FAN BLOWS AIR ACROSS
OF FEEDER)
CONTROL PC BOARD
CONTINOUSLY AT 6200 RPMS.
Classic Ranger 250, 305 V350 DC-400, 600 Square Wave TIG 300/355
Commander 300,400,500 (Common Digital
(Common Analog Controls)
Controls)
Recommended for Recommended for CV Recommended Recommended Not recommended for CC operation
CV operation. operation. for CV for CV and CC because the customer may
(Wire Feed operation. operation. experience short contactor life from
Module Required) May be used for inductive nature of the power source.
pulse welding if Not recommended with high frequency
the welding TIG starti ng.
procedure is
qualified by the
customer.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ElEcTrical DiaGramS
LN-25 PRO DUAL POWER
When tach feed back is lost, the voltage
to the motor is a constant 10VDC.
(controlled by software)
72 HZ TO 1.2 KHZ
Gearbox ratio is 23.5:1
R-B 15.0 VDC
Motor resistance
Motor case is at
B-U 6.2 VDC ANY SPEED
Top of motor
electrode potential is 1.5 ohms
Leads Pass through (METER DEPENDENT)
P9 1
Motor is located
toroid2 times.
2 R
behind
L4
531 3
U
glastic panel
FEED
4
537
B MOTOR /
PLATE
534
5
GEARBOX
6
551 7
B
550 8
W
2.6 V @ 50 IPM
TAKEN WITH 40 V INPUT
gun connector
27 V @ 700 IPM
67C IN CV MODE.
67C & 67D
67D
Leads Pass
through
Trigger Interlock does not stop
toroid 2 times. J11
welding when the arc is broken.
Located on Wire
Pull and release to end the weld.
Drive Panel
TRIGGER
805
L5 S1 INTERLOCK
15V=2 STEP
S2 & S3
0V=TRIGGER 509E
Located on
INTERLOCK
587 Wire Drive
Connects to J10 on
Panel
2-STEP PRESET P C BOARD
509D SEE PAGE 2
COLD FEED 15V=CV
S2
S3 0V=CC
509E CC
N.O.
530A
0V=COLD FEED
CV
(N.O.)
509C
523
P16
4 2 3 1
Located on
top of motor
509
NOT USED
P7-1
3 of 4
550
534 821B
531
551
537 67F 721 530
587 622 500
523 509A
J6-9 J6-10
J4-9 J4-10 J4-2 J5-7 J5-5 J6-3 J6-4 J6-6
J4-7 J4-1 J5-6 J6-2
+15V
+15V
10K
TRIGGER
ohm
CC/CV
TRIGGER INTERLOCK / 2 STEP
COLD FEED
.05 uF
COM
600 V
MICRO
CONTROLLER
METER
COMPENSATION
POLARITY
CIRCUIT
721 IS DRIVEN NEGATIVE TO COMPENSATE
SENSE
FOR THE METER FOR DIODE DROP ERROR
ON THE BRIDGE
+15
MOTOR
SUPPLY
-15
DRIVE
PWM
DRIVE
MOTOR
BRAKE
BRAKE
DRIVE
0.05K MOTOR VOLTAGE
CIRCUIT
ohm
MOTOR CURRENT
COM
0-5V PULSE SIGNAL
TACH
FREQUENCY = SPEED
FEEDBACK
0V = MIN SPEED
WIRE FEED
5V = MAX SPEED
SPEED
GAS PURGE
GAS SOLENOID
PROGRAM
FLEXIBLE POWER P.C. BOARD
+5V
SCHEMATIC = G4783
P21 J3-7
RED 8 RED A
FAN TO PRESET
PROGRAMMING PCB
P. C. BOARD
BLACK 6 BLACK A FACTORY USE ONLY
Miller Inverters STT II Note:
Most semiautomatic wire
welding processes perform
better using constant voltage
Recommended Not recommended power sources. Be sure the
for CV voltage for STT operation. proper power source is used
for your application. Contactor
sense operation.
life may be shortened in
Not
recommended for applications using CC
use when pulse machines with high OCV.
welding.
