F-1

DIAGRAMS

F-1

POWER WAVE 455/STT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram 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. Give the equipment code number..
(220-230)
H2A
(380-415) H4A
H1A
4
6
H3
H6A
(550-575)
1
4
H1A
H2
H1
H5A
33
H5
(440-460)
H6
1
H4
2
6
2
5
(200-208)
H3A
5H6A
P50 JUMPER
(MAY NOT BE PRESENT
ON EARLIER MACHINES)
612A
CB310A
BREAKER
TO CB4
TO SW1
TO J61
CB3
612A
612
H1A
TO AUX #2
CIRCUITCB46A
BREAKER
CIRCUIT
612B
"H1A TO AUX #2"CONNECTED HEREON EARLIER MACHINES
H1 JUMPER (H1A)
TO AUX #1
-
TO J9
202
WORK
202A
TO R1
TO TP6
TO TP3 TO
CB1
S1WIREFEEDERRECEPTACLE
J47
+
ELECTRODE
223
221
206A
R3
C8
TO D5
289D
R2
2Y
288C
288D
289E288E
TO
3R3R
3W
238
15
5
J10
TO
SSR
RECT
THERM
223
222
CHOPPER BD
SEC
(BOTTOM
LEFT)
POWER BDRECTIFIER
AC
EMITTER
212
213
813
811
216
4
CONTROL BOARD
+
TO J61
CR1
X4
6
TO AUX #1
503
504
505
506
INPUT
20D
1718
STT SNUBBER
1516
F1
F1
TO
CB1
J41
1
4R
J4
251
20
C
J47
TO
P90
P91
RECT
292
SEC
(TOP
LEFT)
U
TO SW1
L1A
V
L3
AC
3
TO
CR1
SW1
CB4
L3A
T2
L2
AC
2
H1D T3
T1
T2
612
T3
NEG
1
2
3
4
+
4W
346
C3
AUX. #1
TO
4
3
D3
TO
CHOKE
THERM
D
CURRENTTRANSDUCER
TO C8
19D
SWITCH BOARD#2
289A
-+
288B
TO C10
SW1POWER
C10
289F
A
202
225
J7
2
J2
206
S1
TO
52
J5
ELECTRODE
CB2
AUX 2
TO
32
STT
WORK
TO
TP6
1
2
3
4
5
6
7
J3
4
5
6
3
2
4
1
8
7
6
5
4
3
2
1
289E
289D
289C
289B
288E
288D
288C
288B
289C
R4
289A
2Y
TO C10
289B
NEG
STT
X1
+
8
G
601
TO J60
L1
20NEG
19C
T1
REAR OF MACHINE
TO J6,J10B
6
TO SOLID STATE RELAY
32
TO SOLID STATE RELAY
444
FANTHIS AREA VIEWED FROM
288F
RECONNECTPANEL
TO
CR1
J6
231
AUX #1
J61 5
6
7
8
9
POS
D1
TO
MAIN
TRANSFORMER
50
TO
L2
CB110A CIRCUIT
BREAKER
R
1
TO
WORK
BUSS BD
TP3
TO R1
CB210A CIRCUIT
BREAKER
1B
TP2
206
TO J9
202A
TO
S4
31
AUX 2
TP5
33
WORK
206A
NEG
7
PRI
(BOTTOM
RIGHT)
TO
SWITCH
BD #2
15
14
12
18
TO
SWITCH
BD #1
TO
SWITCH
BD #2
MAINTRANSFORMERLEFT SIDE
X2
NEG
POS
C3
.05/600V
2W
403
288A
2B
604
14
7
9
8
1
12 16
7
10
8
CONNECTOR CAVITY NUMBERING SEQUENCE(VIEWED FROM COMPONENT SIDE OF BOARD)
11
6
561
3
TO SW1
200-208V
220-230V
440-460V
550-575V
POS
POS
AC
1
TO SUPPLY LINES
S2VOLTAGESENSERECEPTACLE
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
S3RS232CONNECTOR115VRECEPTACLE
TO RECONNECT PANEL
12
PRI
(BOTTOM
LEFT) 1112
20C
++
TO AUX#1
404405406
21A
2
51
3
4
54
E
53
J9
TO
8
3
1
16
67A
TO C3
4
J46 3
2
1
POS
POS
DC BUS BOARD
12
J41
ELECTRODE
C6
TO TP6
50Y
C2
N.A.
.05/600V
STATUS LED (R/G)
TO J7
N.A.
THERMAL LED (Y)
TO J7
1W
TO
J4
J11
C4
13
14
+
SWITCH BOARD#1145
X3A
19
TO FAN

