Lincoln Electric IM619 POWER WAVE 455 - Manual (Page 26)

F-1 DIAGRAMS F-1
POWER WAVE 455
612B
H2A
H3 H2
(220-230)
H1
POS
CR1
AC1
A
T3
T2
REAR OF MACHINE
L1B
H3A H5A H2A H1A
C7
L1A
TO SW1
SWITCH
LEAD FILTER
440V .0047uF
6
67B
2B 226
5
211
J22
51A
1
LED
4
RECT.
54A
2
THERM.
3 2 1
52A
1
E
253
2
214 213 212
TO P91
X5
S1
WIRE
FEEDER
RECEPTACLE
6
NEG
C3
F4
TO
NEG
N.D.
F4
10W 2.7
SECONDARY
(TOP LEFT)
POS POS
OUTPUT RECT
J27 J22 TO
INTERFACE
USER
212
TO J21A
213
1
211
2
TO AUX#1
216
3 4
++
P91
CURRENT
TRANSDUCER
L2 CB1 TO
50 51
MAIN CHOKE
L1 MAIN TRANSFORMER
LEFT SIDE
5
4
6
SWITCH BOARD #1
TO C5
TO INPUT RECT
TO J61
CB3
10A CIRCUIT
BREAKER
TO
1
J32,J40 J50,J81
403
406
TO J23
TO SW1
1
2
TO CR1 J60
X3A
H1
L3A
H4
TO C4 TO INPUT RECT
A
51 51A
B
53A
C D
254
251
TO L4
3
21A
20 4 R1
50
TP3
N.A. N.A.
352
50
6
J22,J61
5
5
J24,J31
6
1
BRACKET
TO
8
J27,J28
4
W=WHITE U=BLUE
TO AUX #1
TRANSFORMER
TO CURRENT
11
351
H1D
PRIMARY
(TOP RIGHT)
TO SWITCH
BD #1
13
F1 F1
.022
206A
J32
J31
X1
RECT
2.7
800V
10W
POWER BD
202A
52
J24
L1A
4
351
J27
350
J28
3 4 5 6
273 274 53
ALIGNS WITH BLACK LEAD OF LED SOCKET.
403
J40 J50 TO
506 404 235 604 405
1B
239 238 406
J60
1W
TO
503
TO MAIN TRANS
1 1
N.D.
N.D.
TP7
TM
POWER WAVE 455 (380-415, CE) WIRING DIAGRAM
LEFT SIDE OF MACHINE
CONTROL BOARD
612B
AUXILIARY TRANSFORMER #1
TO POWER BD. RECTIFIER
W
H5
X1
H5A
X2
X3
THERM.
X3
H2
X4
(200-208)
BD #1
14
C1
202
15
405
TRANSFORMER
404
TO CURRENT
L5
FRONT OF MACHINE
TP1
TO R1 202A
WORK
-
TO J20
202B
S4
220V RECEPTACLE
5
234
6
503
235
239
TO J23
506
218
CURRENT
TRANSFORMER
SECONDARY (BOTTOM RIGHT)
TO
RIGHT SIDE
TO MAIN TRANS TRANSFORMER TO CURRENT
17
18
1
2
3
4
RECT.
224
TO J22
F3 F3
SECONDARY (BOTTOM
LEFT)
2.7
220
10W
D4
.022 800V
D3
.022 800V D1 D2
AUX. #1
800V .022 291
TO
C3
THERM
SECONDARY
(TOP RIGHT)
F2
X2 NEG
F2
AC
N.D.
