Lincoln Electric IM690-A manual Diagrams, Power Wavetm 455 / R Wiring Diagram

Page 36

POWER WAVE 455/R

POWER WAVETM 455 / R WIRING DIAGRAM

				TO TP6											CONTROL BOARD																					LEFT SIDE OF MACHINE
				202	TO J9						TO	DEVICE NET			CONTROL BOARD													3R	J7	3W
					TO TP3						TO	DEVICE NET				1												3R	J7	3W
												GATEWAY						FEED HEAD				DIGITAL POWER							TO
											CB1	GATEWAY				2		FEED HEAD				DIGITAL POWER
				202A							J47	BOARD				3			BOARD			SUPPLY BOARD						+ 3		4 -																							TO SW1				CB3
				202A									1			4				1	743																																	612B
			-	TO R1									1			4				1	743				1												AUXILIARY TRANSFORMER #1																	612B
			-										2			5				2	741	TO			1	225	TO										AUXILIARY TRANSFORMER #1																				10A
		WORK											3			6			J81	3	800	J72			2	223	J4 SOLID									X1	W	H6			H6A													TO CB4		CIRCUIT
		WORK											4			7				4	840		J42		3	221	STATE									X1	(51V)	(550-575)			H6A													612A		CIRCUIT
																8							J42		4	227	STATE										(51V)	H5			H6															BREAKER
				C1						L5		L2	5		J1	9				1	153				5	222	RELAY									X2	U	(440-460)			H5A													H1A
				.05/600V									6			10				1	153	TO			6			2		1								H4			H5												TO AUX #2
				.05/600V									7			10				2	154	TO			6			2		1								H4			H4A
			TP1										8			11			J82	3	500	J11			1	475										TO POWER BD.		(380-415)			H4				TO									TO J61		CB4
		S5										J70	9			12				4	540	J47			2	477	TO									RECTIFIER					H4				AUX #2									CB3
												J70	9			12				4	540	J47			2	477	TO									RECTIFIER									AUX #2									CB3
													10			13				1	539		J41		3	476	J47	444	TP4	X3A						X3	W	H3			H3A				CB4									612A		6A
		DEVICENET											11			14				1	539				4	478										X3		(220-230)			H3A				RECONNECT PANEL									612		CIRCUIT
		CONNECTOR							A	53			12			15				2	541				1		TO FAN TO AUX#1							224A		X4	(24V) N	H2			H3															BREAKER
		1		TO					A	53	TO		12			15				2	541	TO			1	346	TO FAN TO AUX#1							224A	CHOKE		(24V) N	H2			H2A													H1		BREAKER
		1		TO		S1					TO		13			16				3	521	TO				346									CHOKE			(200-208)			H2A													H1
+24V		2	894	J75		S1			B	54	P73		14			1	251		J83	4	522	S6			2	268A	MAIN CHOKE				TO RECT				THERM	X5	(115V) R	H1			H2												TO AUX #1
						WIRE					J2VS											D6			3	268A	MAIN CHOKE									X5					H1
+24V GND 3			893			WIRE			C	67A	CB1		15		J2	2	253	TO		5	886				4	226	TO		L1		THERM			291	TO				TO FAN														TO SOLID STATE RELAY
CAN_H		4	892			FEEDER					J47		16			3	253	TO		6	880				5	274	J4								TO																			444
CAN_L		5	891	RECEPTACLE					D	52	J47		1			4	254	S3							6	266	J11								CR1
CAN_L		5	891	RECEPTACLE					D	52			1			4	254			1	841		J43		6	266	R5			P91					CR1																						FAN
													2			1				1	841		J43		7	345				P91					J60																						FAN
		S6							E	51			3			2				2	842				8		TO J8	216		4
									E	51						2				3	843	TO																X3A
																				3	843	TO
												J71	4			3			J84	4	844	S6			9	228		211		3	+		CURRENT																					X5
ROBOTIC/												J71	5			4			J84	5	845				10	273		213		2	+		CURRENT					TO SOLID STATE RELAY																TO AUX#1
WIREDRIVE													6		J3	5				6	846				11	267		212		1		TRANSDUCER														THIS AREA VIEWED FROM
WIREDRIVE													7		J3	6				6	846				12	262	TO J5	212		1																THIS AREA VIEWED FROM
INTERFACE											TO		8			7				7	847						TO J5																				REAR OF MACHINE
INTERFACE											TO		8			7				8														MAIN													REAR OF MACHINE
RECEPTACLE											S1		9			8								DC BUS			224																								N.B.
RECEPTACLE													10			9				1	851			DC BUS			224											TO J6,J10B													N.B.
							S2						1	743	TO	10				1	851			BOARD		TO C3	220		OUTPUT			TRANSFORMER
							S2						1	743	TO	1				2	852					TO C3	224A		OUTPUT					LEFT SIDE												RECONNECT SWITCH
