Lincoln Electric IM807 POWER WAVE 455M - Manual (Page 37)

F-1 DIAGRAMS F-1
POWER WAVE 455M (CE)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag
ram 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. G
ive the equipment code number..
-
TO J9
202
W
ORK
202A
TO R1
TO T
P 6
S1
A RCL
INK
REC
EPT
A CLE
+
E
LECTROD
E
223 221
206A
R3
C8
TO D5
289D
R2 2 Y
288C
288D
289E
288E
J1
4 5
3R3R 3W 238
5
J10
TO STA
TUS
LED RECT THERM
223 222
CH
O
PPER
BO
ARD
SEC
(BOTT
O M
LE
FT)
POW
ER BD
REC
TI
FI
ER
AC EMIT
TE
R
212 213 813 811 216
4
CONTRO
L BO
ARD
+
TO J61
CR1
X4
6
TO AUX
#1
503 504
505 506
INPU
T
20D
17 18
15
16
F1 F1
TO CB1 J41
1
4R
J4
251
20 C
J47
TO P90 P91
RECT
292
1 2 3 4
SE
C
(TO
P
LE
FT)
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 CH
O K E
TH E R M
D
CURRENT TRANSDUCER
TO C8
19D
S W
ITCH
BO
ARD
#2
289A
- + 288B TO C10
SW
1
POWER
C10
289F
A
202
225
J7
2
5
J2
206
52
J5
32
TP
6
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 ST
T
X1 +
G
601 TO J60
L1
20 NEG 19C
T1
TO HA
R M O N IC
FIL
TE
R
RE
AR OF MA
CHINE
TO J6,J10B
6
TO
SOLID ST
A TE RELAY
3
2
TO
SOLID S
TA
TE RELAY
444
FAN
THIS AR
EA
VIE
W
ED FR
OM
288F
RE
CON
NE
CT
PANE
L
TO CR1 J6
231
AUX #1
J61
5 6 7 8 9
POS
D1
H1
50
CB
1
10A
C IRCU
IT
BRE
A KER
R1 TP
3
TO R1
CB
2
10A
C IRCU
IT
BRE
A KER
1B
TP
2
206
TO J9 202A
TP
5
33
206A
NEG
7
PR
I
(B OTT
O M
RIGHT)
TO SWITCH BD #2 15 14 12 18 TO SWITCH BD #1 TO SWITCH BD #2
MA
IN
TRANSFORMER
LE
FT
SI
DE
X2 NEG
1
POS
2 3
C3
J2
.05/600V
2W 403
288A
2 1 6
2B
511
604
H1A
TO
AUX #2
CB3 3.
5A
BRE
A KER
TO SW1
200-
208V
220-
230V
440-
460V
550-
575V
POS
POS AC 1
TO SUPPLY
LINE
S
S2
VOL
TA
GE
SEN
SE
REC
EPT
A CLE
TO
A SYS
TEM GROU
ND PER
NA
TIONAL ELECTRICAL
CODE.
S3 RS2
32
CONN
ECT
OR
FR ONT OF M ACHINE
115V
REC
EP
TA
CLE
TO RECONNEC
T PANEL
1 2
J74 J76
PR
I
(B OTT
O M
LE
FT)
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 BU
S BOARD 12
J41
C6
50 Y
C2
N.D.
.05/600V
S TA
TUS LED
(R/G)
TO
J 7
N. A .
THER
M A L LED
(Y
)
TO
J 7
1W
TO J4 J11
C4
13 14
+
S W
ITCH
BO
ARD
#1
1
4 5
X3A
19
TO FAN
X1
224A 291
CB3
TO J61 TO INPU
T SWITCH
612B 612 H1
TO AUX
#1
AUX
IL
IARY
TRANSFORMER
#1
SE
C
(BOTTO
M
RIGHT)
TO SWITCH BD
#2
POS
TO SWITCH BD
#1
11
12
20D
TO SWITCH BD
#2
H5 H6
CAPACI
TORS=MF
D/VOLT
S
RESIS
TORS=OHMS/WAT
TS
H1 (200
-208
)
H2 (220
-230
)
PR
I
(TO
P
LE
FT)
R
(115V
) N
(24V)
X4
COLLECTOR
2 6
TO J61 H1D
(TO
P)
LOAD LINE
TO CB4 612B
L3A L1A
TO CON
TA
C TOR
S4
TO T
P 3
31
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 8 7 9
232 X3 604 238 601
INPU
T BO
ARD
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
AUX
IL
IARY
TRANSFORMER
#2
NOTES: N.
A.
P IN NE
ARE
S T
THE FL
A T EDG
E OF L
ED
LE
N S (CA
THODE)
A
LI
GNS
W
IT
H BL
ACK
LE
AD OF L
ED SOCK
E T.
