ELECTRICAL DIAGRAMS
G-3
G-3
WIRING DIAGRAM - ENTIRE MACHINE - CODES 10957 - 11311 (G4420)
NOTE: 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.
POWER WAVE 455M/MSTT
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-
TO J9
202
WORK
202A
TO R1
TO TP6
S1
ARCLINK
RECEPTACLE
+
ELECTRODE
223
221
206A
R3
C8
TO D5
289D
R2
2
Ω
288C
288D
289E
288E
J1
4
5
3R
3R
3W
238
5
J10
TO
STATUS
LED
RECT
THERM
223
222
CHOPPER BOARD
SEC
(BOTTOM
LEFT)
POWER BD
RECTIFIER
AC
EMITTER
212
213
813
811
216
4
CONTROL BOARD
+
TO J61
CR1
X4
6
TO AUX #1
5
0
3
5
0
4
5
0
5
5
0
6
INPUT
20D
17
18
15 16
F1
F1
TO
CB1
J41
1
4R
J4
251
20
C
J47
TO
P90
P91
RECT
292
1
2
3
4
SEC
(TOP
LEFT)
6
U
L1B
V
L3
AC
3
TO
CR1
SW1
CB4
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
CURRENT
TRANSDUCER
TO C8
19D
SWITCH BOARD
#2
289A
-
+
288B
TO C10
SW1
POWER
C10
289F
A
202
225
J7
2
5
J2
206
52
J5
34
TP6
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
2
Ω
TO C10
289B
NEG
STT
X1
+
G
601
TO J60
L1
20
NEG
19C
T1
TO
HARMONIC
FILTER
REAR OF MACHINE
TO J6,J10B
6
TO SOLID STATE RELAY
3
2
TO SOLID STATE RELAY
444
FAN
THIS AREA VIEWED FROM
288F
RECONNECT
PANEL
TO
CR1
J6
231
AUX #1
J61
5
6
7
8
9
POS
D1
H1
50
CB1
10A CIRCUIT
BREAKER
R1
TP3
TO R1
CB2
10A CIRCUIT
BREAKER
1B
TP2
206
TO J9
202A
TP5
33
206A
NEG
7
PRI
(BOTTOM
RIGHT)
TO
SWITCH
BD #2
15
14
12
18
TO
SWITCH
BD #1
TO
SWITCH
BD #2
MAIN
TRANSFORMER
LEFT SIDE
X2
NEG
1
POS
2
3
C3
J2
.05/600V
2W
403
288A
2
1
6
2B
511
604
H1A
TO AUX #2
CB3
3.5A
BREAKER
TO SW1
200-208V
220-230V
440-460V
550-575V
POS
POS
AC
1
TO SUPPLY LINES
S2
VOLTAGE
SENSE
RECEPTACLE
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
S3
RS232
CONNECTOR
F
R
O
N
T
O
F
M
A
C
H
IN
E
115V
RECEPTACLE
TO RECONNECT PANEL
1
2
J74
J76
PRI
(BOTTOM
LEFT)
20C
+
+
TO AUX #1
4
0
4
4
0
5
4
0
6
21A
2
51
3
4
54
E
53
3
1
67A
TO C3
4
J46
3
2
1
POS
POS
DC BUS BOARD
12
J41
C6
50
Ω
C2
N.D.
.05/600V
STATUS LED (R/G)
TO J7
N.A.
