Section
J6 INPUT RECEPTACLE
L1
WIRE DRIVE CONTROL PCB
| J8 OPTIONAL | |
| INPUT RECEPTACLE. | |
J9 OPTIONAL | IF CONFIGURED AS BOOM, CONNECTS VIA | |
ARCLINK CABLE FROM WIRE DRIVE (J9) | ||
OUTPUT | ||
OR POWER WAVE 455. | ||
RECEPTACLE | ||
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67 |
(BOOM) |
Return to
Return to
COMMUNICATION - | A | 541 |
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COMMUNICATION + | B | 542 |
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ELECTRODE | C |
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VOLTAGE SENSE |
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+40 VDC | D | 540 |
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0 VDC | E | 500 |
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541
3J1
L1
542
5J1
L2
540
7J1
L2
500
9J1
COMMUNICATION - |
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COMMUNICATION - | 1J2 |
COMMUNICATION + |
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COMMUNICATION + | 2J2 |
+40 VDC |
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+40 VDC | 4J2 |
0 VDC |
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0 VDC | 3J2 |
| L7 |
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541D | 541D | A | A | 541 |
| L8 |
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542D | 542D | B | B | 542 |
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| C | C | 67 |
| L9 |
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540D | 540D | D | D | 540 |
| L10 |
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500D | 500D | E | E | 500 |
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L1
541
L1
542
L2
540
L2
500
1J7
3J7
6J7
4J7
OR
1P7
3P7
4P7
541A
542A
500A
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| OR | 67 |
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| J6 OPTIONAL |
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| OUTPUT |
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| (BENCH) | 67 |
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| RECEPTACLE |
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| 67 | C | ELECTRODE |
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| VOLTAGE SENSE |
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1J2 | COMMUNICATION - | COMMUNICATION - | 1J1 | 541D | 541D | A | COMMUNICATION - |
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L8 |
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2J2 | COMMUNICATION + | COMMUNICATION + | 2J1 | 542D | 542D | B | COMMUNICATION + |
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L9 |
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3J2 | +40 VDC | +40 VDC | 4J1 | 540D | 540D | D | +40 VDC | P.C. BOARD | 1 | 8 |
L10 |
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TOC
BLOCKING
RECTIFIER
MOTOR
TACH
540B
6J1
540C
10J1
R
1J4
U
2J4
B
3J4
+40 VDC | COMMUNICATION - | 2J1 | |
WIRE DRIVE PCB | COMMUNICATION + | 4J1 | |
CIRCUIT SUPPLY | |||
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| +40 VDC | 8J1 | |
+12 VDC | 0 VDC | 1J1 | |
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TACH SIGNAL INPUT |
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0 VDC |
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541A
542A
500A
540A
INTERNAL HARNESS AND CONNECTOR USED ONLY IF UNIT CONFIGURED AS A BENCH FEEDER.
541A
542A
500A
67
540A
1J7
3J7
4J7
5J7
6J7
5P7
6P7
67
540A
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| 0 VDC | 3J1 | 500D | 500D | E 0 VDC | 1J1 | 2J1 | 3J1 | 4J1 | 5J1 | 6J1 | 7J1 | 8J1 |
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4J2 | 0 VDC |
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| CONTROL BOX |
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| 550 | 552 | 551 | 512 | 500 |
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| USER INTERFACE PCB |
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| 512 |
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| * SERIAL | +12 VDC - | 1J4 |
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| 551 |
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| PERIPHERAL | * MOSI - | 2J4 |
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| INTERFACE | 512C |
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| +12 VDC - |
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| 0 VDC - | 4J4 |
| DUAL |
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| 552 |
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| ENCODER |
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SHUT DOWN
570
7J5
571
9J5
| STATUS LED | 8J5 | |
| (HIGH FOR GREEN) | ||
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SIGNAL COMMON | STATUS LED | 10J5 | |
(HIGH FOR RED) | |||
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CONTROL SIGNAL |
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OPEN = FAULT |
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* SCK - | 5J4 |
B |
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| CATHODE | |
| RED/GREEN | |
W | STATUS | |
LED | ||
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552 | ELECTRODE VOLTAGE SENSE |
* LATCH - | 6J4 | 550 | P.C. BOARD |
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- | 7J4 | 500C | 1J1 | 2J1 | 3J1 | 4J1 | 5J1 | 6J1 | 7J1 | 8J1 | B | CATHODE |
0 VDC - | 8J4 |
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554 |
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ENCODER 1, SIG. B - | 9J4 |
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553 |
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ENCODER 1, SIG. A - | 10J4 | 500C | 512C | 555 | 556 | 553 | 554 |
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ENCODER 2, SIG. B - | 11J4 | 556 |
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555 |
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ENCODER 2, SIG. A - | 12J4 |
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B |
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STATUS LED (HIGH FOR GREEN) - | 13J4 |
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Return to Master TOC
GUN | GUN |
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RECEPTACLE |
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CONTROLS |
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DUAL | (P11) (J11) | L3 | 555 |
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PROCESS | D |
| 2J5 | |
| L4 |
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| E |
