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G-3
SCHEMATIC - ENTIRE MACHINE - (G4198-1)
G4198-1
ENGINEERING CONTROLLED
RELEASED A.03 FROM "X"
MANUFACTURER:
No
General Notes:
Codes 10864,11033 & 11035 do not support the high/low speed gear
change. Only the high speed (1.8" diameter) gear may be used.
Error
Description
Cause and Remedy
Code
Err 0081
Average
The wire drive has exceeded the current rating:
motor Over-
10 amps for 0.5 seconds or
current
3.5 amps for 10 seconds.
shutdown
Wait 45 seconds for the error to reset.
Reduce the current load on the motor by:
Verifying the electrode slides easily through the
liner of the gun.
Reduce the spindle brake resistance.
Reduce the amount of tension in the wire drive
pressure arm.
Use only Lincoln electrodes.
Err 0086
Trigger
The voltage into the feed head board exceeds 150
lockout
VDC.
Some inverters and choppers may have spikes on the
output that charge the capacitors inside the LN-15
beyond limits.
If this error occurs, lower the OCV of
the power source. It may be likely that a different
power source is required.
WFS Display
Voltage Display
Voltage LED
SPI DISPLAY
L11757-1
YELLOW
RED
RED
RED
RED
Not Used
The di s play board communicates to the feedhead board through the SPI
bus. Only the power supply sig nals can be monitored during servicing.
The WFS al w ays shows the present WFS.
The voltage display shows the voltag e while welding, plus hol d s the
voltage for 5 seconds after the weld. It shows "- - -" when idle. A negative
"-" sign will automaticall y be shown when welding with reverse pol arity
procedures.
All the LEDs, including thos e not used, will briefly ligh t on power up. The
LED's not used are vi s ible behind the nameplate when lit.
15-110 VDC from
welding power
source
All LED's light
briefly
Show CC/CV
mode and HI/LO
gear
Enter Press and
Spin Mode
Idle:
Display WFS, "---"
Wire Drive: OFF
Gas Solenoid: OFF
ELECTRICAL DIAGRAMS
LN-15 ACROSS THE ARC MODEL
Boost Board
Located on the right
Schematic M19 752
side of the control box.
- INPUT
Common
COM
to '-' input
ISOLATION
enabling
SWITCH (FET)
circuit
COM
COM
Positive
BOOST BOARD
The boost board takes the weld voltage
and boosts it to 80VDC for the rest of
Voltage
the LN-15. There are two supplies on
the boost board, one for the motor and
the other for the feedhead board. With
Feedback
two supplies, even if the motor supply
should droop because of heavy loads,
power to the feed head board is not
affected.
The rectifier allows the LN-15 to
ON/OFF
be powered either electrode
SWITCH
21A
positive or electrode negative
without any switches for the
customer to set.
526B
526C
Located under the cover
in the control box ably.
BRIDGE
RECTIFIER
Input
526B
Power
Circuit
TOROID
21B
567
67
FEEDPLATE
TOROID
21
Input
Voltage
Protection
INPUT ELECTRODE
CABLE CONNECTION
WORK
CLIP
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. TOGGLE SWITCHES AND POTENTIOMETERS SHOWN FROM CONNECTION SIDE OF SWITCH.
Model
Ranger 8,9
Classic
Ranger 250, 305
V350
DC-400, 600
Commander 300,400,500
(Common Digital
(Common Analog
Controls)
Controls)
K1870-1,-2 Across
Recommended
Recommended for CV
Recommended for CV
Recommended for
Recommended
the Arc
all CV operation.
operation. (Wire
operation.
CV operation.
for CV and CC
Feed Module
operation.
Required)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Gas Solenoid
Wire Drive
Circuit
Circuit
80VDC or weld voltage,
whichever is higher
COM
FEEDHEAD SUPPLY
J47
8
MOTOR SUPPLY
7
502
5
501
COM
POS
3
NEG
1
527A
526A
TOROID
TOROID
J2
8
7
552
This large MOV
absorbs the
6.5 VDC when gas flowing
inductive energy in
Coil measures 21 ohms
the weld cables and
power source when
Measure B to U
Located under the cover at
the contactor
W
B
120 Hz @ 50 in/min
553
the rear of the feeder
opens.
1.6 kHz @ 700 in/min
GAS
15 VDC Tach Supply
150V, 300J
MOTOR /
1
SOLENOID
GEARBOX
2
2.6 VDC @ 50 in/min
R
3
27.4 VDC @ 700 in/min
526
TACH.
MOV ASBLY
8 sec average Current
U
4
Located in the control box next
limit = 3.5 Amps
B
5
to the Feedhead board.
(Limit is software set)
TOROID
6
10K Ohms
WIRE FEED SPEED
Located behind the insulating
3-1/2 turns
526C
Access this connec tor
CONTROL
wire drive pan el. Remove the
by removing the wire
POTENTIOMETER
1
wire drive ably t o gain access.
2
drive asbly.
Located on the case
3
15- 110 VDC
front. Remove the wire
MOV ASBLY
drive asbly to gain
GND-B
Not a PC board; no schematic.
access.
527
Located behind the wire drive
1M ohms
GND-A
320V, 150J
320V, 150J
.0047/.005 mfd,
1400VDC
The contactor is
567A
located behind
the glastic panel
Bussbar from i n put
next to the motor.
Pigtail
stud to contactor
CONTACTOR
300A 60%
250A 100%
Coil measures 4.4 ohms.