THERMAL LED (Y)
TO J7
1W
TO
J4
J11
C4
13
14
+
SWITCH BOARD
#1
1
4
5
X3A
19
TO FAN
X1
224A
291
CB3
TO J61
TO INPUT SWITCH
612B
612
H1
TO AUX #1
AUXILIARY TRANSFORMER #1
SEC
(BOTTOM
RIGHT)
TO
SWITCH BD #2
POS
TO
SWITCH BD #1
11 12
20D
TO
SWITCH BD #2
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 CB4
612B
L3A
J
TO CONTACTOR
S4
TO TP3
32
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
H1
H2
H3
812
813
287
811
816
F3
F3
+
+
F2
F2
19C
17
11
TO
SWITCH
BD #1
5
1
4
1
AUXILIARY 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
1
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
512
4R
4
3
4W
2
1
VOLTAGE SENSE
SELECT
BOARD
TO
SWITCH BD #1
D4
J40
F4
4
0
3
F4
THERM
1
2
3
4
1
2
3
4
J72
J75
WIRE DRIVE INTERFACE
MODULE
BOARD
11
J42
TO J5
6
5
4
3
2
+
225
1
SEC
(TOP
RIGHT)
2
3
5
J50
C5
J60
10
10
9
8
7
6
5
4
273
3
228
274
226
TO J8
4
1
2
J43
251
253
254
NEG
DIGITAL POWER
SUPPLY BOARD
3R
TO
3W
J7
MAIN CHOKE
221
4
3
231
232
291
X3A
.05/600V
C1
TP1
TO C8
288A
345
287
TP7
RECTIFIER
SWITCH
RECONNECT
TO
16
4
1
4
H4
'A
'
LEFT SIDE OF MACHINE
RECONNECT SWITCH
6
5
1
1
TP4
444
TO FAN
TO
J47
475
477
1
2
476
216
478
211
3
213
212
4
W
W=WHITE
U=BLUE
R=RED
COMPONENT VALUES:
N=BROWN
R
E
A
R
O
F
M
A
C
H
IN
E
G=GREEN
B=BLACK
LEAD COLOR CODING
TO
CB3
ELECTRICAL SYMBOLS PER E1537
H1A
AUX #1
L3B
X5
TO AUX#1
2
1
OUTPUT
RECT
D2
J6
5
6
253
7
2
254
8
3
9
4
B
A
TO J46
1
2
3
4
POWER BD RECT
1
2
3
4
J10A
J11
812
TO
886
880
TO J8
X2
U
TO
J42
J43
TO POWER BD.
RECTIFIER
(51V)
(380-415)
X3
W
H3
TO
X3
AUX #2
X5
RECONNECT PANEL
TO
MAIN TRANSFORMER
TO D5
3
4
-
TO
J4
SOLID
STATE
RELAY
2
1
W
H5
(440-460)
H4
H5
2
Ω
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
DIODE
.022
800V
2.7
10W
2.7
10W
.022
800V
N.C.
N.J.
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
52
CONNECTOR
DEVICENET
5
1
4
2
3
I/O
RECEPTACLE
3
4
2
1
5
6
ROBOTIC/WIREDRIVE
INTERFACE RECEPTACLE
CIRCUIT
10A
FUSE
J83
D6
P90
P91
J82
N.B., N.G., N.H.
67C
67B
1W
1B
892
892
851
852
853
854
855
856
54
53
222
891
7
8
9
10
857
858
859
860
3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE
L4
2B
2W
+40VDC
267
266
268
THERM
S5
S6
S7
GND-B
267
266
268A
893
894
227
227
WATER
COOLER
RECEPTACLE
2
1
350
352
N
A
B
C
D
E
F
G
H
J
K
L
M
539
541
521
522
BLACK
847
11
12
861
862
J82
154B
153B
4
3
2
1
51B
52B
WHITE
J84
6
5
1
2
3
4
847
8
7
880
886
522
521
541
539
J83
6
5
1
2
3
4
856
855
854
853
852
851
J85
6
5
1
2
3
4
857
8
7
511
512
862
861
860
859
9
15
12
16
14
13
11
10
858
H6
(550-575)
H6A
H6
TO
CR1
J60
CHOKE
THERM
TO RECT
THERM
TO
RECONNECT
SWITCH
H6
5
(550-575)
H6A
P50
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
S8
20µF
400V
20µF
400V
+24V
+24V GND
CAN_H
CAN_L
4
1
8
5
1
8
800
840
1
518
2
414
J10B
TO
SSR
405
404
893
891
894
1
2
3
4
J73
6B
6W
743
741
800
840
AC
AC
346
345
830
R5
TO
262
268
268A
R5
220A
292
262
R5
W
R
4
1
(115V)
TO
S4
CB2
350
352
P52
4
32
33
1
6
33A
2
(230V)
3
4
33A
224A
224
220
220A
TO
J4
J43
TO RECT
THERM
TO
AUX #2
S1
100V
2400
µ
F
500V
3500
µ
F
500V
3500
µ
F
19
20
HARMONIC
FILTER
20C
19D
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
ALIGNS WITH WHITE LEAD OF LED SOCKET.
