Lincoln Electric POWER WAVE 455TM IM583-A - Manual (Page 26)

F-1 DIAGRAMS F-1
POWER WAVE 455
3
1
L3A
18
TO AUX #1
TO CURRENT
32 33
4
POS X2
4
POWER BD RECTIFIER
J24
NEG
TO J32
NEG NEG NEG
POWER BD RECT
C3 +
32
TO J81
L1A
A
H1D
31
TO J61
612B
S4
TO CB3
(TOP) 2
FRONT OF MACHINE
110V RECEPTACLE
TO TP3
TO CONTACTOR TO CONTACTOR
TO RECONNECT PANEL
11
TO SWITCH
11
16
BD #1
12
TRANSFORMER TO CURRENT
BD #2
16
PRIMARY
(TOP LEFT)
TRANSFORMER
RECT.
TO CURRENT
F4
TO SWITCH
THERM.
C3
D4
TO
OUTPUT RECT
273 274
TO J27 J22
SECONDARY
(BOTTOM
LEFT)
PRIMARY (BOTTOM
LEFT)
SECONDARY
(TOP LEFT)
MAIN TRANSFORMER
LEFT SIDE
N.D.
TO CURRENT
3
ELECTRODE
21A
WORK
4
4
MAIN CHOKE
L1
3
TP1
2
H1A
++
P6
TO AUX #2
J20
612B
54A 67A
TO SW1
67B
TO J61
CB3
612A 612 H1
TO AUX #1 TO SOLID STATE RELAY
4
TO CB4
C1
612A
AUXILIARY TRANSFORMER #1
TO AUX #2
H1A
TO
H5
S4 CB2
6 1
(440-460)
H5A
P81
3
(380-415) H3
H4A
H2
2
(220-230)
H3A H2A
H1 (200-208)
4
AUXILIARY TRANSFORMER #2
5
4
6
SWITCH BOARD #1
J21A,J21B
TO SW1
RECONNECT PANEL
CB3
10A CIRCUIT
BREAKER
1
’A’
J32,J40 J50,J81
403
406
TO J23
D2
10W 2.7
AUX. #1
1
THERM CHOKE TO
10W 2.7 10W 2.7
TO J22
CB2 L2
N.D.
C3 TO 224 224A
AC
52A
1
4 3 2
TRANSFORMER
218
TO CURRENT TRANSFORMER
D1 800V .022
POS POS
2.7 10W
N.D.
TRANSFORMER
15
.022 800V
POS
RECTIFIER
INPUT
U
SWITCH
TO
RECONNECT
L1A
T2 TO SW1
503
234
4 5 7
L3A
8
TO A SYSTEM GROUND PER NATIONAL ELECTRICAL CODE.
4
TO SUPPLY LINES
G
AC1 POS
AC2
J22
3 4
254 253
7 6 5 4 3 2 1
6
D C B A
2 1 8 7 6 5
(220-230)
H3A
H2 H1
H2 H3 (200-208)
N
H1
(24V)
R (115V) (51V)
6
5
H4
W R +
19D
J50
(115V)
403 503 506 404 235 604 405
1B
239 238 406
1W
TO MAIN TRANS
1 1
2B 214 213 212
N.D.
212
50
NEG
CB1
3 2
221
1
9 8 6 5
POWER BD TO
TO AUX #1
2
T1
3
T2
TO
J61
CR1
6
612
SW1 CB4
H1D
9
T3
T1
L2
WORK ELECTRODE
206A
J27
TO S4
31
J81
CR1
X4
S3
RS232
CONNECTOR
REAR OF MACHINE
ELECTRODE
4
LOAD LINE
SW1
POWER
G3051-1
S1
WIRE
FEEDER
RECEPTACLE
FAN
CB4
6A CIRCUIT BREAKER
TM
POWER WAVE 455 WIRING DIAGRAM
S2
VOLTAGE
SENSE
RECEPTACLE
D
202A
TO TP3
TRANSFORMER
+
NEG
NEG AC3 T3 L3
TO SW1
W
V
CB4
S2
H4A
RECONNECT PANEL
202
2
2
3
14 8
TO
251
11
S3
12
253
1
254
2 3
J40
+
C4
13
14
POWER BOARD
H5A
H5
(440-460) H4
U
(380-415)
TO J20
-
202
+
X5
TO RECT THERM
224A
CHOKE
-
WORK
LEFT SIDE OF MACHINE
CONTROL BOARD
N.C.
