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655-R
User Manual
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Lincoln Electric 655-R User Manual

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Page 1
POWERWAVE 655/R
RETURN TO MAIN MENU
For use with machines having Code Numbers: 10630, 10863, 11410
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought­ful operation on your part. DO
NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most
importantly, think before you act and be careful.
SVM180-A
January, 2008
TM
View Safety Info View Safety Info View Safety Info View Safety Info
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Page 2
i i

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
ARC WELDING
CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
KEEP
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
CCAANN BBEE HHAAZZAARRDDOOUUSS..
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered 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.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel nearanopenflame weld­ing arc or when the engine is running. Stop the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
may be dangerous
Route the electrode and work cables together - Secure them with tape when possible.
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
Page 3
ii ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
vapors
to
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug ʻ06
Page 4
iii iii
SAFETY
WELDING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturerʼs recommendations.
Mar ʻ95
Page 5
iv iv
SAFETY
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 suiv­antes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc­tionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayon­nement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar ʻ93
Page 6
I I
RETURN TO MAIN MENU
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
RETURN TO MAIN INDEX
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-392
POWER WAVE 655/R
Page 7
A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Frequency Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
TABLE OF CONTENTS - INSTALLATION SECTION
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Fuse and Supply Wire Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Input Voltage Change Over (For Multiple Input Voltage Machines Only) . . . . . . . . . . . . . . . . . . . . . . .A-4
Welding with Multiple Power Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Electrode and Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Cable Inductance and its Effect on Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Negative Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Work Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Electrode Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Power Wave / Power Feed Wire Feeder Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Control Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
External I/O Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
High Speed Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
Dip Switch Settings and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Control Board Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Feed Head Board Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Devicenet/Gateway Board Dip Switch, Bank (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Devicenet/Gateway Board Dip Switch, Bank (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11
POWER WAVE 655/R
Page 8
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 655/R (K1519-1, K1519-2)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
CODE NUMBERS
10630 10863
INPUT VOLTS
460/575V - 60HZ.
OUTPUT
CONDITIONS
600A@44V.100%
815A@44V. 60%
INPUT
CURRENT
AMPS
43/34 53/42
IDLE
POWER
POWER FACTOR
@ RATED
OUPUT
EFFICIENCY
@ RATED
OUPUT
11410
OPEN
CIRCUIT
VOLTAGE
75 VDC
PROCESS CURRENT RANGES (DC)
460/575V - 60HZ.
CURRENT
RANGE
20-880
MIG/MAG
INPUT
VOLTAGE /
FREQUENCY
400V - 50HZ.
550A@44V.100%
675A@44V. 60%
600A@44V.100%
815A@44V. 60%
40 51
41/33 53/42
400 Watts
Max.
OUTPUT
PULSE
FREQUENCY
0.15 - 1000 Hz
FCAW SMAW
Pulse
PULSE
VOLTAGE
RANGE
5 - 55 VDC
PULSE AND
BACKGROUND
TIME RANGE
100 MICRO SEC. -
3.3 SEC.
AUXILIARY POWER
(CIRCUIT BREAKER
CURRENT
50-815 Average Amps 40-815 Average Amps 30-600 Average Amps
15-880 Peak Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
TYPE 75°C
COPPER WIRE IN
CONDUIT AWG[MM
SIZES
2
]
TYPE 75°C
GROUND WIRE IN
CONDUIT AWG[MM
SIZES
.95 MIN.
PROTECTED)
40 VDC AT
10 AMPS
110 VAC AT
10 AMPS
TYPE 75°C
(SUPER LAG)
2
OR BREAKER
]
SIZE (AMPS)
84%
460V - 60HZ. 575V - 60HZ.
HEIGHT
26.10 in 663 mm
WIDTH
19.86 in 505 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
POWER WAVE 655/R
6 (16)
6(16)
8 (10) 10 (6)
70 60
PHYSICAL DIMENSIONS
DEPTH
32.88 in 835 mm
STORAGE TEMPERATURE RANGE
-40°C to +40°C
WEIGHT
306 lbs.
139 kg.
Page 9
A-3 A-3
INSTALLATION
SAFETY PRECAUTIONS
Read this entire installation section before you start installation.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equip­ment. Turn off the input power to any other equipment con­nected to the welding system at the disconnect switch or fuse box before working on the equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug (located inside the reconnect input access door) to a proper safety (Earth) ground.
-------------------------------------------------------------
SELECT SUITABLE LOCATION
Do not use Power Waves in outdoor environments. The Power Wave power source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.
