Lincoln Electric POWERWAVE 655/R Service Manual page 120

G3498-2
ENGINEERING CONTROLLED ADDED LABEL SHEET TO PRINT NOTE.
CHANGE DETAIL:
MANUFACTURER: No
TO J9
202
ETHERNET 1
TO
CB1 BOARD 2 CONTROL BOARD
J47
202A 3
TO R1 4
-
5
6
7
C1
8
J70
.05/600V
9
L2 10
L5
11
TP1 J1
WORK
- 12
13
14
15
TO 16
A
53
J2VS 1
S1
B 54
J73 2
WIRE
J47 3
C 67A
FEEDER
CB1 4
RECEPTACLE 5
D 52
J71 J2
6
7 N.E.
E 51
8
9
S2 10
1 743
VOLTAGE 1 TO
L4 2 741
J72 J81
2 TO J3
SENSE 3 800
21A
3 J9
4 840
RECEPTACLE 4
1 TO
53
S1
2 54
J73
3 CONDUCTOR 3
1
TWISTED/SHIELDED
SHIELD GROUND TO CASE 4
2 253
3 254 1
J74
4 2
S3
5 TO 1 892
RS232 6
J2 2 893 TO
CONNECTOR 7 251 S5
3 J4
J75
4
891
20
5 894
6
CB1
52 TO 1
10A CIRCUIT
L2 830
2
J76
BREAKER
J47 3
50
4
1 J5
2
TO
N.E. 3
TP3 WORK
4
ELECTRODE
5
J77
6
7
EARLIER MODEL
8
S4 115V
9
115V RECEPTACLE
10
(NEUTRAL FLOATING) 1 J6
RECEPTACLE
2
(NEUTRAL BONDED)
3
4
31 32
5
32A J79
32A 6
7
32 34
8
TO
33 9
S4
CB2
AUX 2 10
AUX FAN
1
2
TO 3
N.E.
AUX 2 4
J710
CB2 5
AUX FAN
6
J7
7
S5
8
DEVICENET 1
CONNECTOR 202A
N.E. 2
1 3
TO
R 4
+24V 2 894 TO 50 J712
1 WORK
5
+24V GND 3 893 J75
ELECTRODE
6
CAN_H 4 892
CAN_L 5 891 206A 7
8
AUX. DRIVER BOARD
S6
J8
ROBOTIC/ 1 222
2 222A
WIREDRIVE
CB2 3 503 TO
INTERFACE 4 506 J4
10A CIRCUIT
302
RECEPTACLE 5 J6
BREAKER J1AD
6 225 J40
7 225A J42
A 841 34 J9
TO 403 J50
8
B 844
S4
9 406
C 842
33 AUX 2
10 301
D 843
J10A
E 845 VOLTAGE SENSE
F 846
J10B
D6 SELECT BOARD
G 847
H +40VDC
I 67B
TO DIODE 1 512 J11
J 539
J83
2
K 541 J84
67B TO
880 3
L J2VS
TO J1 J9
4 511
M J83 J85
5
N 521 AC AC 886
6
1
P 522 67A TO
J2
2 67 S1
S6
R
S
T GND-A
U
V
W
TO J9
X
206
S7 +
1B
1W N.D.
12 PIN STATUS LED (R/G)
CONNECTOR
TO J7 TP2
1 1 851 2B 2W
N.A.
2 2 852
TO R1
THERMAL LED (Y)
3 3 853
206A
TO J7
4 4 854
+
5 5 855
TO
6 6 856 ELECTRODE
7 7 857 J85
TO RECONNECT PANEL
(TOP)
8 8 858
NOTES:
A
9 9 859
LOAD LINE N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE) ALIGNS WITH BLACK LEAD OF LED SOCKET.
10 10 860 TO J61 TO CONTACTOR
11 11 861 H1D L3A N.B. CTs MUST BE ORIENTED IN THE PROPER DIRECTION. TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED
862
12 12 SIDE OF CT TO THE SWITCH BOARD. THE ARROW ON THE CT SHOULD POINT FROM THE SWITCH BOARD TO THE TRANSFORMER.
SW1
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.
POWER
GND-B
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH BLACK LEAD OF LED SOCKET.
TO CB3 A
GND-A
612B L1A N.E. ON SYNCHRONIZED TANDEM MIG APPLICATIONS J77, J712 OF THE ETHERNET BOARD AND J3, J7 OF THE CONTROL BOARD ARE USED.
