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ELECTRICAL DIAGRAMS
G-3
POWER WAVE 450
SCHEMATIC - COMPLETE MACHINE
7-21-95E
G
380-415V
440-460V
W
G
CR1
TP4
TP5 TP6
POS
+
NEG NEG
2
W
3
5
N
U
R
(24V)
(42V)
(115V)
H1
H2
H3
H4
1
2
3
H1
H2
H3
H4
AC2
L2
L1A
L3
L3A
(24V)
U
V
L1
T1 T2 T3
326
324
321
323
AC1 AC3
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
NATIONAL ELECTRICAL CODE.
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON
CODE NUMBER.
D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET.
N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.
THE INTERCHANGEABILITY OF A COMPLETE BOARD,
6
(440-460)
H5
(200-208)
(220-230)
(380-415)
H5
5
1
4
200-208V
220-230V
N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET.
D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET.
3T
4T
3B
4B
12D
3W 3R
9D
407
408
4W4R
3B
4B
3W
3R
4W4R
406
405
9C
12C
3T
4T
2W 2R
2R
2W
402
401
9A
12A
1T
2T
1W1R
1T
2T
1W
1R
404
403
9B
12B
1B
2B
1B
2B
12A
12B
12A
12B
9A
9B
9A
9B
9C
9D
12C12D
9C
9D
L1A
T3
11J30
16J30
1J30
6J30
SOFT START
RELAYS
125/40
125/40
4J32
6J32
324
326
T1
T3
1J32
3J32
H2
H4
H5
1J31
10J31
12J31
14J31
12K
9J
12J
9K
12K
9K
9J
12J
1K
POS
NEG
C3
C4
C1
C2
RUN MODE
24VAC
0VAC
1J40
9J40
3J40
11J40
6J40
14J40
8J40
16J40
3W
3R
3W
3R
4W
4W
4R
4R
1J41
9J41
10J41
2J41
7J41
15J41
16J41
1W
1W
1R
1R
2W
2W
2R
2R
24V
42V
0
PROTECTION BOARD
2J39
3J39
4J39
3J36
4J36
1J36
2J36
361
362
(+)
(-)
361
362
4 PRIMARY LEADS 1T,1B,4T,4B
ARE FEEDED THRU CURRENT TRANSFORMER
CURRENT TRANSFORMER
3J50
1J50
6J50
4J50
Iout
SHUNT BOARD
7J62
4J62
2J62
499
467
11J60
1J62
DIVIDER
&
BUFFER
2.7/10
2.7/10
.047/1200
320V 160J
.047/400 .047/400
320V 160J 320V 160J
6J62
SNUBBER BOARD
203
204
205
208
203
205
208
CONTROL BOARD
PROTECTION BOARD
POWER BOARD
< 25uS
50uS
D1-D6
INPUT RECTIFIER
380-460V
208-230V
25/25
25/25
R6
R5
R10
7.5K/25
3500uF
450V
.047/1200
.047/1200
SWITCH BOARD #3
(LEFT TOP)
(LEFT BOTTOM)
SWITCH BOARD #4
R8
R7
3500uF
450V
.047/1200
.047/1200
25/25
25/25
R2
R1
R9
25/25
25/25
7.5K/25
3500uF
450V
.047/1200
.047/1200
SWITCH BOARD #1
(RIGHT TOP)
(RIGHT BOTTOM)
SWITCH BOARD #2
R4
R3
25/25
25/25
3500uF
450V
.047/1200
.047/1200
R11
40/100
ELECTRODE
WORK
MACHINE SCHEMATIC
(ON OUTPUT RECTIFIER ASBLY)
POWER SWITCH
ON
OFF
ELECTRICAL SYMBOLS PER E1537
204
8J41
L3A
T1
461
462
464
S1
TOP
FAN
BOTTOM
FAN
RECONNECT PANEL
RECONNECT PANEL
1J19
2J19
3J19
4J19
5J19
6J19
7J19
8J19
9J19
10J19
11J19
12J19
13J19
14J19
15J19
16J19
1J18
2J18
3J18
4J18
5J18
6J18
7J18
8J18
9J18
10J18
LCD DISPLAY
KEYPAD
ISOLATED
CIRCUIT
ISOLATED
CIRCUIT
GD
GD
261
262
265
266
263
264
1J26
2J26
5J26
6J26
3J26
4J26
1J14
2J14
5J14
4J14
6J14
3J14
E
F
G
77
76
75
E
F
G
277
276
275
4J10
5J10
1J10
3J10
8J10
9J10