X5
H5 H4
444
H3 H2
RECONNECT SWITCH
TO SWITCH BD #2
THIS AREA VIEWED FROM REAR OF MACHINE
TO L7
206A
405
404
1
TO CURRENT
X3A
TO SOLID STATE RELAY
TO AUX#1
P6
USER
INTERFACE
220
14
15
CURRENT
800V .022 800V .022
P91
CURRENT
TRANSDUCER
TO J24 TO J22
50
CB1
10A CIRCUIT
BREAKER
TP2
TO WORK
1W 2W
C2
ELECTRODE
N.A.
206
N.A. THERMAL LED (Y)
TO J20
STATUS LED (R/G)
52
1B
.05/600V
2B
TO R1
8 7 6 5 4 1 3 8 7 6 5 4 3 2 16 15 14
J21B J21A
506
239
TO SWITCH
TO J23
11
2
1
3 7
TRANSFORMER
TO R1
291
THERM.
TO J21A
216 211 213
TO SWITCH BD #1
20C
TO INPUT RECT
19C
POS
TO SWITCH BD #1
N.B.
NEG
TO INPUT RECT
TO SWITCH BD #2
20D 19D
14
J20,J26
7
9
8
1
12
16
7
10
L1
J23
8
CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)
1
1 6
J22,J61
5
6
1
J24,J31
228
L2 TO
225 50
2 2
S1 TO
67B 51A 54A 52
13
CURRENT
12
J27
TO
11
TO
10
67A
9 8
POWER BD
J20
CB1
L2
TO
.05/600V
TO MAIN TRANS TRANSFORMER
8 7
J60
6
231
5 4 3
232
2
604 238 X3 601
3
INPUT BOARD
4
17
18
1
2
10
5
21A 53A
2
51A 51
3
52A
4
1
53A
54
E
53
TO AUX#1
J31 S1 TO
51
X1
53
X3A
TO SOLID STATE RELAY
274
TP4
J32
273
STATUS LED
AC
POS NEG POS POS
6 5 4
J60 J50 J40 TO
231
THERM.
TP3
220 2W
12 11 10 9
J26
9 10 7 6 5 1 3 2 11 13 12 10 13 4
4
3
54
12
1
4 2 AUX #1
J25
380-415V
3R 3W
CAPACITORS=MFD/VOLTS RESISTORS=OHMS/WATTS
TO
1
CB3
6
440-460V 220-230V 200-208V
6 5 4 3 2 1 16 15 14 1
211
1
216 218
444
50WT
221 222 223 224 225 226
TO J31
1
LED
J31
THERMAL
5 6 7 8 9 10 11 12
RECT.
4
P91 TO
N.D.
L7
235
F2 F2
SECONDARY
(BOTTOM RIGHT)
BD #1
PRIMARY
(TOP RIGHT)
13
SECONDARY
(TOP RIGHT)
RIGHT SIDE
15
16
PRIMARY (BOTTOM RIGHT)
C5
17
BD #2 TO SWITCH
F1 F1
SWITCH BOARD #2
20D
TO RECONNECT SWITCH
TO CR1 J23 AUX #1
222 223
3
214
2
51BK
TO FAN
233
X1
W
H5
CONNECTION SHOWN IS FOR 440-460V OPERATION.
8
J60 1
3
5
COMPONENT VALUES:
ELECTRICAL SYMBOLS PER E1537 LEAD COLOR CODING B=BLACK G=GREEN
NOTES: N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
N=BROWN U=BLUE R=RED W=WHITE
RIGHT SIDE OF MACHINE
J27,J28
N.D MAY NOT APPEAR ON ALL MACHINES. N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
J25
4 3
J28
8 7 6 5 3 2 1 4 5 6
202A
226
TO RECONNECT SWITCH
12
20C
19C
228
10 9
33
J25
20
TO
251
TO J61
J20
TO J60
TO
601
291
D3
R1
TP7
1
CB2
10A CIRCUIT
BREAKER
7
234 233 232
J23
4 3 2
F4
TO
F3 F3
TO FAN
H3 H4
W
H2A
X4 X3 X3 X2
J60 CR1 TO
TO POWER BD. RECTIFIER
3W
SOLID STATE RELAY
J24 TO
3R
206
6 5
S1 TO
1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag
ram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. G
ive the equipment code number..