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| ELECTRICAL DIAGRAMS |
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SCHEMATIC - ENTIRE MACHINE - CODE 11075, 11076, 11077 (G4617) |
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| Values for CV300. Others |
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| may be different. |
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| 0 VDC @ 0 = 5.8 Arc Volts |
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| 6.6 VDC @ 10 = 40 ArcVolts |
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| 75A | 1 | 75 |
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| CONTROL | |||
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| 76A | 2 | 76 | 10K/2W | VOLTAGE |
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| 77A | 3 | 77 |
| POTENTIOMETER |
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| (OPTIONAL) | |||
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| Connector located | 4 |
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| behind case front |
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| P7 |
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| 577 | 3 | 577A |
| WIRE FEED |
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| 576 | 2 | 576A | 10K/2W | |
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| 575 | 1 | 575A |
| SPEED |
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| Connector located | Gearbox ratio is 2:47 |
| CONTROL | ||||
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| Motor resistance | 4 |
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| by sheet panel | Motor is at electrode | 0 VDC MIN. WFS | POTENTIOMETER | ||||
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| is 1.5 ohms | 5 | ||||||
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| potential |
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| 1 |
| 6 | 5 VDC MIN. WFS |
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| 575 |
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| Motor is located |
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| Off = 0 VDC |
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| L4 |
| 2 | behind |
| P8 |
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| OCV = 59 VDC |
| 575B |
| 563 | 3 | glastic panel |
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| FEED |
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| On = 7.7 VDC | 575C | 562 |
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| 562 | 4 | MOTOR / | Connector located |
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| 563 |
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| PLATE | behind case front |
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| 575B | 5 | GEARBOX |
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| 553 |
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| Located on |
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Coil | case back |
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| 551 | 7 | B |
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| To Power Source Electrode Connection |
measures |
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| 550 | 8 | W |
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21 ohms | GAS |
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| P5 | 1.6V @ 50 IPM |
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| SOLENOID |
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| 30.6V @ 800 IPM |
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| 552 |
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| 67 |
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| 552B |
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| L2 |
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| TRIGGER |
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| INPUT |
| Plug for future |
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| Located behind |
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| 556 | A | TRIGGER |
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| 554 | B |
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| P9 |
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| C | CONNECTOR |
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| D | J4 |
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| 15V SIGNAL |
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| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
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| 552B |
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| D 100 msec PULSES |
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| Located on |
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| POSTFLOW |
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| TOGGLE GAS FLOW ON/OFF |
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| POSTFLOW |
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| 50 |
| 41A |
| 51 |
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| 552C | internal panel |
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| TIME RANGE | POT. |
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| 552C |
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| .25 - 10 SEC |
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| 41A |
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| 5V SIGNAL |
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| FIXED |
| c | D |
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| COM |
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| GAS FLOW |
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| PULSE |
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| PREFLOW & |
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| Located on |
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| WIDTH |
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| + | 552A |
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| GENERATOR |
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| OUTPUT | +15V | TIMER KIT |
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| On |
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| LOGIC | POT |
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| PREFLOW |
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| SCHEMATIC = |
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| THERMAL LED |
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| motor thermal LED for 0.5 seconds. |
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| A | b | BURNBACK |
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| (OPTIONAL) |
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| TIME FIXED | COM |
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| Lights when motor | |||||||
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| 5 | VDC |
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| AT 30msec |
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| current exceeds 4 | ||||||
| trigger depressed, welding will not start |
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| 41 | 580 | 42 |
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| Located on |
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| when lit | B |
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| 601 |
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| Timer Board Summary |
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| Case Front |
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| 605 | 607 | 515A |
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| extended time. | ||||||||
| depressed again. |
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| • Has potentiometers for burnback and postflow. |
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| B |
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| L1 |
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| • | Preflow fixed at 30msec. |
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| 15 VDC Open | COLD FEED |
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| • Burnback range is 0 to 0.25 sec. |
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| 0 VDC Closed |
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| Located on | |||||||||||
| ARC CURRENT |
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| • Postflow range is 0.25 to 10 sec. |
