M22578 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED A.02 FROM "X".

MANUFACTURER: No
J1 Circular connector located Switch located on
on back of machine case front
8 308 CONTROL P.C. BOARD CONTROL P.C. BOARD
P2 9 309 PRIMARY SIDE SECONDARY SIDE
120 VOLT GND GND
NEMA 5-15P Plug 25 amp
CONNECTOR 7 307
Breaker
14 GA. 3-Conductor 6 306
Top Front (lays flat)
WHITE CB1
5 305
8 4 304 S1 Schematic : G4822
BLACK 9
2 302 GND Breaker on All measurements made with
GND case back Industrial & Retail version :
GREEN 3 303
AUX XFMR: has a potted tray respect to Board Common
7
1 301
Coils are in series for 230V connection and 203 at 4-J5 or 1-J3
JMP 6 Fan and Aux TS2 Coils are in parallel for 120V connection
6
JMP 5 reconnect FAN
4 H1 Voltage Control
Input Cord 301B Trigger Status fixed Continuous Control = 10K ~ 2 to 5 vdc across pot. (industrial versions only)
to be connected 2 +15vdc burn-back
802
804

803
801

to Ground per N.E.C. JMP T1 reconnect J4 control Voltage Control

during operation 3 P4
1 tapped 703 circuit Right Front
3

4 2 1 3
15vdc IC CONTROLS ARE
701 BOARD MOUNTED
regulator
1

and isol Trigger PWM

P2 303B
Circuits Amplifier
Control
BLACK
WHITE

Left Front
BLUE
RED

230 VOLT 702

2

NEMA 6-50P Plug CONNECTOR

14 GA. 3-Conductor WFS 10K ohms .7v to 9.1v
WHITE 704 203 Common 19 - 30 VDC to run continuous control (no tap control)
4

Air flow is back to front solenoid and one WFS

8 Same speed when WFS Control MotorOverload
BLACK 9 T1 connected to 120V or 230V FAN motor at a time FET and Feedback
GREEN GND
H2 opto
TRIAC Control isolation
7 4" lamination stack FAN FET Controller bleeder resistor +15VDC
6 Fan and Aux Copper Windings 165 turns PWM Control turns on after trigger release = spot timer option & wiring
JMP 1
5 reconnect 91 turns between H2 and 303 and Overload for a fixed time.Three 5W,
4 TS1 Protection 51ohm resistors in parallel. 203 = factory connections to control bd.
Base Front below choke
Input Cord BLACK
to be connected 2 +15VDC
to Ground per N.E.C.
JMP 3 T1 reconnect RED
during operation
full 115VAC
1 WHITE
R
BLUE
203 OPTIONAL
BLACK SPOT TIMER
P.C. BOARD
J3 2 9 3 8 6 7 1 10 5 4 J5 Schematic M20960-1
RED

4
2
6
3
1
5
230VAC S26766
WHITE P7 P9 harness plug wire reel center panel area

203B
543B

4B
2B

215B
544B
(timmer option)
BLUE M21182 +
harness
FAN CONNECTION MOTA1

544B
543B

2C
4C
timer option

203B
215B

2C
4C
Control Board

2B
J9

4B
Trigger Circuit P1

3
1

2
4
OPEN = 0V
Top Rear P8 CLOSED = 13.8V
J1

8
spool gun

7
5

6
5
4
3

2
1
1

3
6

2
4
option

MOT-
TMP
TMP
GND

CAP+
CAP-
MOTB

SOL
SOL
GAS
SOLENOID 544A +15VDC +15VDC
12vdc rated 22 ohms
Pull = 12vdc, Hold = 6vdc MOTA2
2 4 wire reel center panel area
open circuit overload protected by PC board. J7 9 8 6
spool gun J8 Spool-gun/ Logic
2 3 7 1 10 5 4 option standard gun

2
6

4
3
CW

1
5
typically equals Shut off is approx. 1.25A of current draw switch Spot Time
board input volts 2 9 3 8 6 7 Full CCW
1 10 5 4 standard P5 shown in std. gun position

2
3
6

4
1
5
P3 = OFF
use plug-in 4A Adjusts from
543A 200mS to 10S
2A CCW
Toolless Drive Roll Change Over
BOARD POWER Twist lock type drive roll retainer clip.
inner / outer wire slide guide
Supplies power to the wire drive and solenoid Load compensated type control for this
motor. Does not tend to stall if liner is
Comes with unit: .025 smooth clogged like in older small SP’s.

MOT-

MOT+
Wound inside of .035 smooth WFS Range :
TMP main transformer TMP Feeder
.030/.045 knurled 50 to 500 + ipm
Motor 1.5 to 12.5 vdc
(non-replaceable) Retail version has a plastic
N.C. gear front housing. brass Current Limit to approx 2.5 amps
right front (forward stud) right side bushing
Industrial version has a metal Duty Cycle:
19 - 30 VDC to run CHOKE ELECTRODE housing (silver in color). Gear Box
solenoid and one WFS below pc board same thermostat on all machines 230V INPUT:
motor at a time (aluminum) 30% duty 130 amps @ 20 v

STANDARD
TRIGGER 30 to 180 amps
544A

GUN
OCV = 33 vdc
base rear BACK OF OUTPUT STUD 120V INPUT :
AC D1 AC C1 (on CE version only) 20% duty 90 amps @ 19.5v
MAIN left outer plate 120,000mf/50vdc 30 to 140 amps
BRIDGE OUTPUT CAP
use one or the other but
right outer plate not both at the same time OCV = 33 vdc

SPOOL GUN
W
W TRIGGER
1
left and right side 2 3 R + -
Use Penetrox A13 compound
rear area
(E2529) to reconnect cap WORK 4 B MOTOR
16 BUTTON DIODES right front (rear stud)
543A lower case front Spool-gun option K2532-1
LEAD COLOR CODE: COMPONENT VALUE UNITS: J6 Same motor control
Magnum 100 SG circuits, but for a smaller
B-BLACK CAPACITOR: MFD/VOLTS motor
G-GREEN
O-ORANGE RESISTOR: OHMS/WATTS
R-RED
U-BLUE CONNECTOR PIN NUMBERS:
W-WHITE EX. 12 PIN CONNECTOR
Y-YELLOW
1 2 6 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
LABELS: PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
COMMON UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE: POWER MIG 180 DUAL 1
1 OF ___
PAGE ___

SOLID EDGE
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
7 12 ON 3 PLACE DECIMALS IS ± .002 in. ±( 0.05 mm) DRAWN BY: jmilligan DOCUMENT
FRAME GROUND LATCH ON ALL ANGLES IS ± .5 OF A DEGREE
IF PRINTED
@ A1 SIZE SUBJECT: MACHINE SCHEMATIC
DOCUMENT
NUMBER: REVISION:
ENGINEER: S. CRESCENZE

EN-170
MATERIAL TOLERANCE ("t ") TO AGREE
EARTH GROUND VIEW OF CONNECTOR ON PC BOARD WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: BS
UNITS:
INCH
MATERIAL
DISPOSITION: NA APPROVAL
DATE:
4/8/2011 PROJECT
NUMBER: CRM44286
REFERENCE:
-
M22578 A
Insight