Lincoln Electric IM924 manual Power Wave 455M/STT CE Wiring Diagram

TM

POWER WAVE

455M/STT (CE) WIRING DIAGRAM

LEFT SIDE OF MACHINE

ETHERNET / DEVICENET OR

DEVICENET MODULE

DIGITAL POWER

SOLID

3R

TO

3W

CB3

MODULE

STATE

J7

3.5A

SUPPLY BOARD

RELAY + 3

CIRCUIT

6W

1

225

TO

4

-

AUXILIARY TRANSFORMER #1

H1A

TO AUX #2

BREAKER

TO TP6

202 TO J9

2

223

J4

X1

W

H6

H6A

H1B

N.L.

6B

J42

3

221

(550-575)

TO INPUT SWITCH

CONTROL BOARD

4

227

(51V)

H5

H6

612B

TO TP3

5

222

1

X2

U

(440-460)

H5

TO J61

10A

1

743

TO R1

6

2

H4

H4

H4B

N.D.

J72

2

741

WORK

202A

1

475

TO POWER BD.

(380-415)

TO

612

FUSE

3

800

-

J41

2

477

TO

444

RECTIFIER

N.J.

AUX #2

4

840

3

476

J47

TP4

X3A

X3

W

H3

CB3

TO AUX #1

153B

251

1

X3

H3

H1

S5

L2

1

154B

4

478

(220-230)

RECONNECT PANEL

J73

2

2

J2

1

346

TO FAN

TO AUX #1

224A

CHOKE

(24V)

N

H2

H2

DEVICENET

3

51B

253

X4

(200-208)

CONNECTOR

4

52B

3

2

268A

TO RECT

THERM

(115V)

R

H1

H1

6B

1

254

4

3

TO

X5

TO SOLID STATE RELAY

1

J74

4

226

THERM

291

TO FAN

6W

2

C1

1

267

J4

MAIN CHOKE

TO

444

+24V

2

894

892

1

5

274

J11

+24V GND 3

893

893

2

TP1

.05/600V

2

266

J43

6

266

R5

P91

CR1

FAN

CAN_H

4

892

3

3

268

7

345

J60

CAN_L

5

891

891

4

J75

4

228

8

228

TO J8

216

4

CURRENT

X3A

X5

894

5

5

9

211

3

+

TRANSDUCER

6

J4

6

226

10

273

TO SOLID STATE RELAY

TO AUX#1

7

227

TO

213

2

S9

1

8

11

267

212

1

THIS AREA VIEWED FROM

830

2

J76

221

J42

12

262

ETHERNET

3

10

222

R5

MAIN

REAR OF MACHINE

CONNECTOR

4

11

223

DC BUS BOARD

224

TO J6,J10B

N.B., N.G., N.H.

RJ 45 TYPE

12

225

220

OUTPUT

TRANSFORMER

ETHERNET

1

TO

TO C3

224A

220A

LEFT SIDE

RECONNECT SWITCH

L10

2

224

1

POS

RECT

PORT

J5

3

220

THERM

J46

2

POS

TO

RECONNECT

J710

4

3

NEG

292

16

414 418 403 404 405 406

13

SWITCH BD #2

TO

1

231

4

NEG

TO

RECT

14

POS

SWITCH BD #1

PANEL

2

232

1

51

CHOKE

THERM

19C

N.C.

TO SW1

THERM

291

SEC

PRI

TO

J70 & J71

3

TO

2

N.J.

ONLY PRESENT IF FEEDHEAD

3

50

TO

(TOP

(TOP

SWITCH

19

4

J20

LEFT)

LEFT)

BD #2

THE ETHERNET CONNECTION

ARE NOT USED

MODULE IS PRESENT

5

504

J40

J47

4

475

CB1

1 2 3 4 5 6

TO

TO AUX #1

200-208V

IS ONLY PRESENT IN THE

6

503

J50

5

J41

D4

HARMONIC

H2

220-230V

6

476

J82

’A

ETHERNET / DEVICENET MODULE

ONLY PRESENT IF FEEDHEAD

7

406

S1

F4

FILTER

TO

H3

440-460V

MODULE IS NOT PRESENT

J6

8

238

8

478

18

J40

SWITCH BD #1

H5

’

550-575V

9

NEG

H6

10

505

F4

SWITCH BOARD

20D

11

220A

TO RECT

TO

12

604

THERM

12

#1

SWITCH BD #2

TO

13

506

292

20

14

CHOPPER BOARD

2.7 10W

+

3500oF

HARMONIC

MACHINE

J16

15

403

FILTER

16

404

TO

4W

6

289B

F3

SEC

PRI

TO

C4

500V

TO

S8

7

2W

(BOTTOM

11 12

153B

1

1

COLLECTOR

TO D5

.022

(BOTTOM

LEFT)

