ELECTRICAL DIAGRAMS
G-5 G-5
SCHEMATIC - ENTIRE MACHINE - CODES 10957 - 11311 PG 1 OF 3 (G4421)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455M/MSTT
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EN-170
S
O
L
ID
E
D
G
E
G4421
ENGINEERING CONTROLLED
MANUFACTURER:
No
CONTROL BOARD, CHANGED 2J4 TO 3J4
G4421
INVERTER WELDERS
455M MACHINE SCHEMATIC
NONE
G4050
F.Valencic
S.Poole
.
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
2/1/2007
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM22115-GC
PAGE ___ OF ___
3
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
F
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE
DIFFERENT
FROM AN ACTUAL MACHINE.
CHANGE DETAIL:
TP4
MAIN
TRANSFORMER
H6
X2
X5
202
-
H3
(550-575)
H1
5
H2
612A
H4
(220-230)
H1
232
CR1
X4
L1
U
L3A
OFF
H1D
A
SW1
ON
V
POWER
(380-415)
612
4J51
1J51
CB4
10 A
10J61
8J61
2J61
4J60
3J60
8J60
FAN
1J9
3J9
0V
24V
H5
(440-460)
(200-208)
X4
INPUT
RECTIFIER
3R
+
3W
SOLID STATE
RELAY
T2
T1
T3
+13V
SINGLE PHASE DETECT
MAIN CONTACTOR CONTROL
INPUT BOARD
6J61
X3
4J61
1J60
33
115V
RECEPTACLE
34
601
CR1
T3
T2
T1
L3
POS
L2
W
AC1
NEG
AC2
NEG
AC3
604
238
231
H6A
X1
444
X3A
SWITCH BOARD #2
32
- ELECTRODE
VOLTAGE SENSE
+ELECTRODE
VOLTAGE SENSE
206
52V
115V
X3
H5
H6
440-460V
550-575V
AUX. RECONNECT
AUXILIARY
TRANSFORMER T1
H6A
(550-575)
H6
H1
H1A
1
3.5 A
CB3
X3
POWER BOARD
32
CB2
33
3J50
503
504
4J50
505
5J50
6J50
506
115V
230V
0V
IGBT DRIVE (+)
V/F (+)
V/F (-)
IGBT DRIVE (-)
HARMONIC
FILTER
L1A
612B
+
C6
3500uF
500V
16
18
612
AUXILIARY
TRANSFORMER T2
H3
220-230V
FAN CONTROL (-)
IGBT DRIVE (-)
-15V
RS232 +5V
RS232 COM
+13V
403
10J6
1J10B
5J6
14J6
2J5
3J5
15J7
16J7
9J6
12J6
1J6
2J6
8J4
11J4
4J11
5J4
6J4
3J11
}
+5V ARCLINK +5V
ARCLINK COM
THERMOSTAT
+5V
232
231
604
238
MAIN CONTACTOR CONTROL
PRECHARGE CONTROL
505
514
504
FAN CONTROL (+15 VDC)
(NORMALLY CLOSED)
THERMOSTAT
2J10B
518
IGBT DRIVE (+)
503
6J6
16J6
404
8J6
405
1J10A
414
418
2J10A
CT CURRENT (-)
CT CURRENT (+)
V/F (+)
V/F (-)
V/F (+)
V/F (-)
CT CURRENT (-)
CT CURRENT (+)
SINGLE PHASE DETECT (LOW=1 PHASE)
7J4
POWER DOWN
1J4
SPI COM
2J4
+15V SPI
1J8
CURRENT FEEDBACK
2J8
3J8
CONTROL BOARD COMMON
6J8
+15V
-15V
1
0
J
4
3
5
J
4
3
9
J
4
3
4
J
4
3
1
J
4
2
3
J
4
2
5
J
4
2
2
J
4
2
1
2
J
4
3
3
J
4
3
4
J
4
2
P
O
W
E
R
D
O
W
N
IN
T
E
R
U
P
T
1
1
J
4
3
6
J
4
3
2
2
5
2
2
2
H1D
601
3J40
403
404
4J40
405
5J40
6J40
406
IGBT DRIVE (+)
V/F (+)
V/F (-)
IGBT DRIVE (-)
+
C6
3500uF
500V
13
11
414
RED(-)
418
WHITE(+)
221
223
266
267
274
273
226
228
227
2
6
8
A
2
6
2
262
268
268A
10 ohms
3
J
4
+
5
V
S
P
I
212
213
211
216
220
224
CONTROL BOARD
10A
224
Schematic: G3789
Schematic:L11385
Located in reconnect
cavity in rear of machine
Located on rear of control box (left)
Ad
di
t
i
on
al i
np
u
t
/ o
u
t
p
u
t
s
a
r
e
illus
t
r
a
t
ed
o
n
s
c
h
emati
c
page 2
.
(left, rear)
(right, rear)
Schematic numbers are given for reference only.
SWITCH BOARD #1
1
Located in Rear of
PowerSource
Located behind control board
(left side)
Located in rear of machine
behnid reconnect panel.