N.
B.
P LAC
E S
W
IT
CH
IN AP
PROPR
IA
TE PO
S IT
ION FOR IN
PUT
OPER
A TI
ON.
N.C.
PL
ACE "
A"
LE
AD ON
A P PROPR
IA
TE CONNEC
TION FOR
OPER
A TI
ON.
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
R
IGHT
SI
DE
13
512
4R
4 3
4W
2 1
VO
LT
AGE
SENS
E
SELEC
T
BO
ARD
TO SW
IT C H B D # 1
D4
J40
F4
403
F4
THERM
1 2 3 4
1 2 3 4
J72
J75
W
IRE DR
IV
E
IN
TERFAC
E
MODULE
BO
A
R D
11
J42
TO
J5
6 5 4 3 2
+
225
1
SE
C
(TO
P
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
D
IG
ITA
L PO
W
E R
SUP
P LY
BO
ARD
3R
TO
3W
J7
M A IN CHO
KE
221
4 3
231 232
291
X3A
.05/600V C1
TP
1
TO C8 288A
345
287
TP
7
REC
TI
FI
ER
SWITCH RECONNECT
TO
16
414
H4
’A ’
LEFT SID
E OF MACHINE
RECONNEC
T SW
ITCH
6 5 1 1
TP
4
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 VALU
ES:
N=BROW
N
REAR OF MACHINE
G=G
REEN
B=BLACK LEAD COLOR CODIN
G
TO CB3
ELECTRICAL SYMBOLS PER E1537
H1A
AUX #1
L3B
X5
TO AUX#1
2 1
OUT
PUT
REC
T D2
J6
5 6
253
7
2
254
8
3
9
4 B A
TO J46
1 2 3 4
POWER BD REC
T
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
W
H3
TO
X3
AUX #2
X5
RECONNECT PANEL
TO
MAIN
TRANSFOR
MER
TO D5
3
4-
TO J4
SO
LI
D
ST
A TE
RE
LA
Y
2
1
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
.0 22 800
V
PR
I
(TO
P
RIGHT)
POS POS
NEG NEG AC
D IODE
.0 22 800
V
2. 7 10 W
2. 7 10W .0 22 80
0V
N.
C.
N.
J.
INPU
T VO
LTAG
E.
CONNEC
TION SHO
WN
IS FOR 5
50-575V
52
CONNECT
OR
DE
VI
CEN
ET
5 1 4 2 3
I/O REC
EPT
A CLE
3 4 2 1 5 6 ROB
O TIC/W
IREDR
IV E
IN
TERF
A CE R
ECE
P TA
CLE
C IRCU
IT
10A FUS
E
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 C
O ND UC
TO
R
TW
IS TE D /S H IEL
D ED
SH IEL
D G R O U N D T O CASE
L4
2B
2W
+40
VDC
267 266 268
THERM
S5 S6 S7
GND-
B
267 266 268A
893 894
227
227
WA
TE
R
COOLE
R
RE
CEPT
A C LE
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
WH
IT E
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 THERM
TO RECT THERM
TO RECON
NECT
SWITCH
H6
5
(550
-575
)
H6A
P50
VOLT
AG
E. CONNEC
TI
ON SHO
WN
IS FOR 4
40-575V
S8
20
F
400V 20
F
400V
+24V
+24
V 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
26 2
26 8
26 8A
R5
22 0A 29 2
262
R5
W R
4 1
(11
5V)
TO S4 CB 2
35 0 35 2
P5 2
4
32 33
1 6
33 A
2
(23
0V)
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 FI
LT
E
R
20C
19D
N.D.
PIN NE
AR
E S T T
HE FL
A T EDG
E OF L
ED L
ENS (ANOD
E)
A
LIGNS W
ITH
WH
ITE L
E AD OF L
ED SOCK
E T.
2 4
5B 5W
6W 6B
53A 54A
67
52A 51A
J1
6
M ODU
LE
IN
TERF
A C E
CONN
ECT
OR
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
S TT
SNU
BBER
RES
IS TOR B
A NK
ST T S
N U B BER
CA
PA C IT O R B AN
K
S TT
CURREN
T
TRANSDUCER
D5 ST
T S
N U B BE
R
DI O D E
TO HA
R M O N IC
FIL
TE
R
RE D
BL AC
K
BL
AC K
BL
AC K
GR E EN
WHITE BLACK RED BLACK GREEN
H1B
.0047/3KV C11
ETH
ERN
ET
S9
CB2
5A
C
IRCU
IT
BRE
A K ER 351 352
A
32 S4
22
0V
RECEP
TA
CLE
C
E Mod
el
ETHE
R N ET / DEVI
CE
NET OR DEVICE
NET MO
D U LE
MOD
U LE
TO CON
TA
C TOR
C
B
A
IN P U T
LI N E
FIL
TE
R
L3
A .0047
o F
440
C6 C7
L1A
SW
IT CH LE
A D
FILT
E R
L3
FR
O N T
HO
R IZ O NT
A L
BA
FFLE
RE
AR
HO
R IZ O N TA
L
BA
FF LE
FA N SHRO
UD
RE
CO
NNE
CT
SH
E LL
RE
C O NN
EC T
BR
AC
KE
T
CA
SE
FR
O N T
FR
O N T
UP
PE
R
BA
SE
RE
AR
UP
PE
R
BA
SE
A UX. 2
A UX. 1
PRO
TE
C TIVE BOND
ING
C IRCU
IT
35 2A
P51 N.