Do not mount the PowerWave over combustible sur­faces. Where there is a combustible surface directly under stationary or fixed electrical equipment, that sur­face shall be covered with a steel plate at least .060" (1.6mm) thick, which shall extend not less than 5.90" (150mm) beyond the equipment on all sides.
state fan control relay, located on the back of the Control PC board enclosure.
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 maximum of 3 high.
CAUTION
The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machines toppling over if this precaution is not taken.
-------------------------------------------------------------
MACHINE GROUNDING
The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods.
HIGH FREQUENCY PROTECTION
Locate the Power Wave away from radio controlled machinery.
Place the welder where clean cooling air can freely cir­culate in through the rear louvers and out through the case sides and bottom. Dirt, dust, or any foreign mate­rial that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake because the air flow will be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.
Machines above code 10500 are equipped with F.A.N. (fan as needed) circuitry. The fan runs whenever the output is enabled, whether under loaded or open circuit conditions. The fan also runs for a period of time (approximately 5 minutes) after the output is disabled, to ensure all components are properly cooled.
If desired, the F.A.N. feature can be disabled (causing the fan to run whenever the power source is on). To disable F.A.N., connect leads 444 and X3A together at the output of the solid
CAUTION
The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.
------------------------------------------------------------------------
POWER WAVE 655/R
Page 10
A-4 A-4
W / L3
V / L2
U
/ L1
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
X
A
S
24190
use or service this equipment.
D
o not touch electrically live parts.
removed.
Only qualified persons should install,
Do not operate with covers
inspecting or servicing machine.
Disconnect input power before
.
.
.
.
C
R1
INPUT SUPPLY CONNECTION DIAGRAM
INSTALLATION
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.
INPUT CONNECTION
WARNING
Only a qualified electrician should connect the input leads to the Power Wave. Connections should be made in accordance with all local and national electrical codes and the connection dia­gram located on the inside of the reconnect/input access door of the machine. Failure to do so may result in bodily injury or death.
-------------------------------------------------------------
Use a three-phase supply line. A 1.75 inch (45 mm) diameter access hole for the input supply is located on the upper left case back next to the input access door. Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal located on the
inside of the input access door or refer to Figure A.1 .
INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS
Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and
wire sizes. Fuse the input circuit with the recommend-
ed super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” circuit breakers). Choose an input and grounding wire size according to local or national electrical codes. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high currents.
INPUT VOLTAGE CHANGE OVER (FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY)
Welders are shipped connected for the highest input voltage listed on the rating plate. To move this con­nection to a different input voltage, see the diagram located on the inside of the input access door. If the main reconnect switch or link position is placed in the wrong position, the welder will not produce output power.
If the Auxiliary (A) lead is placed in the wrong position, there are two possible results. If the lead is placed in a position higher than the applied line voltage, the welder may not come on at all. If the Auxiliary (A) lead is placed in a position lower than the applied line volt­age, the welder will not come on, and the two circuit breakers in the reconnect area will open. If this occurs, turn off the input voltage, properly connect the (A) lead, reset the breakers, and try again.
POWER WAVE 655/R
Page 11
A-5 A-5
-
+
POWERWAVE
-
+
POWERWAVE
Connect All Work Sense
Electrode Lead
Electrode Lead
Leads at the End
of
the Joint
Connect All Welding Work Leads at the Beginning of the Joint
Travel
Direction
INSTALLATION
WELDING WITH MULTIPLE POWER WAVES
CAUTION
Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified.
Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of the work leads into one lead. Perform welding in the direc­tion away from the work leads. Connect all of the work sense leads from each power source to the work piece at the end of the joint.
FIGURE A.2
TWO POWER WAVES
For the best results when pulse welding, set the wire size and wire feed speed the same for all the Power Waves. When these parameters are identical, the pulsing fre­quency will be the same, helping to stabilize the arcs.
Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover­age.
Do not attempt to supply shielding gas for two or more guns from only one regulator.
If an anti-spatter system is in use then each gun must have its own anti-spatter system. (See Figure A.2.)
POWER WAVE 655/R
Page 12
A-6 A-6
B
A
C
FIGURE A.3
POWER WAVE
WORK
A
C
B
POWER W
AVE
FIGURE A.4
K
1796 COAXIAL CABLE
M
EASURE FROM END OF OUTER JACKET OF CABLE
C
A
B
W
ORK
SLIDING GROUND
INSTALLATION
ELECTRODE AND WORK CABLE 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 contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work and wire feeder. Avoid excessive lengths and do not coil excess cable.