A			841			VOLTAGE			1	L4		J72	2	741	J81	2	267			3	853				1	POS	220A		RECT																	RECONNECT SWITCH
B			844			VOLTAGE			2		TO		3	800		2	266			4	854				2	POS																			TO
C			842			SENSE			3	21A	J9		4	840	TO	3	268			5	855		J46		3	NEG				292						16						13			SWITCH BD #2						TO			RECONNECT
D			843	RECEPTACLE					4				1	53		4				6	856																	414	418	403 404 405 406		13									SWITCH BD #1			RECONNECT
E			845	RECEPTACLE								J73	2	54	S1	5	228			7	857	TO			4	NEG	TO		RECT									414	418	403 404 405 406		14				19D					19C			PANEL
F			846										3		J4	6	226		J85	8	858	TO			1	51	CHOKE		THERM																						19C					TO SW1
F			846	3 CONDUCTOR									3		J4	6	226		J85	8	858	S7			1	51	THERM							SEC	PRI	TO																				TO SW1
G			847	TWISTED/SHIELDED					1				4			7	227	TO		9	859	S7			2	500				291				SEC	PRI	TO
G			847	SHIELD GROUND TO CASE					1	253			4			7	227	TO		9	859				3	50	TO			291				(TOP	(TOP	SWITCH										POS										N.C.
H									2	253		J74	1			8	221	J42		10	860				3	50	TO							(TOP	(TOP	SWITCH		1	2 3 4 5 6							POS										N.C.
I			67B	TO					3	254		J74	2			9		J43		11	861		J47		4	540	CB1							LEFT)	LEFT)	BD #2		1	2 3 4 5 6						TO									TO AUX #1			200-208V
I			67B	TO			S3		3	254			2	892		9	222	R5		11	861	TO			4	540	J41																		TO									TO AUX #1			200-208V
J			539	J83					4				1	892		10	222	R5		12	862	TO			5	475	J41			D4															INPUT RECT									H2			220-230V
J			539	J84					4		TO		2	893	TO	11	223			12	862	J1VS			6	476	J82			D4																								H2		'A	220-230V
K			541	J2VS		RS232			5		TO		2	893	TO	11	223			13	512	J1VS			6	476	S1				F4																				TO			H3			380-415V
L						RS232			6		J2	J75	3		S5	12	225			14	511				7	477					F4					18															TO			H4			440-460V
M				CONNECTOR					7	251		J75	4	891		1		TO		15					8	478										18				J40											SWITCH BD #1			H4		'	440-460V
M				CONNECTOR					7	251			4	891		1		TO		15					8	478														J40											20C			H5		'
N			521										5	894	J5	2	224	RECT		16					220A						F4						SWITCH BOARD									20D					20C			H5
									20				6		J5	3	220	THERM				DC BUS			220A		TO RECT										SWITCH BOARD								TO
P			522										1	830		4				1		DC BUS					THERM									12			#1						SWITCH BD #2
							CB1					J76	2	830		1	231			2		THERM			292											12															NEG
R										52	TO	J76	3			1	231			2					292																										NEG
R										52	TO		3			2	232			3				CHOPPER		BD	2.7 10W													+	3500μF										TO
S						10A CIRCUIT					L2		4			2	232			4																				+	3500μF										INPUT RECT
S			GND-A			10A CIRCUIT					L2		4			3				4											.022				PRI	TO				C4	500V										INPUT RECT
T			GND-A			BREAKER				50	BUSS BD					4			J86	5				COLLECTOR							.022				PRI	TO				C4	500V															350	1	S8
U						BREAKER				50						4			J86	6				COLLECTOR							800V (BOTTOM				(BOTTOM SWITCH																					350	1	S8
V																5	504	TO		7					1		TO D5							LEFT)	LEFT)	BD #1	11	12																		352	2	WATER
V																6	503	J20		7		345					TO D5										11	12			TO
W																6	503	J20		8		345					287			D3											TO													TO
X																7	406	J40		8		4R			2					D3									20C 19C MAIN TRANSFORMER															TO			3	COOLER
X											TO					8	405	J50		9		4R			3	J10	TO C8																											AUX #2			3	COOLER
										TP3	TO				J6	9	238			10		346			4	J10	TO C8				F3					14																				33A	4	RECEPTACLE
										TP3	WORK				J6	9	238					346			4		289A				F3					14																				33A	4	RECEPTACLE
											ELECTRODE					10	505			1					5												15 16 11	12		TO RECONNECT SWITCH
		S7														11				1		4W			6		289B				F3						15 16 11	12		TO RECONNECT SWITCH
		S7														12	604			2				EMITTER			TO C10
MACHINEOFFRONT		12 PIN					S4				TO		5		J85	13	3W			3		TO		EMITTER										(TOP	(TOP	SWITCH			514	518 503 504 505 506							2		T1										REAROFMACHINE