E.
N. F.
N.
G.
H4B
N. J.
N.
E .
LE
AD 3
3 IS
PRES
ENT
IN MODEL
S W
IT
H 1
15
V R
ECE
P TAC
LE
ON
TH
E C
ASE FRON
T.
L E AD 35
2A
IS
PRESEN
T ON
LY
IN
MOD
EL
S W
ITH
22
0V
R
E CEPTACL
E ON
TH
E C
ASE FRON
T.
N.F. ON
LY
PRE
S ENT
ON "C
E"
MODE
LS
.
N.G.
ON
LY
PRE
S ENT
ON NON-C
E MODE
LS
.
N.H. "C
E"
MODEL
S DO NOT
H
AVE A R
ECONNEC
T SW
IT
CH.
PO
S L
E AD
CONN
ECT
S D
IRECT
LY
T
O
(+) OF C
4.
L
E AD C CONN
ECTS
(-) OF C4 T
O
(+) C5 AND N
E G L
E AD CONNECTS
T
O (-) OF C5.
N.J.
T
HE "C
E"
MODE
LS
DO NO
T H
A V E A
R
ECONNECT
P
ANE
L.
INST
E A D
LE
AD H
4B
CONNECTS
H
4
TO
S W
1.
N.
K .
ON C
E MOD
E LS
L E ADS
T1,
T
2 AND T
3
ARE
R
E P LAC
ED
B Y L
E ADS
A , B
AND C.
L
E AD
S A
, B
AND C
ARE
CONN
ECT
ED T
O T
HE INPUT
RECT
IFIER T
ERM
INAL
S R
A THER T
HAN CR
1.
N.
L.
1
0
A M
P C
IRCUIT
BRE
A K ER
IS
U
S ED I
N P
LACE
OF FU
S E ON CODES
B E LO
W
1 11
50
.
TO
S W 1
J1 &
J3
AR
E NOT
U
S ED
153B 154B 67B 52B 51B
51 A 53A 54A 67A 52A
CA
SEF
RO
NT
67
CONNECT
OR
O N LY
P R ES
EN
T IF F EE
D H E AD
M O D U LE
IS
NO
T P
R ES
EN
T
ONLY
P
R ESEN
T IF FE
EDH
E AD
MODULE
IS
P R ES
ENT
J70 &
J71
AR
E NOT
U S ED
GND-
A
FEE
D HEAD
TO TH E RM
A L
LE
D
OR
67
TO T
P 3
N. D.
L1
0
J710
ETH
E R N ET
PO
RT
RJ 45
TY
PE
THE
ET
HE
RN
ET
CO
NN
ECT
IO
N
IS O N LY
P R ES
EN
T IN
TH
E
ETH
E R N ET
/ D
E VI C E N E T MO
DUL
E
CA
SEF
RO
NT
PA
NEL
N. D.
TO J40 J50 TO J43
TO
J47
TO J2
TO J20 J40 J50
N. F.
N. F.
CO
MP
ON
ENT
V A LU
E UN
ITS
:
CA
PA
CIT
O R : MFD
/V O LTS
RE
SI STO
R : O
H M S /W
ATTS
CO
NN
ECT
OR
P IN N U M B ER
S:
VIEW
OF
C O N N EC TO
R ON
P C B O ARD
1
2
6
71
2
LA
TC
H
E X . 1 2 P IN C
O NN
E CTO
R
1 3 8 7 6 5
475 476 477 478 50 51
TO WOR
K
TO ELE
C TRODE
3 4 5 1 6 J1
6
OR
TO
W
O R K
153B 154B 52B 51B
OR
TO
MA
IN
TRA
N SFOR
MER
TO
RE
CON
N EC
T
SW
IT C H
LE
G EN
D
DAS
H ED
"
" = ST
T MA
C H IN E O
N LY
PH
AN
TO
M "
"
= OP
TI O N
N. L.
TM
POWER WAVE 455M (CE) WIRING DIAGRAM
G4420
E N.
K.
ENHANCED DIAGRAM