77
76
75
277
276
275
111A(R)
112A(W)
117A(R)
118A(W)
112A(W)
117A(R)
118A(W)
111A(R)
1J27
4J27
1J28
4J28
N
N
67
167A
67
167A
8J60
15J60
9J60
13J60
121A
221A
121A
221A
H
H
C
C
D
D
32B
32C
32D
32E
42B
42C
31B
31C
102B
105A
102D
106A
J
A
K
I
L
M
M
L
J
A
K
I
31B
31C
32B
32D
42B
42C
32C
32E
8J34
12J34
10J34
13J34
1J34
5J34
3J34
6J34
102B
105A
102D
106A
11J34
14J34
4J34
7J34
D
E 102C
177A
176A
175A
A
B
C
F
7J93
5J93
2J93
3J93
4J93
293
296
294
291
292
294
291
292
10J10
6J10
7J10
6
2
W
3
5
N
U
R
(24V)
(42V)
(115V)
H1
H2
H3
H4
1
2
3
(24V)
6
(440-460)
(200-208)
(220-230)
(380-415)
H5
5
1
4
6
WATER COOLER
3J3
4J3
5J3
6J3
453
454
455
456
453
454
455
456
1J11
3J11
7J11
8J11
2J12
4J12
4J13
2J13
0V
24V
0V
24V
374
371
372
373
24V
24V
WF2 TRIGGER
WF1 TRIGGER
WF2
TRIGGER
1.5V=CLOSE
TRIGGER
1.5V=CLOSE
WF1
CLOSE
CLOSE
371
374
372
373
1J37
4J37
3J37
2J37
24VAC WHEN
WF2 TRIGGER
CLOSE
1J15
2J15
PIEZO
BUZZER
300
301
+
-
10J16
1J16
9J16
6J16
7J16
2J16
3J16
8J16
447
448
446
444
449
443
442
445
ELECT.VOLT.FEEDBACK
WF1 ARC VOLT.FEEDBACK
WF2 ARC VOLT.FEEDBACK
WF1 WORK VOLT.FEEDBACK
WF2 WORK VOLT.FEEDBACK
202
206
201
207
8J20
5J20
4J20
3J20
2J20
6J20
1J20
7J20
202
206
201
207
6J61
10J61
7J61
8J61
1J61
5J61
2J61
9J61
ELECT.VOLT.FEEDBACK
WF1 ARC VOLT.FEEDBACK
WF2 ARC VOLT.FEEDBACK
WF1 WORK VOLT.FEEDBACK
WF2 WORK VOLT.FEEDBACK
WF1 RECEPTACLE
WF2 RECEPTACLE
8J21
3J21
6J21
2J21
1J21
5J21
211
215
213
216
212
218
237
236
235
5J23
6J23
DISPLAY BOARD
234
232
233
4J23
2J23
3J23
234
232
233
9J42
7J22
227
221
1J22
5J42
223
226
224
225
10J22
6J22
11J22
12J22
10J42
6J42
11J42
12J42
FROM POWER BD.
5R
5W
5W
5R
5J22
4J22
5J44
4J44
10J44
11J44
6J44
12J44
3J44
2J44
8J44
447
448
444
449
443
442
9J44
446
445
(+)
(-)
211
215
H1
H1B
H1B
H1
H2
H3H4 H5
H3
H1AH1
H2H2A
H3 H3A
H4
H4A
H5
H5A
H5A
H4A
H3A
H2A
H1A
"A"
321B
321A
321B
321A
POWER WAVE
2990
P73
P70
P71
33
334
333
336
6J33
3J33
4J33
1J33
32A
CB
5A
P5
MAIN CHOKE
302
306
303
307
1J17
7J17
4J17
8J17
2J17
9J17
2
3
1
4
5
6
7
8
20
RS232
CONNECTOR
DEAD TIME
5J4
2J4
2J38
3J38
293
296
115V
(+)CAP3,4
(-)CAP1,2
24VAC TO DISPLAY BD. WHEN TRIGGER CLOSE
AC VOLTAGE FROM CT
RECTIFIED CT VOLT. TO CONTROL BD.
CAP.VOLT. & OUTPUT DISABLE SIGNALS TO CONTROL BD.
CAP.VOLTAGE
SENSING CIRCUIT
351
356
1J35
6J35
3J43
1J43
42VAC SUPPLY, FROM PROTECTION BD.
0 VAC,FROM 1J33
42VAC,FROM 3J33
42V,FROM 3J33
0VAC,FROM 1J33
115VAC,FROM 6J33
0VAC,FROM 1J33
24VAC,FROM 4J33
24VAC WHEN WF1
TRIGGER CLOSE,TO 4J37
115VAC,FROM 6J33
0VAC,FROM 1J33
42VAC,FROM 3J33
0VAC,FROM 1J33
24VAC,FROM 4J33
24VAC WHEN WF2
TRIGGER CLOSE,TO 2J37
24VAC SUPPLY
FOR
PROTECTION BD.
TO WF1 RECEPTACLE
TO WF2 RECEPTACLE
PROTECTION BD.
GND
+15 Vb
+5 Vb
-5 Vb
-8 Vb
+5 Vc
PWR_DN
ISOLATED DC SUPPLIES,TO DISPLAY BD.