SEE S26631 FOR DETAILS.
This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
TO
1 FEED HEAD 3R TO 3W J8
DIGITAL POWER SOLID
J7
2 BOARD
SUPPLY BOARD STATE
3
4 1 743 RELAY 4 -
+ 3
1
5 741 TO 225
2
J81
6 J72 2 223 TO
3 800
7 3 221
4 840 J42 J4
8 4 227
J1AD
9 153 5 222
1
TO
10 6
2 154
2 1
11 J82 J11
3 500 1 475
12 J47
4 540 2 477 TO
13 J41
J47
3 476
14
1 539 444 TP4 X3A
4 478
15 541
2 1
TO
16 521 TO FAN TO AUX#1
3
J83 S6 2
1 522
251 4
3 268A TO
2 886 D6
5
4 226 J4
TO 880
3 253 6
5 274
S3 J11
4 254
6 266
1 841 R5
1 J43
7
842 224A
2
2 8
843
3 TO
3 228 CHOKE
9
4 844 TO RECT THERM
4 S6 273 THERM.
J84 10
5 845
5 11 267
291
6 846
6
12 262
7 847
7
8
8
9
1 851
10 DC BUS
852
2
1 BOARD
267 853
3
OUTPUT RECT
2 266 854
TO 4
3 268 855 1 2.7
J1AD 5 POS .022
4 J42 856 TO 10W
6 2 POS 800V
J46
5 228 J43 857 TO C3
7 3 NEG
R5
6 226 858
8 S7 4 NEG D4A
J85
7 227 9 859
J1VS
8 221 860 1 51
10 S4
9 2 500
11 861 TO
10 222A 3 50
12 862 CB1
11 223 4 540 S4
13 512 J47
J41
12 225A 5 475
14 511
J82
TO 6 476
1 15
S1
7 477 D4B
2 RECT 16
224
8 478
THERM THERM
3 220 S4
1
4
1 2
231
3 S4
2 232 2.7 .022
4
3
10W 800V
5 220A
4 J86 DC BUS
6 D3A
5 504 THERM
TO
7
6 302
J40
8 S3
7 292
J50 9
8 405
J60
10 292
238
9 J1AD
220A S3
10
505
1
11
2 262
12
604 D3B
3
13
4
14
301 268 S3
5 R5
15 268A
6
404
16
7 TO
S3
1
8 J4
J87
2 9 J43
TO J5
3 1W 10
4 1B 11
220
TO 12
5
6 LED 224 RECT.
13
2W
7 14 TO THERM.
8 2B POWER BD
15 C3 224A .022
291
RECTIFIER
9 16 AUX 1 2.7
800V
10
10W
TO
11 POS D2A
CHOKE
12
THERM
S2
13 AC AC X2
TO
14 SSR
15 3R 3R
S2
16 3W NEG
1 211
2 212 X1 D2B
TO
3 213
P90 S2
4
813
P91
5 NEG
811
216 NEG
6
NEG S2
C3
7 816 2.7 .022
POS
8 812 POS 10W 800V
1
206 POS
D1A
TO J1 VOLTAGE SENSE
2
WORK
3 202 S1
ELECTRODE TO
4 67 S2
J46
5
POWER BD RECT
6 21A S1
1 414 R
TO CT #1
2 418 W
1 514 R D1B
2 TO CT #2
518 W
1
154 S1
TO
2
J43
3 273
J82
4 274 S1
AUX.
32A
FAN
352A
TO
J8
C2
.05/600V
P91
CURRENT
TRANSDUCER
TO TP3
+
PRINT DIAGRA M T O 10 X 15.5 ON E3269-9 LABEL SHEET
TM
POWER WAVE 655/R WIRING DIAGRAM
LEFT SIDE OF MACHINE
812 812 1
P90
813 2
(NOT USED)
811 3 4
816 AUXILIARY TRANSFORMER #1
W
H6
X1
H6A
(550-575)
H6
(51V)
H5
X2 H5
U
(440-460)
H4
H4
(380-415)
X3
W H3
X3 H3
(220-230)
(24V)
N H2
TO POWER BD. RECTIFIER TO
X4 H2
(200-208)
CR1
(115V)
R H1
H1
J60 X5
MAIN CHOKE TO FAN
L1
X3A
TO SOLID STATE RELAY
THIS AREA VIEWED FROM LEFT SIDE OF MACHINE
SWITCH BOARD #1 (LEFT)
MAIN TRANSFORMER
1
LEFT SIDE
2
TO J1AD
3 403
J40
4
16 16 404 TO J6
5 405
6 406
SECONDARY
PRIMARY
(TOP (TOP
LEFT) LEFT)
18
+ +
12 C4 C5
11
SECONDARY PRIMARY 13 12 14
(BOTTOM
(BOTTOM
C POS C POS
LEFT) LEFT)
14
12
11
N.B.
