Lincoln Electric 455 M manual Power Wave 455M CE Wiring Diagram

TM

POWER WAVE 455M (CE) WIRING DIAGRAM

F-1

ETHERNET / DEVICENET			OR	DEVICENET MODULE
		MODULE
		6W
		6B
					1	743
N.D.				J72	2	741
					3	800
					4	840
S5		L2			1	153B
				J73	2	154B
DEVICENET					3	51B
CONNECTOR			6B		4	52B
	1				1	J74
			6W		2
+24V	2	894	892		1
+24V GND	3	893	893		2
CAN_H	4	892			3	J75
CAN_L	5	891	891		4
			894		5
					6
		S9			1
			830		2	J76
ETHERNET					3
CONNECTOR					4
		RJ 45 TYPE		ETHERNET
		L10
					PORT
					J710
THE ETHERNET CONNECTION					J70 & J71
				ARE NOT USED
IS ONLY PRESENT IN THE
ETHERNET / DEVICENET MODULE

	TO TP6
	202	TO J9
		CONTROL BOARD
	TO TP3
	202A	TO R1
WORK
	-
		251	1
		253	2	J2
			3
		254	4
	C1		1	267
TP1	.05/600V		2	266
			3	268
			4
			5	228
		J4	6	226
			7	227	TO
			8	221	J42
			9		J43
			10	222	R5
			11	223
			12	225
			1	224	TO
		J5	2		RECT
			3	220	THERM
			4
			1	231
			2	232
ONLY PRESENT IF FEEDHEAD			3		TO
			4		J20
MODULE IS PRESENT			5	504	J40
			6	503	J50
ONLY PRESENT IF FEEDHEAD			7	406
MODULE IS NOT PRESENT		J6	8	405
			9	238

LEFT SIDE OF MACHINE

DIGITAL POWER

SOLID

3R

TO

3W

CB3

STATE

J7

3.5A

SUPPLY BOARD

RELAY + 3

CIRCUIT

1

225

4 -

AUXILIARY TRANSFORMER #1

H1A

TO AUX #2

BREAKER

TO

J42

2

223

J4

X1

W

H6

H6

612B

H1B

N.L.

4

227

X2

(51V)

H5

3

221

(550-575)

H6A

TO INPUT SWITCH

5

222

2

1

U

(440-460)

H5

TO J61

10A

6

H4

H4

H4B

612

1

475

TO POWER BD.

(380-415)

FUSE

TO

TO

2

477

RECTIFIER

N.J.

AUX #2

J41

3

476

J47

444

TP4

X3A

X3

W

H3

CB3

TO AUX #1

4

478

TO FAN TO AUX #1

224A

X3

(24V)

N

(220-230)

H3

RECONNECT PANEL

H1

1

346

X4

H2

H2

CHOKE

(200-208)

2

268A

TO RECT

THERM

X5

(115V)

R

H1

H1

3

TO

THERM

TO SOLID STATE RELAY

4

226

MAIN CHOKE

TO FAN

5

274

J4

291

TO

444

J11

J43

6

266

R5

TO J8

P91

CR1

FAN

7

345

J60

8

228

216

4

CURRENT

X3A

X5

9

211

3

+

TRANSDUCER

10

273

TO SOLID STATE RELAY

TO AUX#1

213

2

11

267

212

1

THIS AREA VIEWED FROM

12

262

TO J5

MAIN

REAR OF MACHINE

DC BUS BOARD

224

TO J6,J10B

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

224A

220

OUTPUT

TRANSFORMER

TO C3

LEFT SIDE

RECONNECT SWITCH

1

POS

220A

RECT

J46

2

POS

TO

TO

RECONNECT

3

NEG

292

16

414 418 403 404 405 406

13

SWITCH BD #2

4

NEG

TO

RECT

14

POS

19C

PANEL

1

51

CHOKE

THERM

N.C.

TO SW1

THERM

SEC

PRI

TO

2

50

TO

291

19

N.J.

