Lincoln Electric IM808-A manual Power Wave 455M/STT CE Wiring Diagram

TM

POWER WAVE 455M/STT (CE) WIRING DIAGRAM

LEFT SIDE OF MACHINE

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

DIGITAL POWER			SOLID	3R	TO	3W
			STATE		J7
SUPPLY BOARD			RELAY + 3			4 -
	1										AUXILIARY TRANSFORMER #1
		225	TO
	2	223	J4								X1	W	H6	H6A
J42	3	221											(550-575)
	4	227									(51V)		H5	H6
	5	222				1					X2	U	(440-460)	H5
	6			2									H4	H4	H4B
	1	475									TO POWER BD.		(380-415)
			TO
	2	477									RECTIFIER			N.J.
J41	3	476	J47	444	TP4	X3A					X3	W	H3
	4	478	TO FAN TO AUX #1						224A		X3	N	(220-230)	H3
	1	346									(24V)		H2	H2
										CHOKE	X4		(200-208)
	2	268A						TO RECT		THERM	(115V)	R	H1	H1
	3		TO					THERM			X5
	4	226	J4			MAIN CHOKE			291	TO			TO FAN
	5	274	J11
J43	6	266	R5							CR1
	7	345			TO J8		P91			J60
	8					216	4		CURRENT
	9	228				211	3	+	TRANSDUCER				X3A
	10	273				213							TO SOLID STATE RELAY
							2
	11	267				212	1
	12	262		TO J5
DC BUS BOARD			224						MAIN				TO J6,J10B
				220		OUTPUT			TRANSFORMER
		TO C3	224A						LEFT SIDE
	1	POS		220A		RECT
J46	2	POS				292					16
	3	NEG											414 418 403 404 405 406	13
	4	NEG	TO			RECT								14
	1	51	CHOKE			THERM
			THERM			291			SEC	PRI	TO
	2	50	TO
	3								(TOP	(TOP	SWITCH
J47	4	475	CB1						LEFT)	LEFT)	BD #2		1 2 3 4 5 6
	5		J41			D4
	6	476	J82
	7	477	S1					F4			18
													J40
	8	478

			CB3
			3.5A
			CIRCUIT
		H1A TO AUX #2	BREAKER
		612BTO INPUT SWITCH	H1B	N.L.
		TO J61	10A
TO		612	FUSE
AUX #2
CB3		TO AUX #1
RECONNECT PANEL		H1
		TO SOLID STATE RELAY
		444
				FAN
		X5
		TO AUX#1
THIS AREA VIEWED FROM
REAR OF MACHINE
	N.B., N.G., N.H.
RECONNECT SWITCH
TO		RECONNECT
SWITCH BD #2	TO
POS	SWITCH BD #1	PANEL
	19C	N.C.	TO SW1
19		N.J.
TO		TO AUX #1		200-208V
HARMONIC		H2	’A	220-230V
FILTER	TO	H3		440-460V
	SWITCH BD #1	H5	’	550-575V

POWER WAVE

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		2	741
	E	BLACK	J81
	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

									10	505
									11
									12	604
									13	506
									14
	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
									8	2B	THERMAL
	MODULE							J7	9		LED
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							5	811	P91
		RECEPTACLE							6	216
				53A					7	816
									8	812
		A		53			206	1
		B		54				2
				54A	L6		202	3
		C		67A	67		67	4	J9
				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

	220A		TO RECT
	292		THERM
CHOPPER BOARD			2.7 10W
	COLLECTOR		TO D5
345	1
	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

D3

2.7

10W

D2

TP7

D1

F4

.022

800V

F3

F3

.022

800V

F2

F2

2.7

10W

.022

800V

F1

F1

		SWITCH BOARD
		12	#1
					+		3500oF
SEC	PRI	TO		C4			500V
	(BOTTOM SWITCH
(BOTTOM	LEFT)	BD #1
LEFT)			20C		19C
								TO
		14				MAIN TRANSFORMER
		11	12
							TO RECONNECT
		15					SWITCH
SEC	PRI	TO
	(BOTTOM SWITCH
(BOTTOM	RIGHT)	BD #2
RIGHT)
		17			TO J6, J10B
		11
			514	518	503	504	505	506	17
SEC	PRI	TO							18
(TOP	(TOP	SWITCH
RIGHT)	RIGHT)	BD #1	1 2 3
						4	5	6
		13
					J50
			SWITCH BOARD
RIGHT SIDE					#2

20D			NEG	H6
TO
SWITCH BD #2		TO	20
		HARMONIC
		FILTER
					350	1	S8
				TO	352	2 WATER
				AUX #2	33A	3 COOLER
						4	RECEPTACLE
					TO
HARMONIC				RECONNECT
				N.G.	SWITCH
20	FILTER		19					REAR
				NEG		POS
				INPUT
20C			19D	RECTIFIER				OF
				NEG			POS	MACHINE
INPUT BOARD				AC	AC		AC
				3	2		1
	1	601		C	B	A
	2	X3	TO
	3	238		N.F.
J60	4	604	CR1
	5	232	J6	INPUT
	6		AUX #1
	7			LINE
	8	231		FILTER

1

2T1

4	T2
	TO

455M/STT

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

CB1	52	TP3	ARE NOT USED
10A CIRCUIT			TO ELECTRODE
BREAKER	50		202A
S2	TO J47
		R1
VOLTAGE		50Y
SENSE
RECEPTACLE
1	L4		206A
2

STT CURRENT					+	3500oF
					C5	500V
TRANSDUCER					15 16
TO J8	P90
					20D 19D
812	1	+
813	2		-	D5
811	3					TO
816	4		+	STT SNUBBER	TO MAIN
						RECONNECT
				DIODE	TRANSFORMER	SWITCH

J61	5		CR1	TO J61
	6	612	SW1					N.K.
	7	H1D	CB4	TO J60	T3	T2	T1
	8
	9	T3		601
	10			CR1
				X4
				TO AUX #1	L3	L2	L1

(CE)

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	67C
J1	3
	4	511
	5
	6
J2	1	67B
	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
4	TO		A		(TOP)
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
	352A
33
			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			20 F
STT					288C	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)
			P52	W
	P51	350	1
					TO
32	1	33A	4	(115V) R
					CB3
33	4	352	2	(230V)	AUX #1
352A	6
					H1
TO						1	H1A
S4	AUXILIARY TRANSFORMER #2
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