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ELECTRICAL DIAGRAMS
G-5
POWER WAVE 455/R
SCHEMATIC-COMPLETE MACHINE CODE 10676
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE
SCALE:
DO NOT SCALE THIS DRAWING
ON 3 PLACE DECIMALS IS± .002
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
DESIGN INFORMATION
t
DRAWN BY:
WITH PUBLISHED STANDARDS.
DATE:
ON 2 PLACE DECIMALS IS ± .02
MATERIAL TOLERANCE (" ") TO AGREE
ON ALL ANGLES IS± .5 OF A DEGREE
SUBJECT:
ENGINEER:
EQUIPMENT TYPE:
DRAWING No.:
TR
LW
INVERTER WELDERS
PW455/R MACHINE SCHEMATIC
G
NONE
9/11/00
REFERENCE:
SUPERSEDING:
G3791
APPROVED:
4009
Chg. Sheet No."X" INFO.
XB-S
5-11-2001F
A
B
FAN CONTROL (-)
IGBT DRIVE (-)
-15V
RS232 +5V
TP4
RS232 COMMON
3J40
403
MAIN TRANSFORMER T1
+
404
4J40
405
5J40
6J40
406
+
418
H3
H4
H3A
H2
H5
H2A
H6
NEG
C3
TRANSFORMER T2
X2
POS
X5
H2A
H3A
H4A
H5A
24000uF/100V
213
212
812
4R
813
ARCLINK -
811
A
ARCLINK +
1W
1B
RED/GREEN
STATUS
LED
53
54
67A
B
+13V
WORK VOLTAGE SENSE
THERMAL LED
S2 VOLTAGE SENSE
RECEPTACLE
THERMAL LED
2B
2W
ARCLINK +
216
292
816
4W
1
J
9
0
2
J
9
0
3
J
9
0
4
J
9
0
+
1
5
V
-
1
5
V
I
O
U
T
202
506
G
N
D
CURRENT FEEDBACK
IGBT DRIVE (+)
-
TRANSDUCER
816
811
813
812
CURRENT
C5
(CAP "B")
3500uF
500V
H3
(550-575)
H1
5
H2
612A
H4
(200-208)
H1
232
CR1
X4
612
L1
U
L
3
A
OFF
H1D
A
SW1
612B
L
1
A
ON
V
POWER
G
(220-230)
612
4
1
F
S
F
14
15
16
13
CB4
6A
7J7
3J7
4J7
DCBUS
THERMOSTAT
CHOKE
THERMOSTAT
2J60
D5
5J60
10J61
8J61
2J61
4J60
3J60
8J60
1J46
2J46
3J46
4J46
FAN
10J6
1J9
3J9
6J8
1J8
3J8
2J8
1J10B
13J7
5J6
14J6
14J7
P90
8J8
7J8
5J8
4J8
R1
CONTROL BOARD
0V
24V
H5
(440-460)
(380-415)
ELECTRICAL SYMBOLS PER E1537
15J6
2J5
3J5
15J7
16J7
9J6
12J6
1J6
2J6
12J4
8J4
10J4
11J4
4J11
5J4
10J43
5J47
7J47
6J47
8J47
5J43
9J43
6J4
4J43
1J47
3J11
3J47
65VDC
X4
}
10A
CONTROL BOARD COMMON
+5V ARCLINK +5V
ARCLINK COMMON
6J10
ELECTRODE
SWITCH BOARD #1 (LEFT)
INPUT
RECTIFIER
RECONNECT
SWITCH
3R
475
+
477
3W
476
478
274
273
DC BUS BD
NEG
NEG
226
POS
POS
SOLID STATE RELAY
3J10
+
STT
PRECHARGE RELAY
T2
+13V
T1
T3
+13V
SINGLE PHASE DETECT
(LOW=1 PHASE)
MAIN CONTACTOR CONTROL
+13V
INPUT BOARD
6J61
X3
612B
4
4J61
1J60
33
S4
110V
RECEPTACLE
32
.05uF
-
320V
80J
TRANSDUCER
CURRENT
202A
TP3
206A
+
1
5
V
I
O
U
T
MAIN
CHOKE
L1
+
ELECTRODE
-
1
5
V
G
N
D
150V
P91
OUTPUT DIODES
D1-D4
212
601
CR1
T3
T2
T1
L3
POS
L2
W
AC1
NEG
AC2
NEG
AC3
604
238
231
STT CHOPPER DRIVE (-)
STT CHOPPER DRIVE (+)
-15V
+
10W
+
150V
R3
R2
C8
4
J
9
1
213
216
3
J
9
1
211
2
J
9
1
1
J
9
1
80J
YELLOW
THERMAL
LED
253
254
S3 RS232
CONNECTOR
251
RS232 TRANSMIT
E
D
RS232 COMMON
0VDC
21A
+40VDC
THERMOSTAT
H4A
H5A
H6A
P80
X1
50
10A
+40VDC POWER
444
X3A
SWITCH BOARD #2 (RIGHT)
NOTES :
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
N.C. R2, R3 AND R4 ARE 2 /300.