3

(TOP

(TOP

SWITCH

1 2 3 4 5 6

J47

4

CB1

LEFT)

LEFT)

BD #2

TO

TO AUX #1

200-208V

475

J41

D4

5

J82

HARMONIC

H2

’A

220-230V

6

476

FILTER

TO

H3

440-460V

7

477

S1

F4

8

478

18

J40

SWITCH BD #1

H5

’

550-575V

10	505
11

220A TO RECT

F4 SWITCH BOARD

20D

TO

NEG

H6

POWER WAVE 455M (CE)

MACHINE					OR
					OR
OF
FRONT		WIRE DRIVE INTERFACE
			MODULE
	ROBOTIC/WIREDRIVE
	INTERFACE RECEPTACLE
	S6	L8	FEEDHEAD
	A	539
	B	541	BOARD
	C	521 L9		1	743
	D	522
	E	BLACK	J81	2	741
	F	847		3	800
	G	WHITE		4	840
	H	BLACK		1	153B
	J	GND-A	J82	2	154B
	K	RED		3	51B
	L	BLACK		4	52B
	M	GREEN	539	1
	N	67C
			541	2
			521	3	J83
			522	4
			886	5
			880	6
	3 CONDUCTOR		WHITE	1
	TWISTED/SHIELDED		RED	2
	SHIELD GROUND TO CASE		BLACK	3
			BLACK	4	J84
	S7		BLACK	5
			GREEN	6
	I/O		847	7
	RECEPTACLE			8
	1	851	851	1
	2	852	852	2
			853

									13	604
									14	506
	J16								15	403
									16	404
153B	1								1
									2
154B	3								3	1W	TO
51B	4								4	1B	STATUS
											LED
52B	5								5
	6
									6	2W
	J16								7		TO
								J7	8	2B	THERMAL
											LED
	MODULE								9
INTERFACE									10
CONNECTOR									11
153B	1	53A							12
									13	4W
154B	3	54A							14	4R	TO
51B	4	51A							15	3R
											SSR
67B	5	67A							16	3W
52B	6	52A							1	211
									2	212
		S1							3	213	TO
								J8	4	813	P90
		ARCLINK									P91
									5	811
		RECEPTACLE							6	216
			53A						7	816
									8	812
		A	53				206	1
		B	54					2
			54A	L6			202
		C	67A		67			3	J9
							67	4
			67	L5				5
		D	52				21A	6
		E	52A			TO	414	1	J10A
			51	L7		J40	418	2
			51A				514	1	J10B
						J50
			C11				518	2
			.0047/3KV				54	1
							53	2	J11
						TO
					TO WORK		273	3
						J43	274	4	J1 & J3
		CB1			TP3
			52					ARE NOT USED
	10A CIRCUIT				TO ELECTRODE
	BREAKER		50	TO J47	202A
		S2
					R1
		VOLTAGE			50Y
		SENSE
	RECEPTACLE

1	206A
2	L4

292	THERM
CHOPPER BOARD	2.7 10W

	COLLECTOR
345		1		TO D5
		2		287
4R
		3	J10	TO C8
346	4			289A
4W		5
	6			289B
	EMITTER			TO C10

262TO J4

R5	268	J43
	268A

POWER BD
RECTIFIER
	POS
		TO
AC	AC X2	C3
		AUX. #1
	NEG
	X1
	NEG
	NEG
	NEG
+	POS
	POS
	POS
C3 2400oF	TO J46		287
100V	POWER BD RECT
	STT CURRENT
	TRANSDUCER
	TO J8	P90
	812	1	+
	813	2
	811	3
	816	4

D3

2.7

10W

D2

TP7

D1

-

+

			12
						+		3500oF
	SEC	PRI	TO		C4			500V
.022		(BOTTOM SWITCH
	(BOTTOM	LEFT)	BD #1
800V	LEFT)			20C		19C
									TO
F3			14				MAIN TRANSFORMER
F3			11	12
								TO RECONNECT
			15					SWITCH
.022
800V	SEC	PRI	TO
		(BOTTOM SWITCH
	(BOTTOM	RIGHT)	BD #2
	RIGHT)
F2			17			TO J6, J10B
F2
2.7			11
				514	518	503	504	505	506
10W										17
.022	SEC	PRI	TO							18
800V	(TOP	(TOP	SWITCH
	RIGHT)	RIGHT)	BD #1	1 2 3
							4	5	6
F1			13
F1						J50
				SWITCH BOARD
	RIGHT SIDE					#2
							+		3500oF
						C5			500V
				15 16
					20D 19D
D5								TO
STT SNUBBER			TO MAIN					RECONNECT
DIODE			TRANSFORMER					SWITCH