PLASTIC HOUSED BOLTED
CONNECTION (BASE CENTER)
67C
67D
From Power
Source (Electrode
copper bar weld cable
Connection)
copper bar
ca se back
strain rel ief
1
2 3 4 CURRENT TRIGGER CONNECTOR
TRANSDUCER J14
801 622A A
TRIGGER INPUT
802 B
804
500A
C
Located on
D Case Front
555A
E
622B
83% WFS SWITCH
0V.=TRIGGER CLOSED
15VDC.=TRIGGER OPEN
509B 509B
TIMER KIT P.C. BOARD
4 O COIL
(OPTIONAL)
0 VDC OPEN
SCHEMATIC = M21341
3 VDC CLOSED
4
622 12 VDC COIL SEE PAGE 2
2 PWM CONTROLLED
500
555
3
607 608 606A 605 4B 509B 601
Located under
1 of 4 Wire Drive Panel
CONTACTOR
P7
8
7 6 5 4 3 2 1
P60
ISOLATED 2-4 TO
POWER SOURCE
4
EXTRA TORQUE
608
555 607 605 601
2 578 507 606
+35V
J5-4 J5-3 J4-8 J4-5 J2-6 J2-3 J2-2 J2-5 J2-1 J2-7 J2-8
J2-10
+15V
20
MOV ohm
MACHINE +5V
OUTPUT
ENABLE
CONTACTOR DRIVE
100K
ohm
COM
GAS
ON - OFF
0V = OFF
20msec ---- 250msec
BURNBACK
YELLOW THERMAL LED
+5V SPI
POLARITY LED COM
J6-14
COM
ARC ESTABLISHED
J6-11
J6-12
J6-5
+5V SPI +15V
-15V
J6-8
J1-10 J1-2 J1-1
SPI DIGITAL COMMUNICATION
AND SUPPLY TO BOARD
PROPRIETARY & CONFIDENTIAL: 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.
MANUFACTURING TOLERANCE PER E2056 SCALE:
CONTROL: CLEVELAND EQUIPMENT TYPE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm)
NONE
DRAWN BY:
ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm) tpearn
IF PRINTED SUBJECT:
ON ALL ANGLES IS ± .5 OF A DEGREE
@ A1 SIZE
MATERIAL TOLERANCE (" ") TO AGREE t ENGINEER: E. ENYEDY
WITH PUBLISHED STANDARDS. UNITS: MATERIAL
DO NOT SCALE THIS DRAWING APPROVED: DRS INCH DISPOSITION:
G-3
Start-Up
On power-up, the LN-25 PRO will light all LED's and displays
2-3 seconds.
If the feeder is powered-up with the trigger depressed, welding will
not start until the trigger is released and then depressed again.
Notes:
Motor overcurrent limit varies with WFS.
The WFS range of the LN-25 PRO
Normal Speed = 40- 700 IPM.
Before 2-20-2009
Current
Level
4.5
3.5
Preset
WFS
After 2-20-2009
Current
Level
4.5
3.5
Preset
WFS
370 530 700
WFS limited by arc voltage when operating across the arc.
Feeder Input Volts Maximum WFS
15 280
17 340
21 440
24 520
27 600
Control Board Summary
Converts arc power to a usable control circuit voltage.
Receives switch signals from Trigger, Cold Feed, Gas
Purge
Reads WFS potentiometer.
Communicates with optional timer kit.
Controls motor speed with PWM.
Turns Gas Solenoid on, off, PWM.
Reads the motor tachometer.
Operating Voltage= 15-110 VDC.
Shut down Voltage= 130 VDC.
Code and Serial numbers are below Wire Drive on plastic
housing Nameplate.
Thermal "Yellow" Light (ERR 82)
4B
Motor Over-Current
Motor and trigger disabled for 30 seconds.
Must retrigger to start welding after 30 seconds
pass.
Shutdown Voltage exceeded
May occur with some inverters.
May occur with some CC machines with high
inductance.
Polarity Indicator
When operating in negative polarity, a "-"
GAS
(minus) sign will appear in the voltmeter
FLOW
display.
ENABLE
15
B 2B
13
1B
THERMO LED AND POLARITY
LED ARE FOUND ON
14
PRESET BOARD.
1W
16
2W
9
708
NO RUN IN SW.
5
708A
707
ARC
2 of 4
PRESET P.C. BOARD
P7
0V = NO SCHEMATIC = G4748
ARC
+15V = ARC
SEE PAGE 2
707A
PRESENT
FOR MORE DETAILS
LN-25 PRO DUAL POWER 1 2
PAGE ___ OF ___
DOCUMENT
MACHINE SCHEMATIC DOCUMENT
NUMBER: REVISION:
G6333
REFERENCE: B
APPROVAL PROJECT
UF 11-20-2009 CRM42139
DATE: NUMBER: G5683-1
Insight
lN-25™ prO DUal pOWEr