FET GATE SIGNALS TO SWITCH BOARDS #1 & #2
FET GATE SIGNALS TO SWITCH BOARDS #3 & #4
+18 Vd
V
V
V
A
V
B
A
B
+15 Va
-15 Va
+5 Va
a_GND
ISOLATED DC SUPPLIES
40mA CURRENT SOURCE
e_GND
+18 Vd
+15 Va
A
FET BANK B
DRIVER
+15 Va
A
DRIVER
FET BANK A
NOISE_GND
DA
NOISE_GND
+15 Va
-15 Va
SHUNT CURRENT
FROM SHUNT BD.
( 5mA AT 400A WELDING CURRENT)
DC SUPPLIES TO SHUNT BD.
RECTIFIED CT VOLT. (+)
RECTIFIED CT VOLT. (-)
OUTPUT DISABE
NOISE_GND
NOISE_GND
40mA
40mA
40mA
40mA
COUPLED TO 3J26
COUPLED TO 1J27
TRIGGER
CIRCUIT
+15 Va
-15 Va
+5 Va
40mA
40mA
40mA
TO 4J22
FROM 4J28
DC SUPPLIES TO SNUBBER BD.
TO SNUBBER BOARD
-15 Va
+15 Va
TO SNUBBER BOARD
ISOLATED DC SUPPLIES FROM POWER BOARD
+15 Vb
+5 Vb
-5 Vb
-8 Vb
DISPLAY BD.GND
GD
GA
+5 Vc
(RS232)
GRS232
PWR_DN
(XIRQ)
(+)
(-)
15V
WHEN WF1 TRIGGER
WHEN WF2 TRIGGER
GA
PRESSURE
(+)
(-)
15 V
WATER COOLER CONTROL
POT.WIPER
POT.MAX
POT.MIN
FOOT AMPTROL REMOTE CONTROL
WIRE FEEDER REMOTE CONTROL
10V
10V
10V
GA
GA
GA
WIPER
WIPER
WIPER
WF1
WF2
GD
5 Vc (RS232)
GRS232
RX
TX
5V
GND
SERIAL
COMM.
ARC & WORK VOLTAGES TO SNUBBER BD.
GROUND PLANE #1
GROUND PLANE #2
d
ad
e
d
b
c
c_GND
b_GND
SHUNT CURRENT TO CONTROL BD.
SNUBBER BD.
GND
.0047/400
10/2
10/2.0047/400
.0047/400
10/2
+15 Va
-15 Va
SHUNT BD.GND
SHUNT BD.
GND
DC SUPPLIES FROM CONTROL BD.
FROM CONTROL BD.
FROM CONTROL BD.
+15 Va
-15 Va
NOISE_GND
ARC & WORK VOLTAGES FROM WIRE FEEDER RECEPTACLES
TERMINAL STRIP
(N.D.)
(N.D.)
P1
FOOT AMPTROL RECEPTACLE
(REMOTE)
105B
4J92
1J92
2J92
3J92
6J92
P81
P83
P82
FOOT AMPTROL TRIGGER
5V=OPEN
5V=OPEN
OR FOOT AMPTROL
24VAC TRIGGER VOLTAGES
+5 Vb
+5 Vb
+5Vb
TRIGGER 24V, 42V, & 115V FROM PROTECTION BD.
115V
42V
(N.E.)
SERIAL LOOP COMMUNICATION
FOR WIRE FEEDERS
SWITCH BD.
TSTAT
FREQ.MODULATED
CAP.DIFFERENTIAL VOLT.
FET BANK B
GATE SIGNAL
SERIAL LOOP
CURRENT
FET BANK A
GATE SIGNAL
FREQ.MODULATED
DIFFERENTIAL CAP.VOLT.
OUTPUT DISABLE
NOISE_GND
(1250Hz WHEN CAP.BALANCED)
(OV = RUN
5V = DISABLE)
24VAC WHEN FOOT AMPTROL
CLOSE,TO 4J37
24VAC FROM 4J33
(N.E.)
F1 5A
SLOW BLOW
FUSE
FEEDED
THRU CT
OUTPUT
RECTIFIER
FLYBACK
D7-D14 IN PARALLEL
IN PARALLEL
FEEDED
THRU CT
FEEDED
THRU CT
THRU CT
FEEDED
OUTPUT
RECTIFIER
D15-D20
IN PARALLEL
N.D. NOT EXIST ON MACHINE WITHOUT WATER COOLER
N.E. NOT EXIST ON PW350 & PW500
FROM CONTROL BD.
FEEDBACK VOLTAGES
TO CONTROL BD.
B
B
FEEDBACK VOLTAGES FROM SNUBBER BD.
OUTPUT RECTIFIER
TSTAT
AUXILIARY TRANSFORMER #2
SHUNT CURRENT FROM SHUNT BD.
24VAC WHEN WF1 OR
FOOT AMPTROL TRIGGER CLOSE
AUXILIARY TRANSFORMER #1
DC SUPPLIES
MAIN TRANSFORMER LEFT SIDE
MAIN TRANSFORMER RIGHT SIDE
(Io = 5mA AT 400A WELDING CURRENT)
213
216
212
218
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.