POWER WAVE™ 455/STT WIRING DIAGRAM

X1
224A
291
CB4
AUXILIARY TRANSFORMER #1
SEC
(BOTTOM
RIGHT)
TO
INPUT RECTIFIER
POS
TO
SWITCH BD #1
11 12
20D
TO
SWITCH BD #2
TO RECONNECT SWITCH
H5
H6
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
H1
(200-208)
H2
(220-230)
PRI
(TOP
LEFT)
R
(115V)
N
(24V)
X4
COLLECTOR
2
6
TO J61
H1D
(TOP)
LOAD LINE
TO CB3
612B
TO CONTACTOR
L3A
L1A
TO CONTACTOR
S4
TO
TO TP3
31
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
8
7
9
232
X3
604
238
601
INPUT BOARD
NEG
H3
H2
TO AUX #1
H2A
H3A
H1
H2
H3
812
813
287
811
816
F3
F3
++
F2
F2
19C
17
11
TO
SWITCH
BD #1
5141AUXILIARY TRANSFORMER #2
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
OPERATION.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
OPERATION.
RIGHT SIDE OF MACHINE
J8
J9
228
226
1
224
220
504
503
406
505
4
506
2
3
211
2
3
816
7
8
21A
418
514
1
273
274
5
6
2
1
TO J6, J10B
RIGHT SIDE
13
4R
4W
TO
INPUT RECTIFIER
D4
J40
F4
403
F4
THERM
9
1
2
3
4
11
J42
TO J5
6
5
4
3
2
+
225
1
SEC
(TOP
RIGHT)
1516
235
J50
C5
J60
10
10
9
8
7
6
5
4
273
3
228
274
226
TO J8
4
TO
S3
1
2
J43
251
253
254
J1 9
7
14
8
6
5
4
1
3
2
NEG
DIGITAL POWERSUPPLY BOARD
3R TO 3W
J7
MAIN CHOKEL1
221
4
3
231
232
291
X3A
.05/600V
C1
TP1
TO C8
288A
345 287
TP7 RECTIFIER
16
414
H4
’A’LEFT SIDE OF MACHINERECONNECT SWITCH
H4A
6
5
1
1
TP4
444
TO FAN
TO
J47
475
477
1
2
476
216
478
211
3
213
212
4
5
6
4
4
W
11
W=WHITE
U=BLUE
R=RED
COMPONENT VALUES:
N=BROWN
REAR OF MACHINE
G=GREEN
B=BLACK
LEAD COLOR CODING
ELECTRICAL SYMBOLS PER E1537
J10,J2VS 21
34
TO SW1
X5
TO AUX#1
2
1
OUTPUTRECT
D2
J6
5
6
253
7
2
254
8
39
4
13
B
11
A
10
L2
TO J46
1
2
3
4
POWER BD RECT
1
2
3
4
TO
WORK
ELECTRODE
J10A
J11
STT CURRENTTRANSDUCER
812
TO J8
X2 U
TO
J42
J43
TO POWER BD.
RECTIFIER
(51V)
(380-415)
X3 WH3
TO
X3
AUX #2
X5
RECONNECT PANEL
TO
MAIN TRANSFORMER
TO D5
34-
TO
J4SOLID
STATERELAY
21
W
H5
(440-460) H5A
H4 H5
2Y
10
15
14
11
12
13
16
10
11
12
10
14
15
11
12
13
16
10
2.7 10W
.022
800V
PRI
(TOP
RIGHT)
POS
POS
NEG
NEG
AC
J10CH
.022
800V
2.7 10W 2.7 10W
.022
800V
N.C.
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
51
1
50
3
475
5
476
6
4777
478
8
52
S2
J2
P90
P91
N.B.
1W
1B
1
2
222
L4
2B 2W
267
266
268
THERM
TO
J40
J50
67A
TO
J43, S1
267
266
268A
227
227
J73
TO
S1
D6
TO
J11
J47
IFACE
ROBOT
TO
J2,J5,J11,
J41,J4
J1VS,J9,J10CH,
J14,J40J42,
J50 J8,
J47,J60 J3,J61
J4,J13,
J43 J1,J6,J7
J10
WATERCOOLER RECEPTACLE
2
1
350
352
TO
J9
J11
CB1
J47
6
5
1
2
3
4
H6
(550-575) H6A
H6
TO
CR1
J60
CHOKE
THERMTO RECT
THERM
TO
RECONNECT
SWITCH
B
G4046
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
S8STT SNUBBERCAPACITOR BANK
STT SNUBBER
20uF
400V
20uF
400V
418518
1
518
2
414
J10B
TO
SSR, J10 CHOPPER BD.
405
404
RESISTOR BANK
DIODE D5
TO
J40,J50
346
345
R5
TO
262268268AR5220A292
262
R5
WR41(115V)
TO
S4CB2350352P52432331233A2(230V)
3
4
33A
224A
224
220
220A
TO
J4
J43
TO RECT
THERM
DC BUS
THERM
L5
TO
AUX #2
S1
100V
2400oF
500V
3500oF
500V
3500oF
2
4
P16USERINTERFCE
51A
53A
54A
67B
52A
53A
54A
51A
67B
52A
POS
NEG
54
53
TO
HARMONIC FILTER
TO
HARMONIC FILTERTORECONNECTSWITCH
19
20
HARMONICFILTER19D20C