BD #1

350

1

154B

3

2

1W

TO

345

1

287

D3

800V

LEFT)

20C 19C

TO

352

2 WATER

51B

4

3

STATUS

2

TO

AUX #2

3 COOLER

4

1B

LED

4R

3

J10

TO C8

F3

OR

5

MAIN TRANSFORMER

33A

4

RECEPTACLE

52B

5

346

4

289A

14

6

6

5

OF

OR

J16

J7

8

2B

THERMAL

TO C10

HARMONIC

RECONNECT

LED

EMITTER

TO RECONNECT

N.G.

MODULE

9

SWITCH

POWERWAVE

INTERFACE

10

SWITCH

20

FILTER

19

FRONT

3 CONDUCTOR

CONNECTOR

TP3

11

262

TO

2.7

15

J61

CR1

TO J61

REAROFMACHINE

WIRE DRIVE INTERFACE

153B

1

53A

12

4W

J4

10W

.022

NEG

POS

MODULE

154B

3

54A

13

R5

268

J43

14

4R

TO

800V

PRI

TO

51B

4

51A

15

3R

SSR

SEC

(BOTTOM SWITCH

INPUT

67B

5

67A

16

3W

RIGHT)

BD #2

ROBOTIC/WIREDRIVE

52B

52A

POWER BD

(BOTTOM

6

1

211

RIGHT)

RECTIFIER

INTERFACE RECEPTACLE

2

212

RECTIFIER

D2

20C

19D

S6

L8

S1

3

213

TO

POS

F2

17

FEEDHEAD

J8

4

813

P90

TO J6, J10B

A

539

ARCLINK

5

811

P91

AC AC

TO

NEG

POS

B

541

BOARD

RECEPTACLE

6

216

X2

C3

F2

C

521 L9

1

743

53A

7

816

INPUT BOARD

AC

AC

AC

D

522

J81

2

741

A

53

206

1

NEG

2.7

11

3

2

1

E

BLACK

4

840

B

54A

L6

X1

TP7

514 518 503 504 505

506

1718

2

X3

C

B

A

G

WHITE

202

3

10W

F

847

3

800

54

2

1

601

H

BLACK

1

153B

C

67A

67

67

4

J9

.022

SEC

PRI

TO

3

238

TO

N.F.

67

L5

5

800V

(TOP

(TOP

SWITCH

4

604

CR1

2

154B

D

52

NEG

RIGHT)

RIGHT)

BD #1

J60

J

GND-A

J82

3

51B

52A

TO

21A

6

J10A

NEG

D1

1 2 3 4 5

6

5

232

J6

INPUT

K

RED

4

52B

E

51

L7

414

1

NEG

6

AUX #1

LINE

L

BLACK

J40

418

2

+

POS

F1

13

7

231

M

GREEN

539

1

51A

J50

514

1

J10B

POS

8

FILTER

N

67C

C11

518

2

POS

541

2

54

1

J50

521

3

J83

.0047/3KV

53

2

J11

C3

2400oF

TO J46

287

F1

SWITCH BOARD

1

TO

2

T1

522

4

TO WORK

273

3

100V

POWER BD RECT

RIGHT SIDE

#2

3

886

5

J43

274

4

T2

880

6

J1 & J3

4

TO

CB1

5

455M/STT

TWISTED/SHIELDED

WHITE

1

52

TO ELECTRODE

ARE NOT USED

STT CURRENT

+

3500

oF

6

612

SW1

N.K.

RED

2

10A CIRCUIT

TO J7

C5

500V

7

CB4

12

862

BLACK

3

1

50

TRANSDUCER

8

H1D

TO J60

T3

T2

T1

SHIELD GROUND TO CASE

BREAKER

TO J47

BLACK

4

J84

S2

202A

P90

15 16

9

601

S7

BLACK

5

R1

TO J8

20D 19D

10

T3

CR1

GREEN

6

VOLTAGE

50Y

812

1

I/O

847

7

SENSE

813

2

+

D5

X4

RECEPTACLE

8

RECEPTACLE

206A

811

3

-

1

851

851

1

1

816

4

+

STT SNUBBER

TO MAIN

TO

TO AUX #1

L3

L2

L1

2

852

852

2

2

L4

DIODE

TRANSFORMER

RECONNECT

3

853

853

3

3

21A

288B

SWITCH

P50

4

854

854

4

4

TO C10

5

855

855

5

288A

N.E.