	CONNECTOR						S4									14	506			4
		1	851				115V									15	403			5					262											15
		1	851			RECEPTACLE				TP6	TO					16	404			6					262		TO			2.7 10W						15									INPUT BOARD
		2	852			RECEPTACLE				TP6	WORK									7							J4				.022														INPUT BOARD
		3	853								STT					1			J87	8					R5	268	J43				.022				PRI												1
		4	854								STT					2			J87	9		TO			R5	268A					800V				PRI	TO											1		601
		5	855	TO												3	1W			10		ROBOT		POWER BD										SEC	(BOTTOM SWITCH												2		X3	TO
		6	856	TO												4	1B			11		IFACE		POWER BD									(BOTTOM		RIGHT)	BD #2											3		238	TO
		7	857	J85			31			32						5		TO		12				RECTIFIER						D2				RIGHT)											J60		4		604	CR1
		8	858				31			32						6		SSR		13										D2															J60		5		232	J6
		9	859								AUX 2	VOLTAGE SENSE			J7	7	2W	J10CH		14						POS	TO				F2					17				TO J6, J10B							6			AUX #1						TO
		11	861								AUX 2	VOLTAGE SENSE			J7	8	2B			15							TO													TO J6, J10B							7									TO
		10	860								TO	SELECT				8	2B			16		TO		AC	AC	X2	C3				F2																		231							SWITCH
		12	862								CB2	SELECT				10						TO		AC	AC	X2	C3				F2																8									SWITCH
												BOARD				9																															8								RECONNECT
												BOARD				11						D6					AUX. #1
																12						J47														11
			GND-B										1	512		12						S1				NEG										11
			GND-B										1	512		13	4W	TO				J11				NEG				TP7																								NEG		INPUT	POS
			GND-A										2			14	4R SSR, J10 CHOPPER BD.													TP7																										INPUT
			GND-A							202A			3	67	TO	15	3R									X1					2.7 10W											17													RECTIFIER
										202A			3	67	TO	15	3R									X1								SEC	PRI							17													RECTIFIER
												J1	4	511	J9	16																		SEC	PRI	TO						18					1
								Ω	R		WORK		6			1	211					J73			NEG									RIGHT)	RIGHT)	BD #1											3								NEG			POS
							50		R		WORK		6			2	212								NEG						.022																3								NEG			POS
									1		ELECTRODE		1	67A	TO	2	212	TO							NEG					D1	.022								1	2 3 4 5 6							4		T2	TO
												J2	1	67A	TO	3	213	P90						C3	NEG						800V																5			TO
										206A		J2	2	67B	S1	4	813	P91				+				POS					F1					13									J61		6		612	CR1					AC	AC		AC
															S6 J8	5	811									POS					F1					13											6		612	SW1					3	2		1
						CB2										6	216									POS														J50							7		H1D	CB4
						CB2				31	TO					7	816					2400μF				TO J46		287			F1									J50							8		H1D
					10A CIRCUIT						TO					8	812					2400μF				TO J46		287										SWITCH BOARD									9
					10A CIRCUIT						S4		D6			8	812					100V				POWER BD RECT				-				RIGHT SIDE				SWITCH BOARD									10		T3
						BREAKER				33	AUX 2		D6			1	206	TO J1 VOLTAGE SENSE												-				RIGHT SIDE						#2
													+40VDC		J9	2	202	WORK												+																							TO J61
													DIODE		J9	3	202	ELECTRODE												+	STT SNUBBER									+	3500μF												TO J61
																4	67	S2							STT CURRENT						STT SNUBBER									+	3500μF
						1B	1W	N.A.					880	TO		5	21A								STT CURRENT					288B	DIODE D5									C5	500V											TO J60		T3		T2		T1
								N.A.						TO		6	21A								TRANSDUCER					288B																						TO J60		T3		T2		T1
								STATUS LED (R/G)						J83		1	414	TO							TRANSDUCER				288A									15 16															601
								TO J7				AC	AC	886		1	414	TO											288A
						2B	2W	TO J7				AC	AC	886	J10A	2	418	J40,J50							TO J8		P90			TO C8 TO C10										20D 19D
						2B	2W	N.A.							J10B	1	514								TO J8		P90													20D 19D													CR1
								N.A.								2	518									812	1	+																									CR1
								THERMAL LED (Y)								1	154									813	2																										X4
								TO J7							J11	2	153									811	3														TO												X4
																3	273	TO								816	4										TO			RECONNECT												TO AUX #1			L3	L2		L1