2
4
5B
5W
6W
6B
53A
54A
67
52A
51A
J16
MODULE
INTERFACE
CONNECTOR
3
4
5
1
6
J81
741
743
4
3
2
1
L2
GND-A
67C
153B
154B
51B
52B
L8
L9
L7
L5
L6
STT SNUBBER
RESISTOR BANK
STT SNUBBER
CAPACITOR BANK
STT CURRENT
TRANSDUCER
D5
STT SNUBBER
DIODE
TO
HARMONIC
FILTER
RED
BLACK
BLACK
BLACK
GREEN
WHITE
BLACK
RED
BLACK
GREEN
H1B
.0047/3KV
C11
ETHERNET
S9
CB2
5A CIRCUIT
BREAKER
351
352A
32
S4
220V RECEPTACLE
CE Model
ETHERNET / DEVICENET OR DEVICENET MODULE
MODULE
TO CONTACTOR
C
B
A
INPUT
LINE
FILTER
L3A
.0047
µ
F
440
C6
C7
L1A
SWITCH LEAD
FILTER
L3
FRONT
HORIZONTAL
BAFFLE
REAR
HORIZONTAL
BAFFLE
FAN
SHROUD
RECONNECT
SHELL
RECONNECT
BRACKET
CASE
FRONT
FRONT
UPPER
BASE
REAR
UPPER
BASE
AUX.
2
AUX.
1
PROTECTIVE BONDING CIRCUIT
352A
P51
N.E.
N.F.
N.G.
H4B
N.J.
N.E. LEAD 33 IS PRESENT IN MODELS WITH 115V RECEPTACLE
ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN
MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.
N.F. ONLY PRESENT ON "CE" MODELS.
N.G. ONLY PRESENT ON NON-CE MODELS.
N.H. "CE" MODELS DO NOT HAVE A RECONNECT SWITCH. POS LEAD
CONNECTS DIRECTLY TO (+) OF C4. LEAD C CONNECTS
(-) OF C4 TO (+) C5 AND NEG LEAD CONNECTS TO (-) OF C5.
N.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD
LEAD H4B CONNECTS H4 TO SW1.
N.K. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS
A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT
RECTIFIER TERMINALS RATHER THAN CR1.
N.L. 10 AMP CIRCUIT BREAKER IS USED IN PLACE OF FUSE ON CODES
BELOW 11150.
N.M. ON SYNCHRONIZED TANDEM MIG APPLICATIONS J77, J712 OF THE
ETHERNET BOARD AND J3, J7 OF THE CONTROL BOARD ARE USED,
SEE S26631 FOR DETAILS.
TO SW 1
J1 & J3
ARE NOT USED
153B
154B
67B
52B
51B
51A
53A
54A
67A
52A
CASEFRONT
67
CONNECTOR
ONLY PRESENT IF FEEDHEAD
MODULE IS NOT PRESENT
ONLY PRESENT IF FEEDHEAD
MODULE IS PRESENT
J70 & J71
ARE NOT USED
GND-A
FEEDHEAD
TO
THERMAL
LED
OR
67
TO TP3
N.D.
L10
J710
ETHERNET
PORT
RJ 45 TYPE
THE ETHERNET CONNECTION
IS ONLY PRESENT IN THE
ETHERNET / DEVICENET MODULE
CASEFRONT
PANEL
N.D.
TO
J40
J50
TO
J43
TO J47
TO
J2
TO
J20
J40
J50
N.F.
N.F.
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PC BOARD
1 2
6
7
12
LATCH
EX. 12 PIN CONNECTOR
1
3
8
7
6
5
475
476
477
478
50
51
TO WORK
TO ELECTRODE
3
4
5
1
6
J16
OR
TO WORK
153B
154B
52B
51B
OR
TO MAIN
TRANSFORMER
TO RECONNECT
SWITCH
LEGEND
DASHED " " = STT MACHINE ONLY
PHANTOM " " = OPTION
N.L.
32
CB2
10A CIRCUIT
BREAKER
33
115V
(EARLIER MODEL)
31
RECEPTACLE
(NEUTRAL BONDED)
(NEUTRAL FLOATING)
LOAD
LINE
1
2
3
4
5
6
7
J3
8
9
10
N.M.
N.M.
J77
1
3
2
9
8
7
6
5
4
N.M.
10
J712
6
5
1
3
4
8
7
2
N.M.
G4420
J
N.K.