C8 AND C10 ARE 20 mfd/400V.
51
228
31
+15
50
CONTROL BOARD COMMON
- ELECTRODE VOLTAGE SENSE
+ELECTRODE VOLTAGE SENSE
2J40
C4
(CAP "A")
3500uF
500V
2
3
4
5
6
7
1
4
2
3
20
3J2
4J2
1J2
6J9
8J7
L5
ELECTRODE SENSE
S1 WIRE FEEDER
RECEPTACLE
ARCLINK -
STATUS LED (HI FOR RED)
52
C
51
L2
L4
+5V
+15V
232
STATUS LED (HI FOR GREEN)
231
604
238
3W
3R
MAIN CONTACTOR CONTROL
220
224
PRECHARGE CONTROL
403
505
514
504
RS232 RECEIVE
FAN CONTROL (+)
(NORMALLY CLOSED)
THERMOSTAT
211
4R
206
COMMON
4W
17
12
F
F
S
CHOPPER BOARD
11
D
S
15
16
S
18
C
(380-415)
3
(440-460)
2
(220-230)
52V
6
115V
X3
H2
H5
H3
H6
A
200-208V
220-230V
440-460V
550-575V
AUX. RECONNECT
19C
19D
20C
20D
380-460V
208-230V
.022u
800V
.022u
800V
.022u
800V
.022u
800V
2.7
2.7
2.7
2.7
10W
10W
10W
CONTROL BOARD COMMON
STT FEEDBACK
-15V
+15V
414
1J40
AUXILIARY
TRANSFORMER T1
H6A
(550-575)
H6
H1
H1A
1
10A
CB3
(200-208)
2
X3
1J42
3J42
5J42
2J42
225
221
222
223
1J41
2J41
3J41
4J41
POWER BOARD
52
352A
32
33A
352
350
2
3
4
1
S8 WATER COOLER
RECEPTACLE
TP6
R4
C10
TP2C2
600V 160J
320V
TP1
160J
.05uF
C1
600V
320V
TP5
160J
.05uF
C6
600V
2J10B
518
220A
OUTPUT RECTIFIER
THERMOSTAT
291
224A
FEED HD BD
GATEWAY BD
4J81
3J81
4J82
3J82
2J81
1J81
1J85
851
2J85
852
3J85
853
4J85
854
5J85
855
6J85
856
7J85
857
8J85
858
9J85
859
10J85
860
11J85
861
12J85
862
7J4
4J42
227
1J84
841
2J84
842
3J84
843
4J84
844
5J84
845
6J84
846
7J84
847
RECEPTACLE
841
A
B
C
D
E
F
G
I
J
K
N
P
T
S7 I/O
RECEPTACLE
851
1
2
3
4
5
6
7
8
9
10
11
12
INTERFACE
S6 ROBOTIC
844
842
843
845
846
847
67B
539
541
521
522
GND-A
852
853
854
855
856
857
858
859
860
861
862
TACH 1A DIFF SIGNAL
TACH 1B DIFF SIGNAL
TACH 2A DIFF SIGNAL
TACH 2B DIFF SIGNAL
SINGLE TACH INPUT
VOLTAGE SENSE
MOTOR "+"
MOTOR "-"
SOLENOID +40VDC
SOLENOID INPUT
TACH COMMON
TACH +15VDC
TRIGGER +15VDC
TRIGGER INPUT
DUAL PROC. INPUT
4 STEP INPUT
COLD INCH +15VDC
COLD IN. FORWARD
COLD IN. REVERSE
GAS PURGE INPUT
SHUTDOWN +15VDC
SHUTDOWN 1 INPUT
SHUTDOWN 2 INPUT
INPUT B
TRIGGER +15VDC
TRIGGER INPUT
DUAL PROC. INPUT
4 STEP INPUT
COLD INCH +15VDC
COLD IN. FORWARD
COLD IN. REVERSE
GAS PURGE INPUT
SHUTDOWN +15VDC
SHUTDOWN 1 INPUT
SHUTDOWN 2 INPUT
INPUT B
POWER BD. RECT.