																4	274	J43																			MAIN				SWITCH
							TO J9									4	274	J43												NOTES:							TRANSFORMER				SWITCH
							TO J9											J88												NOTES:																								TO SW1		TO SW1
							206																																															TO SW1		TO SW1
							206																							N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)																P50								L3A		L1A
																														N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)															H6	P50								L3A		L1A
																														ALIGNS WITH BLACK LEAD OF LED SOCKET.															H6		5	H6A
																														ALIGNS WITH BLACK LEAD OF LED SOCKET.															(550-575)		5	H6A						W		V	U
										C2			C6	TO TP6																N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT											P52			W	H5		6	H5A						W		V	U
										C2			C6																	N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT										350	P52			W	(440-460)		6	H5A							TO SUPPLY LINES
							TP2			.05/600V	TP5		.05/600V							TO D5										VOLTAGE. CONNECTION SHOWN IS FOR 380-460V									1	350	1		(115V) R		H4		3	H4A							TO SUPPLY LINES
							TP2				TP5				288D		289D			TO D5										OPERATION.							32		1				(115V) R		(380-415)		3
							TO R1								288D	R2	289D			288A																	33		4	33A	4		(230V)		H3		2	H3A			TO
							TO R1									R2				288C										N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR							33		4	352	2		(230V)		(220-230)						TO						G
							206A			TO TP3						2Ω					20uF C8	STT SNUBBER								INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-460V								2		352	2				H2		4	H2A			CB3						G
						+				TO TP3			+		288E	2Ω	289E			289A	400V	STT SNUBBER								OPERATION.															(200-208)						AUX #1
						+							+		288E		289E			289A		CAPACITOR BANK								OPERATION.							TO								H1		1	H1A			AUX #1
				ELECTRODE TO RECONNECT PANEL									STT			R3				289C																	TO										1	H1A						TO A SYSTEM GROUND PER
				ELECTRODE TO RECONNECT PANEL							(TOP)					R3				289C																	S4	AUXILIARY TRANSFORMER #2																TO A SYSTEM GROUND PER
									A		(TOP)				288F	2Ω	289F			288B																	CB2	AUXILIARY TRANSFORMER #2																NATIONAL ELECTRICAL CODE.
										TO J61	LOAD LINE	TO CONTACTOR			288F		289F			288C																								J2,J5,J11,		J1VS,J9,J10CH,			J8,
										TO J61	LOAD LINE	TO CONTACTOR								288C																								J2,J5,J11,		J1VS,J9,J10CH,			J8,
										H1D		L3A				R4				288D			RIGHT SIDE OF MACHINE												ELECTRICAL SYMBOLS PER E1537							J10,J2VS		J41,J46,J72		J14,J40J42,			J47,J60		J3,			J4,J13,				J1,J6,J7
										H1D		L3A				R4				288E																						J10,J2VS		J41,J46,J72		J14,J40J42,			J47,J60		J3,			J4,J13,				J1,J6,J7
																2Ω				288E	C10																						J74	J73,J76,J81		J50,J75,J83			J84		J61,J86			J43,J71				J10,J70,J85
							SW1								STT SNUBBER					289B	20uF														LEAD COLOR CODING										J82													J87
							SW1								STT SNUBBER					289C	400V														B=BLACK		COMPONENT VALUES:						1	1	J82	1	3		1	4	1	5	1	6	1		7	J87	8
						POWER									RESISTOR BANK					289C															B=BLACK		COMPONENT VALUES:						1	1	2	1	3		1	4	1	5	1	6	1		7	1	8
						POWER						TO CONTACTOR			RESISTOR BANK					289D															G=GREEN		CAPACITORS=MFD/VOLTS
										TO CB3		TO CONTACTOR								289E															N=BROWN		RESISTORS=OHMS/WATTS
										612B		L1A																							R=RED								2	3	4	4	6	5		8	6	10	7	12	8		14	9	16
																																			U=BLUE								2	3	4	4	6	5		8	6	10	7	12	8		14	9	16
																																			W=WHITE								CONNECTOR CAVITY NUMBERING SEQUENCE								(VIEWED FROM COMPONENT SIDE OF BOARD)							11-2000A
																																											CONNECTOR CAVITY NUMBERING SEQUENCE								(VIEWED FROM COMPONENT SIDE OF BOARD)							11-2000A