POS
TO S3
224A
CHOKE
2.7 10W
3W
-
TO J24
3R +
221
1
225 223 222 228 226
202
274 273
2
21A
3
SOLID STATE RELAY
TO S1 S2 L5 L6
67A 206
P6
6 5 4
J27 J20 TO
8
J60
4 5 6
CR1
7 8
J23
J61
AUX #1
231
2 3 4 5 6 7 3 2
232 604 238 X3 601
INPUT BOARD
C
10 9 8
A B 612
214
+
TO L7
TO R1
TP2
206
1W
L6
2W
TO
CB2
5A CIRCUIT
BREAKER
THERMAL LED (Y) STATUS LED (R/G)
WORK
1B
ELECTRODE
2B
206B
TO J20
TO J24 TO J22
8 7 6 5 4 1 3 8 7 6 5 4 3 2 16 15 14
J21B J21A
53A 53 54
1
3 4 5 6 7
P6
TO J25
51 52
TO CB1 TO POWER BD
14 8 11 12
TO CURRENT TRANSDUCER
51BK 50WT
POWER BOARD
THERMAL
J31 J32
J25
L7
444 TO FAN
TP4
TO
H1A
TO AUX #2 TO J61 CB3 612A 612
CB4
6A CIRCUIT BREAKER
444 X5
TO AUX#1
FAN
J60
TO SWITCH BD #2
NEG
J21A,J21B
NEG
C
AC3
INPUT
RECTIFIER
B
AC2 C6
L1 T1
U
L1B
G
NATIONAL ELECTRICAL CODE. TO A SYSTEM GROUND PER
TO SUPPLY LINES
TO CR1
L3B L3
.05/600V
6 4 1
H3
6
(440-460)
B
352
H5
TO
H2 (200-208)
B
H1
350
CB2
3
S4
(220V)
H4A
(220-230)
P81
(380-415)
2
AUXILIARY TRANSFORMER #2
TO TP3 C2
NOTES:
14
G3051-3
7
9
8
1
12
16
7
10
J23
J20,J26
8
CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)
1
1 6
3-19-99D
1 2
J23
TO
3
S2
VOLTAGE
SENSE
RECEPTACLE
L2
4
POWER BD
5 6
232
7
233
8 9
234
CB1
10A CIRCUIT
BREAKER
9
1
2
.05/600V
TO
10
L4
L2
L4
11 12 13
X3A
54A 67A 67B 52
216 218 221 222 223 224 2W 225 231
2
228 220
1
TO J31
2 3 4
NEG
C
15
16
C5
SWITCH BOARD #2
J50
TO CURRENT TRANSFORMER
11
12
C
POS
C4
+
13
14
J40 3
TO SWITCH BD #1
POS
4 3 2 1 11 9 7 8 12 4 6 5 1 10 3 2 5
RECONNECT
RECONNECT
SHROUD
HORIZONTAL
AUX #1
BAFFLE
BAFFLE
AUX #2
REAR UPPER BASE
FRONT UPPER
CASE
BASE
FRONT
RIGHT SIDE OF MACHINE
INPUT RECT SW1
3
1
CB4
B=BLACK G=GREEN LEAD COLOR CODING ELECTRICAL SYMBOLS PER E1537
COMPONENT VALUES:
PROTECTIVE BONDING CIRCUIT
HORIZONTAL
REAR
FAN
FRONT
12 11 10 9
J26
9 10 7 6 5 1 3 2 11 13 12 10 13
TO TO J81 CB2 J81 WORK ELECTRODE
5 8 7 6
TO S4
4
TO J60
54
12
AC
POWER BD RECTIFIER
3R 3W
CAPACITORS=MFD/VOLTS RESISTORS=OHMS/WATTS
TO
1
CB3
3 J25
AUX #1 2 4
1
6 5 4 3 2 1 16 15 14
SOLID STATE RELAY
15
TO CURRENT TRANSFORMER
TO SWITCH
PRIMARY (BOTTOM RIGHT)
STATUS LED
D2
4
254
3
253
2 1
251
4 3 2 1
L3B
V L2
16
11
L3
W
INPUT LINE
FILTER
X4 601
17
BD #2
THERM.
PRIMARY
(TOP LEFT)
16
TRANSFORMER TO CURRENT
CHOKE
(115V)
R
291
TO FAN
(24V)
N W
H3
TO RECT THERM
4
3
612A
TO CB4
TO SOLID STATE RELAY 233
NEG
N.D.
NEG
TO
NEG
POS
TO
C3
POS
S1
+
POS
1 2
SHELL
J20
7
(51V)
H3A
TO SOLID STATE RELAY
U
(380-415) H4
H4
H4B
SW1
TO AUX #1
H4A
(440-460)
CB4
H1
H5
P80
5 6 7 8 9 10
52A
224A
TO TP3
TO
18
TO SWITCH BD #2
12
TO SWITCH
PRIMARY (BOTTOM
LEFT)
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
S3
RS232
CONNECTOR
N=BROWN R=RED
LOAD LINE
N.D. MAY NOT APPEAR ON ALL MACHINES.
(TOP)
TO SWITCH LEAD FILTER
H4B
TO AUX #1
206A
TO J61
H1D
+
TO CB3
ELECTRODE
SW1
POWER
L3A
TO SWITCH LEAD FILTER
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..