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CHANGE DETAIL: RELEASED FROM "X"
No
L11946
ENGINEERING CONTROLLED
MANUFACTURER:
AUXILLARY
AUXILIARY
CURRENT
J3-3
SENSE
SENSE
TOROID
WELDING
+ STUD
TERMINAL
J3-4
+15V
CONTROL
SWITCH
(2)
J1-4
2-4 SENSE
SHOWN IN "ALWAYS
ON" POSITION
(4)
J1-3
+15V
IDLER
CONTROL
+ STUD
J3-7
IDLE SWITCH SENSE
SHOWN IN "HIGH" POSITION
J3-14
+15V
+ STUD
THERMOSTAT(IF USED)
THERMAL SENSE (if used)
J3-5
J3-1
+15V
+ STUD
J1-13
J1-12
MACH SEL 1
MACHINE IDENTITY TABLE:
PINS JUMPERED TO SELECT MACHINE
J1-8
MACHINE /
MACH SEL 2
J1-5
J1-6
J1-7
J1-8
MACHINE
MODE
RANGER 250 G&D
J1-7
J1-13
RANGER 305 G&D
LOGIC
MACH SEL 3
J1-13
VANTAGE 500
J1-6
J1-13
VANTAGE 575
(CPU)
J1-13
AIR VANTAGE 500
MACH SEL 4
J1-5
+15V
+ STUD
J7-16
TIG MODE
J7-15
TIG
PIPE MODE
4
(NOT AVAILABLE ON AUSTRALIAN
J7-14
VANTAGE 575)
MODE
CC
N/A
3
SELECTOR
J7-13
SWITCH
A
N/A
(AUSTRAILIAN
VANTAGE 575 USES A
J7-12
3 POSITION TOGGLE
2
N/A
SWITCH)
PIPE
1
J7-11
CV
CV MODE
J7-9
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
J7-10
+
+15V
CURRENT FEEDBACK
+ STUD
J7-2
+ STUD
G4107
(ONLY)
-
(206S)
J6-2
-
CURRENT FEEDBACK
SHUNT
G4109
50mV = 400 AMPS
+
(ONLY)
47.5 ohms
+
x80
-
(204S)
J6-1
+ STUD is COMMON
+ STUD
FOR WELD CONTROL
- STUD
CIRCUITS
VOLTAGE FEEDBACK
(208B)
J3-15
+ STUD
(277)
+ STUD
J7-8
(278)
ARC CONTROL
10K
ARC
POT
J7-7
CONTROL
(279)
CIRCUITRY
J7-6
+10V
(77)
J7-1
OUTPUT
(76)
10K
CONTROL
POT
J7-4
(75)
J7-5
LOCAL
THE TOP END OF THE REMOTE POT IN
PRESET
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
+ STUD
TIG MODE
+10V
POT WILL SET MACHINE TO MAX OUTPUT.
(77B)
REMOTE
J1-11
REMOTE
10K
(76B)
ALL OTHER MODES
CONTROL
POT
J1-14
(75B)
J1-10
+ STUD
This diagram is for reference only. It may not be accurate for all machines covered by this manual.