Minimum work and electrode cable sizes are as follows: TABLE 1 (For cable length up to 100 ft, or 30 meters) CURRENT (60% Duty Cycle) MINIMUM COPPER
400 Amps 2/0 (67mm2) 500 Amps 3/0 (85mm2) 600 Amps 3/0 (85mm2)
When using inverter type power sources like the Power Waves, use the largest welding (electrode and ground) cables that are practical. At least 2/0 copper wire - even if the average output current would not nor­mally require it. When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if undersized welding cables are used.
NOTE: K1796 coaxial welding cable is recommended to reduce the cable inductance in long cable lengths. This is especially important when Pulse welding up to 350 amps.
CABLE INDUCTANCE, AND ITS EFFECTS ON PULSE WELDING
For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than 50ft.(15m), tradi­tional welding cables may be used without any effects on welding performance. For the total welding loop length greater than 50ft.(15m), the K1796 Coaxial Welding Cables are recommended. The welding loop length is defined as the total of electrode cable length (A) + work cable length (B) + work length (C) (See Figure A.3).
For long work piece lengths, a sliding ground should be considered to keep the total welding loop length less than 50ft.(15m). (See Figure A.4.)
CAUTION
When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if under­sized welding cables are used.
------------------------------------------------------------------------
Most welding applications run with the electrode being posi­tive (+). For those applications, connect one end of the elec­trode cable to the positive (+) output stud on the power source (located beneath the spring loaded output cover near the bottom of the case front). Connect the other end of the electrode cable to the wire drive feed plate using the stud, lockwasher, and nut provided on the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the connection to the feed plate makes tight metal-to­metal electrical contact. The electrode cable should be sized according to the specifications given in the work cable con­nections section. Connect a work lead from the negative (-) power source output stud to the work piece. The work piece connection must be firm and secure, especially if pulse weld­ing is planned. Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding per­formance.
POWER WAVE 655/R
Page 13
A-7 A-7
INSTALLATION
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as in some Innershield applications, reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud).
When operating with electrode polarity negative the DIP switch 7 must be set to ON on the Wire Feed Head PC Board. The default setting of the switch is OFF to represent positive electrode polarity.
Set the Negative Polarity switch on Wire Feed Head PC board as follows:
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
1. Turn off power to the power source at the disconnect switch.
2. Remove the front cover from the power source.
VOLTAGE SENSING
The best arc performance occurs when the Power Waves has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt­age apparent at the contact tip. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance.
CAUTION
If the voltage sensing is enabled but the sense leads are missing or improperly connected, extremely high welding outputs may occur.
Do not tightly bundle the work sense lead to the work lead.
The ELECTRODE sense lead (67) is built into the K1795 control cable. The WORK sense lead (21) con­nects to the Power Wave at the four-pin connector located underneath the output stud cover. Enable the voltage sense leads as follows:
TABLE 2
Process Electrode Voltage Work Voltage
Sensing 67 lead * Sensing 21 lead
GMAW 67 lead required 21 lead optional** GMAW-P FCAW 67 lead required 21 lead optional** GTAW SAW 67 lead required 21 lead optional**
67 lead required 21 lead optional**
Voltage sense at studs Voltage sense at studs
3. The Feed Head PC Board is on the right side of the power source. Locate the 8­position DIP switch and look for switch 7 of the DIP switch.
4. Using a pencil or other small object, slide the switch right to the OFF position for positive electrode polarity. Conversely, slide the switch left to the ON position for negative electrode polarity.
5. Replace the cover and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately.
1 2 3 4 5 6 7 8
O
N
* The electrode voltage 67 sense lead is part of the
control cable to the wire feeder.
** For consistent weld quality, work voltage sensing is
recommended.
POWER WAVE 655/R
Page 14
A-8 A-8
INSTALLATION
Work Voltage Sensing
The Power Waves are shipped from the factory with the work sense lead enabled.
For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power Wave to the work. Attach the sense lead to the work as close to the weld as practical. Enable the work voltage sens­ing in the Power Wave as follows:
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
1. Turn off power to the power source at the disconnect switch.
POWER WAVE / POWER FEED WIRE FEEDER INTERCONNECTIONS
Connect the control cable between the power source and wire feeder. The wire feeder connection on the robotic Power Waves is located under the spring loaded output cover, near the bottom of the case front. The control cable is keyed and polarized to prevent improper connect.