SWITCH BD #2

TO 20

HARMONIC

FILTER

HARMONIC		N.G.
20 FILTER	19
20C	19D

INPUT BOARD

	1	601
	2	X3	TO
	3	238
J60	4	604	CR1
	5	232	J6
	6		AUX #1
	7	231
	8

1

2T1

	4	T2	TO
J61	5	612	CR1
	6		SW1

7CB4

8H1D

9

10 T3

		350	1	S8
	TO	352	2 WATER
	AUX #2	33A	3 COOLER
			4	RECEPTACLE
		TO
	RECONNECT
		SWITCH
	NEG		POS		REAR
	INPUT
	RECTIFIER				OF
	NEG			POS	MACHINE
	AC	AC		AC
	3	2		1
N.F.	C	B	A
INPUT
LINE
FILTER
TO J61
TO J60	T3	T2		T1		N.K.
601
CR1
X4
TO AUX #1	L3	L2		L1

3	853	854	3
4	854		4
5	855	855	5
6	856	856	6
7	857	857	7
8	858	858	8	J85
9	859	859	9
10	860	860	10
11	861	861	11
12	862	862	12
		512	13
		511	14
		5W	15
VOLTAGE SENSE		5B	16
	SELECT
	BOARD

1 512

2

3 67C

J1 4 511

5

6

167B

J2 2

	D6
	+40VDC
	DIODE
		880	N.D.
		TO
AC	AC	J83
		886
GND-A GND-B
CASEFRONT			CASEFRONT
			PANEL

3 21A

4
			1W	1B	N.D.
S3					STATUS LED (R/G)
					TO J7
RS232			2B	2W
CONNECTOR					N.A.
1					THERMAL LED (Y)
	253				TO J7
2
3	254		TO RECONNECT PANEL		(TOP)
4	TO		A
5	J2
6				TO J61	LOAD LINE TO CONTACTOR
	251
7				H1D	L3A
20			SW1
			POWER
S4				TO CB4	TO CONTACTOR
115V				612B	L1A
RECEPTACLE
32		S4
		220V RECEPTACLE
31	351
	CB2
CB2	5A CIRCUIT		32
	BREAKER
10A CIRCUIT		CE Model
BREAKER
33	352A
			206 TO J9
	OR		206A TO R1
			TO TP3
	ELECTRODE		+
			C2
		TP2	.05/600V

288B

TO C10

288A TO C8

TO WORK
TP6
		288D		289D	TO D5	C8
					288A
			R2		288C	20 F
STT						400V
	+	288E	2Y	289E	289A
			R3		289C	STT SNUBBER
			2Y		288B
		288F		289F	288C	CAPACITOR BANK
		C6	R4		288D
		.05/600V	2Y		288E	C10
					289B
TP5		STT SNUBBER			289C	20 F
		RESISTOR BANK			289D	400V
					289E

RIGHT SIDE OF MACHINE

					P50
	N.E.				H6	5	H6A
					(550-575)
	P51		P52	W
		350	1
					TO
32	1	33A	4	(115V) R
					CB3
33	4	352	2	(230V)	AUX #1
352A	6
					H1
TO						1	H1A
	AUXILIARY TRANSFORMER #2
S4
CB2

TO SW 1

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 VOLTAGE. CONNECTION SHOWN IS FOR 440-575V

OPERATION.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V

OPERATION.

N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH WHITE LEAD OF LED SOCKET.

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.

L3B L1B

L3A	C6	L3	W		V	U
			TO SUPPLY LINES
.0047oF
440
L1A	C7	N.F.			G
	SWITCH LEAD		TO A SYSTEM GROUND PER
	FILTER
			NATIONAL ELECTRICAL CODE.
FRONT	REAR	FAN	RECONNECT RECONNECT
HORIZONTAL HORIZONTAL SHROUD SHELL					BRACKET
BAFFLE	BAFFLE
CASE	FRONT	REAR	AUX.	AUX.		N.F.
FRONT	UPPER	UPPER	2	1
	BASE	BASE
	PROTECTIVE BONDING CIRCUIT
	LEGEND				COMPONENT VALUE UNITS:
DASHED "		" = STT MACHINE ONLY
PHANTOM "		" = OPTION			CAPACITOR: MFD/VOLTS
		LEAD COLOR CODING		RESISTOR: OHMS/WATTS
		B=BLACK
		G=GREEN			CONNECTOR PIN NUMBERS:
		N=BROWN
		R=RED			EX. 12 PIN CONNECTOR
		U=BLUE
		W=WHITE			1	2	6
		COMPONENT VALUES:
		CAPACITORS=MFD/VOLTS			7		12
		RESISTORS=OHMS/WATTS
							LATCH
ELECTRICAL SYMBOLS PER E1537					VIEW OF CONNECTOR ON PC BOARD

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..

DIAGRAMS

F-1