+
CONTROL BOARD
J3-8
40-100VDC
POWER FROM
INPUT
CHOPPER BOARD
-
J3-16
+15V
SILVER
(253)
THERMAL
J3-6
PROTECTION
INDICATOR
(252)
THERMAL LAMP
J3-13
GOLD
+ STUD
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
J4-1
J4-2
J4-3
BLINK (PULLED LOW AND HIGH
J4-4
IN LOOKBACK TO FLASH
DECIMAL POINT)
J4-5
AMMETER
J4-6
DISPLAY
J4-7
J4-8
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
J4-9
METER (-) INPUT
J4-10
METERS OPTIONAL ON VANTAGE
+ STUD
ON / OFF (+5V=ON)
NO J4 OR J5 ON RANGER 250
HOLD(+5V=HOLD)
J5-1
J5-2
J5-3
BLINK (PULLED LOW AND HIGH
J5-4
IN LOOKBACK TO FLASH
DECIMAL POINT)
J5-5
VOLTMETER
J5-6
DISPLAY
J5-7
J5-8
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
J5-9
METER (-) INPUT
J5-10
SELECT CONTROL POINT
+ STUD
CURRENT FEEDBACK
DISPLAY WELD AMPS
PRESET
DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
FEEDBACK
REGULATING
AMPLIFIER
CONTROL POINT
+5V
+5V
+ STUD
+ STUD
OCV
TOUCH START
VARIABLE PINCH
CONTROL
PIPE ARC FORCE
POINT
VARIABLE ARC FORCE
SELECT
FIXED ARC FORCE
PRESET
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
FIXED HOT START
+5V
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
+ STUD
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
+ STUD
PROPRIETARY & CONFIDENTIAL:
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE D ECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGL ES IS ± .5 OF A DEGRE E
MATERIAL TOLERA NCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
+15V
TRANSFORMER
+5V
+3.3V
-15V
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
+15V COM
+ STUD
(NOT ALL MACHINES USE EVERY CIRCUIT)
+15V
+15V COM
DIODE ONLY ON -E
VERSION AND ABOVE
FRAME
IDLE CONTROL
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
J2-12
FOR AUX USE: CONNECT
TO FRAME FOR HIGH IDLE
FRAME
RANGER OIL PRESSURE
+ STUD
V-BATTERY
J2-9
STARTER BUTTON
J2-8
PTC
FUEL SHUTDOWN
J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted
the PTC will change to high impedance
V-BATTERY
CURRENT
+
LIMITS,
BATTERY POSITIVE
J2-7
VREF
AVERAGE,
ABSOLUTE,
-
BATTERY NEGATIVE
& FOLDBACK
J2-3
FRAME
#1
47.5 ohm
CHOPPER
PWM SIGNAL (+12V ON MULTIMETER)
BOARD
J3-9
47.5 ohm
PWM
PWM SIGNAL (+12V)
(ALL MACHINES)
J3-11
CHOPPER
47.5 ohm
PWM COMMON
#2
CONTROL
J3-10
CHOPPER
CIRCUIT
47.5 ohm
PWM COMMON
BOARD
J3-12
(VANTAGE ONLY)
+ STUD
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
RANGER 305D
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EQUIPMENT TYPE:
DESIGN INFORMATION
REFERENCE:
L11943
MACHINE SCHEMATIC
DRAWN BY:
SUBJECT:
BAM
SCALE:
t
ENGINEER:
BAM
MATERIAL
NA
APPROVAL
PROJECT
CRM33549
NONE
2/5/03
-
DISPOSITION:
DATE:
NUMBER:
APPROVED:
+12V Battery Supply to
V-BATTERY
IDLE
the Idle Hold Solenoid
SOLENOID
1
IDLE HOLD COIL
J2-6
J2-5
2
HOLD
RED
COIL
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V
3
when not energized. "HIGH IDLE"
BLK
4
PULL
WHT
COIL
TO IDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
FRAME
J2-4
V-BATTERY
PULL COIL
BOARD
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine
is not ON. +40V or more when the machine is running.
-
J2-1
+
FRAME
POSITIVE
NEGATIVE
BRUSH
BRUSH
FRAME
ROTOR
+15V COM
J2-2
BATTERY
CHARGE
LAMP
-
+
J2-11
+15V when the battery charge light is "OFF"
(Machine running, alternator charging
battery, +1.5V when battery charge light is
"ON" (Battery Low/Not charging and for a few
FRAME
seconds when machine is turned off)
LEAD COLOR CODE:
COMPONENT VALUE UNITS:
B-BLACK
CAPACITOR: MFD/VOLTS
G-GREEN
RESISTOR: OHMS/WATTS
O-ORANGE
R-RED
CONNECTOR PIN NUMBERS:
U-BLUE
W-WHITE
EX. 12 PIN CONNECTOR
Y-YELLOW
1 2
6
LABELS:
COMMON
FRAME GROUND
7
12
EARTH GROUND
LATCH
VIEW OF CONN ECTOR ON PC BOARD
1
2
2
PAGE ___ OF ___
DOCUMENT
DOCUMENT
NUMBER:
REVISION:
L11946
A
RANGER 305D
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Troubleshooting