H6

5

H6A

856

6

1W

1B

TO C8

(550-575)

6

856

N.D.

7

857

857

7

P51

P52

W

858

858

8

J85

S3

STATUS LED (R/G)

350

1

8

859

9

TO J7

32

1

(115V) R

TO

L3B

L1B

9

859

RS232

2W

10

860

860

10

CONNECTOR

2B

N.A.

33

4

33A

4

(230V)

CB3

11

861

861

11

THERMAL LED (Y)

352

2

AUX #1

862

12

6

W

V

U

512

13

2

253

352A

H1

L3A

C6

(CE)

511

14

3

254

TO RECONNECT PANEL

TO

1

H1A

L3

2

5W

15

TO

POWER

S4

TO SUPPLY LINES

VOLTAGE SENSE

5B

16

54

J2

A

(TOP)

CB2

AUXILIARY TRANSFORMER #2

.0047oF

SELECT

6

251

TO J61

LOAD LINE

TO CONTACTOR

440

BOARD

7

H1D

L3A

C7

N.F.

G

20

SW1

TO SW 1

L1A

1

512

J1

3

67C

S4

TO CB4

TO CONTACTOR

SWITCH LEAD

4

511

115V

612B

L1A

TO A SYSTEM GROUND PER

5

FILTER

6

RECEPTACLE

NATIONAL ELECTRICAL CODE.

J2

1

67B

2

NOTES:

D6

32

S4

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)

+40VDC

DIODE

220V RECEPTACLE

ALIGNS WITH BLACK LEAD OF LED SOCKET.

880

31

TO

N.D.

351

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT

AC

AC

J83

TO WORK

886

CB2

VOLTAGE. CONNECTION SHOWN IS FOR 440-575V

OPERATION.

FRONT

REAR

FAN

RECONNECT RECONNECT

CB2

5A CIRCUIT

BREAKER

32

TP6

HORIZONTAL HORIZONTAL SHROUD SHELL

BRACKET

10A CIRCUIT

CE Model

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR

BAFFLE

BAFFLE

GND-A

GND-B

BREAKER

INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V

33

352A

OPERATION.

CASEFRONT

CASEFRONT

N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)

CASE

FRONT

REAR

AUX.

AUX.

N.F.

PANEL

288D

289D

TO D5

C8

ALIGNS WITH WHITE LEAD OF LED SOCKET.

FRONT

UPPER

UPPER

2

1

206 TO J9

288A

N.E. LEAD 33 IS PRESENT IN MODELS WITH 115V RECEPTACLE

BASE

BASE

R2

20 F

OR

STT

288C

400V

ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN

TO R1

+

288E

2Y

289E

289A

PROTECTIVE BONDING CIRCUIT

206A

R3

289C

MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.

LEGEND

STT SNUBBER

COMPONENT VALUE UNITS:

TO TP3

288F

2Y

289F

288B

CAPACITOR BANK

N.F. ONLY PRESENT ON "CE" MODELS.

DASHED " =

" = STT MACHINE ONLY

C6

R4

288C

PHANTOM "

" OPTION

CAPACITOR: MFD/VOLTS

288D

ELECTRODE

.05/600V

2Y

288E

C10

N.G. ONLY PRESENT ON NON-CE MODELS.

RESISTOR: OHMS/WATTS

+

TP5

STT SNUBBER

289B

20 F

LEAD COLOR CODING

289C

B=BLACK

C2

RESISTOR BANK

289D

400V

N.H. "CE" MODELS DO NOT HAVE A RECONNECT SWITCH. POS LEAD

G=GREEN

CONNECTOR PIN NUMBERS:

289E

N=BROWN

TP2

.05/600V

CONNECTS DIRECTLY TO (+) OF C4. LEAD C CONNECTS

R=RED

EX. 12 PIN CONNECTOR

(-) OF C4 TO (+) C5 AND NEG LEAD CONNECTS TO (-) OF C5.

U=BLUE

2

W=WHITE

1

6

RIGHT SIDE OF MACHINE

N.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD

COMPONENT VALUES:

LEAD H4B CONNECTS H4 TO SW1.

CAPACITORS=MFD/VOLTS

7

12

RESISTORS=OHMS/WATTS

N.K. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS

LATCH

A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT

ELECTRICAL SYMBOLS PER E1537

VIEW OF CONNECTOR ON PC BOARD

RECTIFIER TERMINALS RATHER THAN CR1.

N.L. 10 AMP CIRCUIT BREAKER IS USED IN PLACE OF FUSE ON CODES

BELOW 11150.

E

G4420

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