Lincoln Electric IM924 manual DIAGRAMS

F-1
DIAGRAMS
F-1
POWER WAVE 455M/STT (CE)
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..
-
TO J9
202
WORK
202A TO R1
TO TP6
S1
ARCLINK
RECEPTACLE
+
ELECTRODE
223 221
206A R3
C8
TO D5
289D
R2
2
Y
288C
288D
289E288E
J1 4
5
3R3R 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
503
504
505
506
INPUT
20D
1718
1516
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
32
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
Y
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
206TO 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
H1ATO 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
FRONT OF MACHINE
115V
RECEPTACLE
TO RECONNECT PANEL
1
2J74
J76
PRI
(BOTTOM
LEFT)
20C
++
TO AUX #1
404
405
406
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
Y
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
H1TO AUX #1
AUXILIARY TRANSFORMER #1
SEC
(BOTTOM
RIGHT)
TO
SWITCH BD #2
POS
TO SWITCH BD #1
1112
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
L1A
TO CONTACTOR
S4
TO TP3
31
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
514
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
403
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 TO3W
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
414
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
REAR OF MACHINE
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 WH3
TO
X3
AUX #2
X5
RECONNECT PANEL
TO
MAIN TRANSFORMER
TO D5
34-
TO
J4
SOLID
STATE
RELAY
21
W
H5
(440-460)
H4
H5
2
Y
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 THERMTO RECT
THERM
TO RECONNECT SWITCH
H6 5
(550-575) H6A
P50
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
S8
20F 400V
20F 400V
+24V
+24V GND
CAN_H
CAN_L
418
518
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
o
F
500V 3500
o
F
500V 3500
o
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
CBA
INPUT LINE FILTER
L3A
.0047
o
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.
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
126
712
LATCH
EX. 12 PIN CONNECTOR
1 3 8 7 6 5475
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.
TM
POWER WAVE 455M/STT (CE) WIRING DIAGRAM
G4420
E
N.K.