Page 2 - SAFETY; PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; WARNING; ELECTRIC AND; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ; PRÉCAUTIONS DE SÛRETÉ POUR
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Please Examine Carton and Equipment For Damage Immediately
V V TThhaannkk Y Yoouu For selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company prod- uct ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save...
Page 7 - TABLE OF CONTENTS
Vi Vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave® 655/r ....................................................A-1 Safety Precautions.............................
Page 8 - INSTALLATION; OUTPUT
A-1 INSTALLATION POWER WAVE® 655/R A-1 TECHNICAL SPECIFICATIONS - Power Wave® 655/r (K1519-1, K1519-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERATURE RANGES INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS 460/575V - 60HZ. 400V - 50HZ. 460/575V - 60HZ. CODE NUMBERS ...
Page 9 - MACHINE GROUNDING; SAFETY PRECAUTIONS
LIFTING Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave® with accessories attached to it. STACKING Power Wave® machines can be stacked to a maxi- mum of 3 high. The bottom machine must always be placed on a firm, ...
Page 10 - INPUT CONNECTION; FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR; INPUT SUPPLY CONNECTION DIAGRAM; do so will result in damage to the machine.
A-3 INSTALLATION POWER WAVE® 655/R A-3 INPUT CONNECTION Only a qualified electrician should connect theinput leads to the Power Wave®. Connectionsshould be made in accordance with all local andnational electrical codes and the connection dia-gram located on the inside of the reconnect/inputaccess do...
Page 11 - WELDING WITH MULTIPLE Power; Special care must be taken when more than one; TWO Power Wave® S
A-4 INSTALLATION POWER WAVE® 655/R A-4 WELDING WITH MULTIPLE Power Waves® Special care must be taken when more than one Power Wave® is welding simultaneously on a sin- gle part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the ...
Page 12 - E L E C T R O D E A N D W O R K C A B L E; CABLE INDUCTANCE, AND ITS EFFECTS; When pulsing, the pulse current can reach very; NEGATIVE ELECTRODE POLARITY
A-5 INSTALLATION POWER WAVE® 655/R A-5 E L E C T R O D E A N D W O R K C A B L E CONNECTIONS Connect a work lead of sufficient size and length (Per Table 1) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical c...
Page 13 - • Do not touch electrically live parts
VOLTAGE SENSING The best arc performance occurs when the Power Wave® s has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the contact tip. Voltage sense leads improve the accuracy of the...
Page 15 - HIGH SPEED GEAR BOX; ELECTRIC SHOCK can kill.; EXTERNAL I/O CONNECTOR
HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed ( h i g h t o r q u e ) g e a r i s i n s t a l l e d o n t h e f e e d e r . T o...
Page 16 - • Turn off power at the disconnect switch.
A-9 INSTALLATION POWER WAVE® 655/R A-9 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave®. To access the DIP switches: • Turn off power at the disconnect switch. ------------------------------------------------------------- • R e m o v...
Page 18 - OPERATION
B-1 OPERATION B-1 POWER WAVE® 655/R SAFETY PRECAUTIONS Read this entire section of operating instructionsbefore operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrodeand drive mechanism are always elec-trically energized and cou...
Page 20 - RECOMMENDED EQUIPMENT; Automatic Operation; REQUIRED EQUIPMENT; DUTY CYCLE AND TIME PERIOD; GENERAL DESCRIPTION; RECOMMENDED PROCESSES
RECOMMENDED EQUIPMENT • Automatic Operation All welding programs and procedures are set through s o f t w a r e f o r t h e r o b o t i c P o w e r W a v e ® s . F A U N robots equipped with RJ-3 controllers may communi- cate directly to the Power Wave®. Other pieces of equipment such as ply or comp...
Page 21 - CASE FRONT CONTROLS; TABLE 6
B-4 OPERATION POWER WAVE® 655/R B-4 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave®. (See Figure B.1) 1. P O W E R S W I T C H : C o n t r o l s i n p u t p o w e r t o t h e Power Wave®. 2. STATUS LIGHT: A two color light that indicates sys...
Page 22 - CONSTANT VOLTAGE WELDING; Current
B-5 OPERATION B-5 CONSTANT VOLTAGE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed spee...
Page 23 - PULSE WELDING; Time
B-6 OPERATION B-6 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage....
Page 24 - ACCESSORIES; OPTIONAL EQUIPMENT; FACTORY INSTALLED; • Coaxial welding Cable, K1796
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT FACTORY INSTALLED There are no factory installed options available for the Power Wave®. FIELD INSTALLED Gas Guard Regulator (K659-1) The Gas Guard regulator is available as an optional accessory for Power Feed™ Robotic wire drive unit. Install the 5/8-18 male o...
Page 25 - MAINTENANCE; • Only Qualified personnel should; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 POWER WAVE® 655/R SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the d i s c o n n e c t s w i t c h o r f u s e b o xbefore working on this equipment. • Do not touch electrically hot parts. RO...
Page 26 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; CAUTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 POWER WAVE® 655/R If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshoot...
Page 27 - USING THE STATUS LED TO; Read the error code
E-2 TROUBLESHOOTING E-2 POWER WAVE® 655/R USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Status LED on the power source case front can help diagnose problems down to the system c o m p o n e n t ( p o w e r s o u r c e , w i r e f e e d e r, w i r e drive, etc.) level. If, for any reason, ...
Page 28 - PROBLEMS; contact your local Lincoln
E-3 TROUBLESHOOTING E-3 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for t...
Page 32 - ERROR CODES FOR THE POWERWAVE
E-7 TROUBLESHOOTING E-7 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troublesho...
Page 33 - Indication
E-8 TROUBLESHOOTING E-8 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troublesho...
Page 34 - DIAGRAMS
Page 37 - TABLE 5 DEVICENET CONNECTOR S5; PIN, LEAD CONNECTOR DIAGRAMS; TABLE 1 INTERFACE CONNECTOR S6
TABLE 5 DEVICENET CONNECTOR S5 Pin Lead # Function 2 894 +24vdc Devicenet 3 893 Common Devicenet+ 4 892 Devicenet H 5 891 Devicenet L F-4 PIN, LEAD CONNECTOR DIAGRAMS F-4 POWER WAVE® 655/R TABLE 1 INTERFACE CONNECTOR S6 Pin Lead # Function A 841 +15vdc Tach voltage B 844 Tach common C 842 Tach 1A di...
Page 38 - CONNECTION DIAGRAM; Hard Automation and Electrode Positive; CONNECTION DIAGRAM, HARD AUTOMATION
F-5 CONNECTION DIAGRAM F-5 POWER WAVE® 655/R Hard Automation and Electrode Positive Configuration - + W ORK SENSE LEAD K940 WATERCOO LED TORCH ELECTRODE LEAD CONNECTION DIAGRAM, HARD AUTOMATION CONTRO L CABLE K 1795 W ATER CO OLER POW ER CO NNECT ION SHIELDING G AS TO SHIE LDING GAS DEVICE NET CA BL...
Page 39 - Configuration
F-6 CONNECTION DIAGRAM F-6 POWER WAVE® 655/R K1796 COAXIAL WELD CABLE User supplied work lead User supplied electrode lead - + POWERWAVE CONTROL CABLE K1805-1 WORK SENSE LEAD K940 DEVICENET CABLE K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE CONTROL CABLE K1805-1 User suppliedelectrod...
Page 41 - NOTES