COMMON
+40VDC FEEDER
COMMON
+40VDC POWER
COMMON
COMMON
+15VDC TACH
TACH 1A DIFF. INPUT
TACH 1B DIFF. INPUT
TACH COMMON
TACH 2A DIFF. INPUT
TACH 2B DIFF. INPUT
SINGLE TACH INPUT
CB2
33
2J83
1J83
4J83
3J83
541
539
522
521
SOLENOID +40VDC
SOLENOID INPUT
MOTOR "+"
MOTOR "-"
POWER DOWN INTERUPT
+15V
+5V
CONTROL BOARD COMMON
-15V
ARCLINK +5V
ARCLINK COMMON
RS232 +5V
RS232 COMMON
1J43
STT COMMON
346
7J43
345
STT +20V
POWER DOWN INTERUPT
+24VDC
2
+24V GND
894
3
5
CAN_L
CAN_H
S5 DEVICENET
CONNECTOR
4
893
892
891
3J50
503
504
4J50
505
5J50
6J50
506
518
2J50
514
1J50
511
512
741
743
800
840
500
540
ARCLINK H
ARCLINK L
COMMON
+40VDC
2J72
1J72
3J72
4J72
ARCLINK H
ARCLINK L
5J75
2J75
1J75
4J75
IGBT DRIVE (+)503
6J6
16J6
404
8J6
405
7J6
406
1J10A
414
418
IGBT DRIVE (-)
2J10A
N.A.
N.A.
N.A.
CB1
1J73
2J73
53
894
893
892
891
+24VDC
+24V GND
CAN_L
CAN_H
N.A.
N.A.
N.A.
N.C.
115V
230V
0V
1J76
3J76
830
54
346
345
1J10
4J10
D6
880
886
6J83
5J83
+40VDC
880
886
+40VDC
VOLT SENSE BD
N.A.
14J85
13J85
1J1
3J1
1J2
4J1
511
N.A.
2J47
4J47
500
540
+40VDC POWER
512
67
67A
4J9
67
2J2
67B
R5
10
3J4
268
12J43
262
3J43
268A
268A
262
N.C.
ROBOTIC VOLTAGE SENSE
VOLTAGE SENSE SELECT (-)
VOLTAGE SENSE OUTPUT
WIRE FEEDER VOLTAGE SENSE
VOLTAGE SENSE SELECT (+)
COMMON
+40VDC
VOLTAGE SENSE SELECT (-)
VOLTAGE SENSE SELECT (+)
CT CURRENT (-)
CT CURRENT (+)
IGBT DRIVE (+)
V/F (+)
V/F (-)
IGBT DRIVE (-)
CT CURRENT (-)
CT CURRENT (+)
IGBT DRIVE (+)
V/F (+)
V/F (-)
IGBT DRIVE (-)
+20V STT
COMMON
+40VDC
CT CURRENT (-)
CT CURRENT (+)
V/F (+)
V/F (-)
V/F (+)
V/F (-)
CT CURRENT (-)
CT CURRENT (+)
SPI COMMON
SPI +5V
+40V
+40V
+40V COMMON
+40V COMMON
SINGLE PHASE DETECT
(LOW=1 PHASE)
+5V SPI
VOLTAGE SENSE
1J4
11J43
267
SPI COMMON
2J4
6J43
266
+15V SPI
+15V SPI
SPI COMMON
N.A.
154
ARC LINK L
1J11
2J11
ARC LINK H
153
2J82
1J82
ARCLINK H
154
153
ARCLINK L
POS
NEG
HARMONIC
FILTER
19
20
G-5
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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