Located on top
right of case front
Located behind
reconnect panel
Located behind
reconnect panel
Located on rear
horizontal baffle
located on
case front
located on
reconnect panel
located on
reconnect panel
Located on rear of control box (center)
8 Hertz per Volt
325 Volts = 2600 Hertz
+15
-15
frequency = 20 kHz
0
+15
-15
frequency = 20 kHz
0
+15
-15
frequency = 20 kHz
0
}
}
8 Hertz per Volt
325 Volts = 2600 Hertz
}
8 Hertz per Volt
325 Volts = 2600 Hertz
}
}
12J4
10J4
CONTROL BOARD COMMON
+15V
225A
222A
220
R
S
2
3
2
C
O
N
T
R
O
L
C
O
M
+
1
5
V
+
5
V
C
O
M
C
O
M
+
5
V
C
O
M
+
5
V
-1
5
V
C
O
M
+
5
V
+
1
5
V
S
P
I
C
A
N
LEDS - 10 TOTAL
DIP Switch -1, Bank of 8
(See page 3 for detail)
1J46
2J46
3J46
4J46
5J47
7J47
6J47
8J47
DC BUS BD
+40VDC POWER
COMMON
COMMON
+40VDC POWER
Located on rear of control
box (right)
Addi
t
io
na
l
ou
tp
uts
a
re
illustrated on schematic page 2.
NEG
NEG
POS
POS
NEG
POS
65VDC
475
477
476
478
NEG
C3
POS
24000uF/100V
65VDC
POWER BD. RECT.
Located on center baffle left of lift bale
POWER BD. RECT.
Located behind DC Bus board
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PC BOARD
1
2
6
7 12
LATCH
EX. 12 PIN CONNECTOR
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
1J41
2J41
3J41
4J41
4J52
33A
2J52
352
252A
350
220A
292
291
224A
224A
DC BUS
THERM
OUTPUT
RECTIFIER
THERM
CHOKE
THERM
1J40
2J40
514
RED(-)
518
WHITE(+)
1J50
2J50
CT
CT
T1
RECONNECT
SWITCH
20D
380-575V
208-230V
POS
NEG
20C
20
19
19C
H2
200-208V
1
J
9
0
2
J
9
0
3
J
9
0
A
.
0
4
+1
5
V
-1
5
V
I
O
U
T
202
G
N
D
TRANSDUCER
8
1
6
8
1
1
8
1
3
8
1
2
CURRENT
D5
P90
R1
6J10
ELECTRODE
3J10
+
STT
.05uF
320V
80J
TRANSDUCER
CURRENT
202A
TP3
206A
+
1
5
V
I
O
U
T
MAIN
CHOKE
L1
+
WORK
-1
5
V
G
N
D
150V
P91
OUTPUT DIODES
D1-D4
2
1
2
+
+
150V
R3
R2
C8
4
J
9
1
2
1
3
2
1
6
3
J
9
1
2
1
1
2
J
9
1
1
J
9
1
80J
50Ω
4R
206
COMMON
4W
CHOPPER BOARD
TP6
R4
C10
TP2
C2
600V
160J
320V
TP1
160J
.05uF
C1
600V
320V
TP5
160J
.05uF
C6
600V
346
345
1J10
4J10
+20V STT
-
10W
.022u
800V
.022u
800V
.022u
800V
.022u
800V
2.7
Ω
2.7
Ω
2.7
Ω
2.7
Ω
10W
10W
10W
1
4
J
7
4
R
S
T
T
F
E
E
D
B
A
C
K
C
O
N
T
R
O
L
B
O
A
R
D
C
O
M
M
O
N
S
T
T
C
H
O
P
P
E
R
D
R
I
V
E
(+
)
S
T
T
C
H
O
P
P
E
R
D
R
IV
E
(
-
)
-1
5
V
+
1
5
V
1J43
7J43
LEGEND
DASHED = " " STT MACHINE ONLY
PHANTOM= " " OPTION
1
3
J
7
7
J
8
5
J
8
4
J
8
8
J
8
4
W
8
1
6
8
1
1
8
1
3
8
1
2
2
3
4
1
S8 WATER COOLER
RECEPTACLE
33A
S
F
S
14
12
F
B
A
15
17
S
F
C
S
F
D
(Located upper left
from electrode stud)
(Located bottom
left side)
(Located bottom
right side)
IG
B
T
D
R
IV
E
(
-
)
4
0
6
7
J
6
IG
B
T
D
R
IV
E
(
+
)
5
0
6
1
5
J
6
345
346
INPUT LINE
FILTER
N.A.
N.B.
N.B.
.0047uF
C7
440
C6
SWITCH
LEAD
FILTER
L3
L3B
L1B
G
N.B.
N.A.
N.B.
351
32
6J51
1J51
N.A.
220V
RECEPTACLE
NO
TE
S:
N.A. CE MACHINE ONLY.
N.B. NON-CE MACHINE ONLY.
N.C. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS
A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT
RECTIFIER TERMINALS RATHER THAN CR1.
N.D. FOR SYNCHRONIZED TANDEM MIG APPLICATIONS SEE S26631 FOR
DETAILS.
125:1
Located under
Power Switch
325A Max STT output
570A Max Output
Fold Back = 100A
(Located above Main transformer)
(Located right of Work stud)
125:1
(Located Behind
Work Stud)
Located above
Main Transformer
Located behind
Electrode stud
( Located Front Center of Machine)
(Located on left side of Machine)
Undervoltage = 200V
Overvoltage = 467V
CB2
5A
1J52
350
6J51
N.B.
N.A.
(Located right
of Contactor)
(Max Output = 325A)
Located on rear
horizontal panel
S4
(Neutral Bonded)
located on case front
+13V
5J60
2J60
LEDS - 2 TOTAL
(See page 3 for detail)
+72 VDC
V in
V out
+40 VDC
+
LEDS - 1 TOTAL
(See page 3 for detail)
352A
Schematic: L11385
Located on right side of machine
Schematic: M19528
(LOW=1 PHASE)
PRECHARGE
RELAY
+13V
Schematic: G3631
Located on left side of control box
Schematic: M19330
+
NTC
N.C.
N.C.
33
32
31
CB2
10A
located on
front case
4J51
1J51
115V
RECEPTACLE
S4
(earlier version)
(Neutral Floating)