| 554 | 1J5 |
| L5 |
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TRIGGER |
| 556 |
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| A |
| 11J5 | |
| L6 |
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| C |
| 557 | 12J5 |
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FEEDER |
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CONTROLS |
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2/4 STEP | 512A |
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| 560 |
| 6J5 |
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| 559 |
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COLD INCH | 512A | 512 |
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/ |
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| 3J5 | |
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PURGE
558 | 4J5 |
ELECTRODE CABLE |
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J9 OPTIONAL
OUTPUT
RECEPTACLE
ELECTRODE VOLTAGE | 67 |
SENSE FROM | C |
| +40 VDC | 3J3 | |
DUAL PROCESS, | PWM | 6J3 | |
OPEN = PROCESS A | CONTROL | ||
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SIGNAL COMMON |
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GUN TRIGGER, |
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CLOSE = FEED HOT WIRE |
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SIGNAL COMMON | + PWM | 4J3 | |
CONTROL | |||
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| - PWM | 1J3 | |
| CONTROL | ||
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TRIGGER ACTION SELECT, |
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OPEN = 2 STEP |
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PURGE SIGNAL | +12 VDC | 1J6 | |
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+12 VDC |
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COLD INCH SIGNAL | VOLTAGE SENSE | 2J6 | |
SELECT SIGNAL | |||
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WIRE DRIVE |
ASSEMBLY |
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| FROM ADDITIONAL WIRE DRIVE |
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| GAS | THRU CONTROL BOX WHEN |
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| CONFIGURED AS A BENCH FEEDER | |
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| SOLENOID | |
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| WITH J9 OPTIONAL OUTPUT | |
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| 553 |
| RECEPTACLE. |
551 | L11 |
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551 | W |
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| L12 | MOTOR |
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550 |
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550 | B |
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| VOLTAGE SENSE |
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| SELECT PCB |
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512B | 1J1 |
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| (SOLID STATE) |
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| CR1 |
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511 | 4J1 |
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| 67 | J6 INPUT |
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| 2J2 | |
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| CR1 | RECEPTACLE |
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67A |
| 67 | ELECTRODE VOLTAGE |
| 3J1 | 1J2 | C SENSE TO WELDER |
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67 | 67 |
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STATUS LED (HIGH FOR RED) - | 14J4 |
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| 512B |
| UPPER OPTION PANELS. |
+12 VDC - | 1J5 |
| SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN. | |
565 |
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* MOSI - | 2J5 |
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564 |
| DUAL PROCEDURE PANEL KIT | ||
* MISO - | 3J5 |
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500F |
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0 VDC - | 4J5 |
| DUAL PROCEDURE / MENORY PANEL KIT | |
566 |
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* SCK - | 5J5 |
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567 |
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* LATCH - | 6J5 |
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568 |
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PROC. A - | 7J5 |
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569 |
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PROC. B - | 8J5 |
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- | 9J5 |
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- | 10J5 |
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| 512A |
| LOWER OPTION PANELS. |
+12 VDC - | 1J3 | 558 |
| SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN. |
* MOSI - | 2J3 |
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557 |
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* MISO - | 3J3 |
| CV/GOUGE PANEL (STD) | |
500D |
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0 VDC - |
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4J3 |
| "M" PANEL KIT | ||
559 |
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* SCK - | 5J3 |
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560 |
| "MSTT" PANEL KIT | ||
* LATCH - | 6J3 |
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511 |
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POT SUPPLY - | 7J3 |
| "MX2" PANEL KIT | |
561 |
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POT WIPER - | 8J3 |
| "MSP2" PANEL KIT | |
562 |
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MODE 1 - |
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9J3 |
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563 |
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MODE 3 - | 10J3 |
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500E |
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POT COMMON - | 11J3 |
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- | 12J3 |
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ADDITIONAL WIRE DRIVE |
NOTES:
OPTIONAL OUTPUT RECEPTACLE IS REFERENCED (J9) ON WIRE DRIVE AND (J8) ON USER INTERFACE CONTROL BOX.
Return to Master TOC
WIRE COLOR CODE
B = BLACK
U = BLUE
R = RED
W = WHITE
G3602
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
