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G-9
ELECTRICAL DIAGRAMS
POWER WAVE 455/POWER FEED 10
G-9
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POWER WAVE 455 MACHINE SCHEMATIC - CODE 10555
50
224
220
3R
3W
THERMOSTAT
THERMOSTAT
222
223
226
FAN CONTROL (+)
FAN CONTROL (-)
(NORMALLY CLOSED)
51
RS232
NEG
NEG
C3
POS
444
X3A
351
H4A
612
612A
H3A
H2A
612B
H1A
H2
H1
352
350
H4
(380-415)
CB4
24V
6A
H3
CB2
5A
10J61
2J61
4J60
3J60
4J61
8J60
8J61
6J61
232
X4
604
1J32
2J32
4J32
5J32
601
612
CR1
6J31
5J31
50WT
2.7
10W
ELECTRODE
3181-1
S4
220V
RECEPTACLE
.022u
800V
N.A.
600V
MAIN TRANSFORMER T1
N.A.
RED/GREEN
STATUS
LED
S1 WIRE FEEDER
RECEPTACLE
ARCLINK -
ELECTRODE SENSE
N.A.
N.A.
3-19-99D
N.A.
N.B.
N.B.
S5 RS232
CONNECTOR
1B
RS232 RECEIVE
50
506
251
254
PRECHARGE CONTROL
202A
218
PHASE DETECT (5V=RUN)
202
206A
206
503
253
150V
239
234
80J
214
212
213
211
216
D
C
228
RS232 COMMON
X3A
TP4
274
273
444
226
228
-15Va
c
CONTROL
e
+5Ve
CAN
65VDC
NEG
1
6
(440-460)
3
(380-415)
H1
2
(220-230)
25000uF/100V
H5
(440-460)
0V
0VDC
E
D
+40VDC
C
B
A
H4B
X3
(220-230)
H2
115V
(200-208)
H1
52V
FAN
4
B
(115V)
B
1
(200-208)
6
S
F
S
S
F
S
F
+13V
MAIN CONTACTOR CONTROL
INPUT BOARD
PRECHARGE RELAY
+13V
CONTROL BOARD COMMON
IGBT DRIVE (+)
RS232 +5V
+ELECTRODE VOLTAGE SENSE
- ELECTRODE VOLTAGE SENSE
CONTROL BOARD COMMON
CURRENT FEEDBACK
-15V
+15
PRIMARY CURRENT SENSE
PRIMARY CURRENT SENSE
IGBT DRIVE (+)
IGBT DRIVE (-)
CAPACITOR C5 OVERVOLTAGE (LOW=RUN)
CAPACITOR C5 UNDERVOLTAGE (LOW=RUN)
IGBT DRIVE (-)
CAPACITOR C4 OVERVOLTAGE (LOW=RUN)
CAPACITOR C4 UNDERVOLTAGE (LOW=RUN)
CONTROL BOARD COMMON
+13V
MAIN CONTACTOR CONTROL
+15V
+5V
CONTROL BOARD COMMON
-15V
+5V ARCLINK +5V
ARCLINK COMMON
.022u
800V
2.7
10W
2.7
10W
2.7
10W
12
15
17
16
18
15
16
SWITCH BOARD#2 (RIGHT)
C
SWITCH
LEAD
FILTER
L3A
L1A
ON
SW1
POWER
235
403
406
404
233
405
PRIMARY
CURRENT
SENSE
T2
2J91
TP3
CURRENT
TRANSDUCER
213
R1
1J91
.022u
800V
CHOKE
THERMOSTAT
GND
212
I OUT
+15V
216
-15V
211
3J91
-
OUTPUT RECTIFIER
THERMOSTAT
.022u
800V
C1/TP1
4J91
.05uF
600V
C4
(CAP "A")
3400uF
450V
506
C5
(CAP "B")
3400uF
450V
X3
T3
T1
9J23
4J23
5J23
14J23
7J23
13J23
6J23
12J23
3J23
10J23
2J21
4J22
3J21
1J21
10J22
6J21
8J23
2J20
11J23
1J23
6J20
2J23
5J22
1J22
2J22
3j22
4J27
3J27
6J22
8J22
8J31
1J31
2J31
NOT USED
NOT USED
+5Vc
+
+
B
C2/TP2
160J
ELECTRODE
238
231
1J50
4J50
234
53
54
239
235
5J50
POS
POS
X5
X1
X2
H3A
H2A
H5
P80
P81
H5A
H4
0VDC FEEDER
H4A
H3
+40VDC FEEDER
TRANSFORMER T2
CB3
10A
X4
H5A
AUXILIARY
TRANSFORMER T1
SINGLE
PHASE
DETECT
NEG
NEG
AC1
NEG
L3
OFF
612B
SWITCH BOARD #1 (LEFT)
CR1
H1D
INPUT
LINE
FILTER
POS
1J60
2J60
T3
L2
H4B
L1
T2
G
T1
W
AC3
V
AC2
U
INPUT
RECTIFIER
POS
L1B
L3B
POWER BOARD
225
221
222
223
291
224A
232
274
273
ELECTRICAL SYMBOLS PER E1537
11-7-97JLV
3181-1
NOTES :
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.
N.B. L4 IS WOUND ON ONE COMMON CORE.
B.S.
MACHINE SCHEMATIC
G3181
225
221
12-4-98
XB-UF
NONE
CONTROL BOARD
S2 VOLTAGE SENSE
RECEPTACLE
INVERTER WELDERS
2
3
4
5
6
7
4
3J25
2
1
20
4J25
1J25
4J20
7J22
9J22
2J24
4J24
5J27
1J27
8J20
4J21
8J21
7J31
4J31
3J31
11J31
12J31
51BK
11
238
604
231
CB1 10A
10J24
12J24
L4
L4
ARCLINK +
L2
3
L7
L4
ARCLINK +
FEEDER VOLTAGE SENSE
2W
2B
THERMAL LED
21A
THERMAL LED
WORK VOLTAGE SENSE
67A
52
51
1W
ARCLINK -
RS232 COMMON
RS232 TRANSMIT
STATUS LED (HI FOR RED)
STATUS LED (HI FOR GREEN)
403
3J40
406
6J40
404
4J40
233
1J40
405
5J40
A
+
503
3J50
6J50
TESTVa
Vcc(+15)
3W
+15Va
-
+5Va
WELD AND
3R
CURRENT
GND a
+
SOLID
STATE
RELAY
+
320V
160J
.05uF
13
F
14
OUTPUT DIODES
D1-D4
320V
MAIN CHOKE L1
P91
MANUFACTURING TOLERANCE PER E2056
OWNED BY
G
Ch'ge. Sht. No.
SCALE
G
THE LINCOLN ELECTRIC CO.
SUBJECT
DR
DATE
TYPE
EQUIP.
CLEVELAND, OHIO U.S.A.
CHK
REF.
SHT.
SUP'S'D'G
NO.
EMS
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
t
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE DECIMALS IS .002
WITH PUBLISHED STANDARDS.
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
AND IS
THE LINCOLN ELECTRIC CO.
THE LINCOLN ELECTRIC CO.
THIS SHEET CONTAINS PROPRIETARY INFORMATION
YELLOW
THERMAL
LED
5J60
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.