578
0 VDC Open
2.3 VDC Closed
507
WFS
12 VDC coil
PWM Controlled
Control
Circuit
Contactor
Interlock
Square Wave TIG
Miller Inverters
STT II
Note:
Circuit
300/355
Most semiautomatic
wire welding
processes perform
Not recommended
Recommende
Not
better using constant
for CC operation
d for CV
recommended
voltage power sources.
because the
voltage sense
for STT
Be sure the proper
customer may
operation.
operation.
power source is used
experience short
for your application.
contactor life from
Contactor life may be
inductive nature of
shortened in
the power source.
applications using CC
machines with high
OCV.
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
1
3
1
2
J81,J82
J83,J88
4
3
4
6
1
5
J1,J86
J85,J87
6
10
FEED HEAD CONTROL
INPUT VOLTAGE MONITOR
+
Vin
(MOTOR FETS ARE BOTH
OFF WHEN INPUT VOLTAGE
+ MOTOR
S
U
P
P
L
Y
DROPS BELOW 20V)
M
O
T
O
R
V
O
L
T
A
G
E
M
O
N
T I
O
R
+
5
V
J81
+15V
+
V
n i
1
-15V
P
P
O
O
W
W
E
E
R
R
2
J
8
1
4 -
S
S
U
U
P
P
P
P
L
L
Y
Y
-5V
502
+ motor
3
J
8
2
4 -
501
4
+5V(TA
C
H
)
J
8
3
5 -
+5
V
J83
POS
+
6
V
n i
J
8
3
6 -
J82
1200uF
-
J
8
1
3 -
NEG
3
4
J
8
2
3 -
1
COM
COM
2
+ MOTOR
AVERAGE
CURRENT
DRIVE
LIMITING
PWM
MOTOR
CPLD
CONTROL
BRAKE
PULSE BY PULSE
PEAK CURRENT
LIMIT (27 AMPS)
J83
Motor +
550
1
Motor -
551
2
Gas Solenoid +
+15V
552
3
Gas Solenoid -
553
4
see power
5
5
supply section
6
6
COM
molex
MICRO
gas
CONTROLLER
solenoid
+5V (TACH)
PWM control
J84
563
1
ckts
2
3
Tach Signal
TACH INPUT
562
7
Tach COM
561
4
Wiper to COM
COM
5 VDC at 700 ipm
WFS
0 VDC at 50 ipm
J84
ANALOG
POT Supply
INPUT
577
8
COM
Wiper
576
A=1
6
+5V
COM
575
5
A=1
INTERNAL
2
k
SWITCH
E
X
T
E
R
N
A
L
N.C.
INPUTS
+
1
5
V
S
W
T I
C
H
C
OM
2k
N I
P
U
T
S
2
k
4
7 .
5
k
COM
5
0
0
C
O
M
5
0
0
5
0
0
4.75k
4
7 .
5
k
For programming at LECo factory only.
4
7 .
5
k
+15V
4
7 .
5
k
4
7 .
5
k
Not field reprogrammable.
J87
5
6
7
8
9
10
11
13
14
15
12
4
1
2
3
J85
GND-C
1 2
3
4
5
6
7
8
9 10
11
12
13
14
558
512
554
555
559
556
Trigger
TRIGGER
15 VDC when Trigger and 83%
CONNECTOR
Switch Open
587 589
9 VDC when Trigger Open, 83%
Located on the lower left
Switch Closed
of the front of the case.
0 VDC when Trigger Closed
J3
GUN
556
A
TRIGGER
2-STEP
B
554
2 Step Trigger
INPUT
TRIGGER
C
15 VDC for 2 Step
83%
INTERLOCK
0 VDC for Interlock
555
D
PROCEDURE
E
554A
INPUT
83% Procedure Input
589
S2
0 VDC Normal
The 83% procedure reduces the
587
9 VDC 83% switch Closed
WFS to 83% of the set point, but
and Trigger Open
no less than 50 in/min. It is used
Gas Purge
most often when pipe welding.
15 VDC when Purge OFF
COLD INCH/
0 VDC when Purge ON
GAS PURGE
558 (BLK)
512
S1
559 (RED)
Cold Inch
15 VDC when Inch OFF
0 VDC when Inch ON
Gun Trigger
Circuit
Inch/Purge
Circuit
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.
UNLESS OTHERWISE SPECIFIED TOLERANCE
DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
LN-15 (ACROSS THE ARC)
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
G4198
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
E. ENYEDY/KJ
SUBJECT:
MACHINE SCHEMATIC
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
t
ENGINEER:
E. ENYEDY
SCALE:
WITH PUBLISHED STANDARDS.
MATERIAL
APPROVAL
PROJECT
NA
05/27/2003
NONE
DO NOT SCALE THIS DRAWING
APPROVED:
DISPOSITION:
DATE:
NUMBER:
G-3
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
1
4
COLOR CODE
J2,J47,J84
B -
BLACK
5
8
W -
WHITE
R -
RED
1
8
U -
BLUE
9
16
P.C. BOARD
Schematic G3883
ARC VOLTAGE
FEEDBACK
IN PUT
J88
1M
67
4
78k
+
40
k
-
78k
21A
1
1M
+
V
n i
J83
5
J88
PWM
5
CONTROL
FOR
CONTACTOR
4.5 A PEAK
CURRENT
LIMIT
SPI
CKTS
J86
8
9
15
1
2
3 4 5
6
7
10
SHIELDED CABLE
DRAIN LEAD
N.A.
1
2
3 4 5
6
7
8
9
10
J1
DISPLAY P.C. BOARD
Schematic L117 56-x
Display
Board
Circuit
1
1
PAGE ___ OF ___
DOCUMENT
DOCUMENT
NUMBER:
REVISION:
G4198-1
A
CRM35166
LN-15
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