G3792

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..

F-1

DIAGRAMS

F-1

Image 36

Contents Power Wave 455/R Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Table of Contents Installation TechnicalMM2 Physical Dimensions Machine Grounding High Frequency ProtectionInput Connection LiftingInput Fuse and Supply Wire Considerations ’A’Welding with Multiple Power Waves TWO Power WavesElectrode and Work Cable Connections Negative Electrode PolarityVoltage Sensing Work Voltage SensingElectrode Voltage Sensing Control Cable Specifications External I/O ConnectorHigh Speed Gear BOX DIP Switch Settings and Locations Turn off power at the disconnect switchBank S2 Switch Description Safety Precuations OperationPower Wave 455/R General Description Recommended Processes and EquipmentRequired Equipment LimitationsCase Front Controls Figure A.4Constant Voltage Welding Figure A.5Pulse Welding Figure A.6STT Welding Figure A.7Accessories Factory InstalledField Installed Optional EquipmentMaintenance Periodic MaintenanceCalibration Specification Troubleshooting HOW to USE Troubleshooting GuideUsing the Status LED to Troubleshoot System Problems Before the machine is turned offTroubleshooting Guide Authorized Field Service FacilityContact your local Lincoln Lit section Output Problems Welding Problems Error Codes for the Powerwave Error Code # IndicationTroubleshooting Diagrams Power Wavetm 455 / R Wiring DiagramPower Wavetm 455 / R Wiring Diagram North American Connector PIN Definitions Connection Diagram Hard Automation, Electrode Positive, STT ConfigurationPowerwave Dimension Print Power Wave Power Wave 455/R Precaucion Warnung

IM690-A specifications

The Lincoln Electric IM690-A is a sophisticated and versatile multi-process welding machine designed to cater to a wide range of professional welding applications. Combining innovative technology with robust functionality, the IM690-A stands out as a reliable choice for welders across various industries.

One of the primary features of the IM690-A is its multi-process capability, allowing users to perform MIG, TIG, and stick welding with ease. This versatility is essential for welders who need to switch between different welding techniques depending on the project requirements. The machine's advanced control system ensures a smooth transition between processes, optimizing the welder's performance and efficiency.

The IM690-A is powered by a high-performance inverter technology that significantly improves energy efficiency while providing a stable arc. In addition to power efficiency, this technology enables the machine to have a compact design, making it portable and easier to maneuver in tight spaces. The inverter technology also contributes to a reliable and consistent welding output, which is crucial for high-quality welds.

Another notable characteristic of the IM690-A is its user-friendly interface. The machine features a large digital display and intuitive controls, allowing welders to easily adjust settings and monitor performance parameters. This ease of use is particularly beneficial for beginners and experienced welders alike, facilitating quick adjustments during operation.

The IM690-A also incorporates advanced safety features, ensuring the well-being of the operator. Overload protection and automatic thermal shutdown provide peace of mind, allowing users to focus on their work without the constant worry of equipment failure. The rugged construction of the machine adds an extra layer of durability, making it suitable for demanding environments and extensive usage.

Additionally, the IM690-A supports a wide variety of materials and thicknesses, making it ideal for diverse applications, from automotive repair to heavy fabrication. With features like adjustable inductance settings and pre/post gas flow control, users can fine-tune their welding processes for optimal results.

In conclusion, the Lincoln Electric IM690-A is a powerful multi-process welder that combines advanced inverter technology with user-friendly design and safety features. Its versatility, efficiency, and adaptability make it an outstanding choice for professionals seeking a reliable welding solution. Whether you’re working in a shop or on-site, the IM690-A delivers exceptional performance and quality in a compact, durable package.