CURRENT
TRANSFORMER
414 418
RED WHITE
#1
12
N.B.
16 TO
CURRENT
J10A
TRANSFORMER
#2
15
514
518
RED
WHITE THIS AREA VIEWED FROM RIGHT SIDE OF MACHINE
SWITCH BOARD #2 (RIGHT)
SECONDARY PRIMARY
(BOTTOM (BOTTOM
RIGHT) RIGHT)
1
2
TO J1AD
17
3 503
J50
4 504
TO J6
505
5
6 506
11
PRIMARY
SECONDARY
(TOP (TOP
RIGHT)
RIGHT)
+ +
13
C6 C7
16 18 15 17
C
NEG NEG C
RIGHT SIDE
TO
J10B
TO
H6
S8 5 H6A
(550-575)
W
350 1
1
32 (115V) R
33A
4
P50
33
4 (230V) B
352 2
6
352A
TO S4,
H1
AUXILIARY H1A
CB2, 1
TRANSFORMER #2
AUX. FAN
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
RIGHT SIDE OF MACHINE
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
COMPONENT VALUES:
W=WHITE
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
CLEVELAND, OHIO, U.S.A.
PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
CONTROL: CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm) DRAWN BY: RAS
ON ALL ANGLES IS ± .5 OF A DEGREE
PW
MATERIAL TOLERANCE (" ") TO AGREE t ENGINEER:
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: -
CB3
3.5A
CIRCUIT
BREAKER
TO AUX #2
H1A
H1B
TO INPUT SWITCH N.L.
612B
10A
TO J61
TO 612 FUSE
AUX #2
CB4
TO AUX #1
RECONNECT PANEL H1
TO SOLID STATE RELAY
444
X5
FAN
TO AUX#1
THIS AREA VIEWED FROM REAR OF MACHINE
RECONNECT PANEL
TO SW1
'A' 380-415V
H4
H5 440-460V
H6 550-575V
N.C.
TO AUX #1
1
350
352 2
TO AUX #2
33A 3
4
S8
WATER
COOLER
INPUT BOARD
TO SWITCH TO SWITCH
RECEPTACLE
BD #2 BD #1
NEG POS
1
601
2 X3
L6
3 238 TO
4 604 CR1
J60 HARMONIC
5
232 AUX #1
6 J6 FILTER
7
8 231
1 NEG INPUT POS
2 T1 RECTIFIER
3
4 T2
TO NEG POS
5
J61 CR1
6 612
SW1
7
CB4
AC3 AC2 AC1
8 H1D
9
10 T3
TO J61
T3 T2 T1
TO J60
601
CR1
X4
TO AUX #1 L3 L2 L1
TO SW1
TO SW1
L3A L1A
W V
U
G
TO SUPPLY LINES
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS FRONT REAR FAN
RECONNECT RECONNECT
HORIZONTAL HORIZONTAL SHROUD SHELL BRACKET
BAFFLE BAFFLE
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2
6
CASE FRONT REAR AUX. AUX.
UPPER UPPER 2 1
FRONT
7 12 BASE BASE
LATCH
PROTECTIVE BONDING CIRCUIT B
VIEW OF CONNECTOR ON PC BOARD
G3498-2PRINT
SCALE:
EQUIPMENT TYPE: POWERWAVE 655/R
1 1
PAGE ___ OF ___
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DOCUMENT
IF PRINTED SUBJECT: WIRING DIAGRAM DOCUMENT
NUMBER: REVISION:
@ A1 SIZE
B
G3498-2
UNITS: MATERIAL REFERENCE:
APPROVAL 7-13-2007 PROJECT
INCH UF CRM38675
DISPOSITION: DATE: NUMBER: G3498-1
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