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| 558 | ||||||||||||
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| Case Front | ||||||||||||||||
| ARC VOLTAGE |
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| • Receives “Gas Flow Enable” signal. |
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| 515A | S1 | |||||||||||
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| 515 | |||||||||
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| • Outputs 100 msec pulses to turn Gas Flow On, Gas | L3 |
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| Flow Off. |
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| REMOTE |
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| GAS PURGE |
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| VOLTAGE |
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| 15 VDC Open |
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| 20 OHM = OUTPUT ENABLED |
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| 0 VDC Closed |
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| SENSE |
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| TRIGGER | ||||||||
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| HIGH IMPEDANCE = OUTPUT DISABLED |
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| INTERLOCK | |
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| OUTPUT |
| C |
| 2 |
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| 589 |
| Case Front | |||||||
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| CONTROL |
| D |
| 4 |
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| MOLEX |
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| 38VDC at |
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| 576 |
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| 552A |
| 563 |
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| 42VAC input |
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| 577 | 551 | 556 |
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| stop welding when the | |||||||||||
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| NOT USED |
| NOT USED |
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| 580 |
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| 562 |
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| 606 |
| 608 | 607 |
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| 515 | 559 |
| 587 |
| 15 VDC in |
| arc is broken. Pull and | |||||||
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| release to end the weld. | ||||||||
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| 60VDC with |
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| 750 ohm |
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| connected |
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| +POWER |
| 100K |
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| ohm |
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| +5V | +5V |
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| COM |
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| MACHINE |
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| CLOSED = 8V | TRIGGER | OUTPUT |
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| +15V | +15V |
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| ENABLE |
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| POWER |
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Control Board Summary |
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| + POWER |
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| SENSE |
| 0V = 0.02 SECONDS |
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| BURNBACK | 5V = 0.25 SECONDS |
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• Has |
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| DRIVE | MOTOR |
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• Receives switch signals from Trigger, Cold Feed, Gas Purge, Trigger |
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| FET |
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| Interlock |
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| BRAKE | CIRCUIT |
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| EXTERNAL |
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• | Reads WFS potentiometer. |
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| COM |
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| LOW = CONTROL AT CONTROL BOARD |
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| GAS |
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• Communicates with optional timer kit to control burnback, postflow. |
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| SOLENOID HIGH = CONTROL AT TIMER BOARD |
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• Controls motor speed with PWM. |
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| MOTOR |
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• Turns Gas Solenoid on, off. |
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| CURRENT |
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| MICRO |
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• Monitors motor current, lights yellow thermal LED if over 4 amps for an |
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| SCALING |
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| 0.1 ohm |
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| CONTROLLER |
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| extended time period. LED remains lit for 30 – 60 seconds to allow motor |
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| DO NOT USE |
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| to cool. |
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| PROGRAM | NOT FIELD PROGRAMMABLE |
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• Does NOT support |
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| TACH |
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• | Operates on |
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| FILTER |
| FEEDBACK |
| 5V = OFF |
| 200 ohm |
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| FREQUENCY = SPEED |
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| (NOT ACTIVE) THERMAL |
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| be less when operating at 24 VAC. |
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| 4V OR LESS = ON |
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• Does NOT operate on 115 VAC. |
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| 0V = MIN SPEED |
| WIRE |
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| LOW = DISABLE |
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| 5V = MAX SPEED |
| FEED |
| GAS | HIGH = ENABLE |
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| SPEED |
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| PURGE |
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| SOLENOID | 200 ohm |
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| GAS |
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| LOW = DISABLE |
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| ||
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| COLD |
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| ||||
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| FET |
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| SOLENOID | HIGH = ENABLE |
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| ||
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| FEED |
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| ||
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| 0.25 |
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| |
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| 10K |
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| |
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| ohm |
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| |
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| ohm |
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| TRIGGER | LOW = DISABLE |
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| HIGH = ENABLE |
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| |
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| INTERLOCK |
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|
COMMON ANALOG P.C. BOARD
SCHEMATIC = G4559
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.