For convenience, the electrode and control cables can be routed behind the left or right strain reliefs (under the spring loaded output cover), and along the chan­nels formed into the base of the Power Wave, out the back of the channels, and then to the wire feeder.
Output connections on some Power Waves are made via 1/2-13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front. On machines which carry the CE mark, output connections are made via Twist-Mate receptacles, which also located beneath the spring loaded output cover at the bottom of the case front.
2. Remove the front cover from the power source.
3. The control board is on the left side of the power source. Locate the 8-position DIP switch and look for switch 8 of the DIP switch.
4. Using a pencil or other small object, slide the switch right to the OFF position if the work sense lead is NOT connect­ed. Conversely, slide the switch left to the ON position if the work sense lead is present.
5. Replace the cover and screws. The PC board will “read” the switch at power up, and config­ure the work voltage sense lead appropriately.
Electrode Voltage Sensing
Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead must be connected at the wire feeder.
1 2 3 4 5 6 7 8
O
N
A work lead must be run from the power source output stud to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.
CAUTION
Excessive voltage drops at the work piece connec­tion often result in unsatisfactory pulse welding performance.
------------------------------------------------------------------------
CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed system.
CAUTION
The use of non-standard cables, especially in lengths greater than 25 ft(7.6m), can lead to com­munication problems (system shutdowns), poor motor acceleration (poor arc starting) and low wire driving force (wire feeding problems).
------------------------------------------------------------------------
Lincoln control cables are copper 22 conductor cable in a SO-type rubber jacket.
POWER WAVE 655/R
Page 15
A-9 A-9
D
E
F
1
2
3
4
5
6
78
910
11
12
G
H
I
A
B
C
+15 VDC for Trigger Group
Trigger Input
Dual Procedure Input
4 Step Input
+15 VDC for Cold Inch Group
Cold Inch Forward
Cold Inch Reverse
Gas Purge Input
+15 for shutdown group
Shutdown1 input
Shutdown2 input (Water Fault)
Reserved for future use
INSTALLATION
EXTERNAL I/O CONNECTOR
The Power Wave is equipped with a port for making simple input signal connections. The port is divided into three groups: Trigger group, Cold Inch Group and Shutdown Group. Because the Power Wave is a ʻslaveʼ on the DeviceNet network, the Trigger and Cold Inch Groups are disabled when the DeviceNet / Gateway is active.
The shutdown group is always enabled. Shutdown 2 is used for signaling low flow in the water cooler. Unused shutdowns must be jumpered. Machines from the fac­tory come with the shutdowns already jumpered.(See Figure A.5)
FIGURE A.5
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 (high torque) gear is installed on the feeder. To change Gear ratio see Power Feed 10/R Instruction Manual.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-----------------------------------------------------------
1. Set the High/Low switch code on Wire Drive PC board as follows:
• Turn off power to the power source at the discon­nect switch.
• Remove the front cover from the power source.
• The wire feed head board is on the right side of the power source. Locate the 8­position DIP switch and look for position 8 of the DIP switch.
• Using a pencil or other small object, slide the switch right to the OFF position, when the low speed gear is installed. Conversely, slide the switch left to the ON position when the high speed gear is installed.
• Replace the cover and screws. The PC board will “read” the switch at power up, automatically adjusting all control parameters for the speed range selected.
1 2 3 4 5 6 7 8
O
N
POWER WAVE 655/R
Page 16
A-10 A-10
INSTALLATION
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:
WARNING
• Turn off power at the disconnect switch.
------------------------------------------------------------------------
• Remove the top four screws securing the front access panel.
• Loosen, but do not completely remove, the bottom two screws holding the access panel.
• Open the access panel, allowing the weight of the panel to be carried by the bottom two screws. Make sure to prevent the weight of the access panel from hanging on the harness.
• Adjust the DIP switches as necessary.
• Replace the panel and screws, and restore power.
Control Board
Left
Feed Head Board
Right
Feed Head Board DIP Switch:
switch 1 = Object Instance LSB (see table 3) switch 2 = Object Instance MSB (see table 3) switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select
switch 7 = negative polarity switch
switch 7
off positive (default) on negative
switch 8 = high speed gear
switch 8
off low speed gear (default) on high speed gear
electrode polarity
wire drive gear
DeviceNET/Gateway Board DIP Switch:
Bank (S1)
switch 1 = Object Instance LSB (see table3) switch 2 = switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select switch 7 = Reserved for future use switch 8 = Reserved for future use
:
Object Instance MSB (see table 3)
DeviceNET/Gateway Board
Control Board DIP Switch:
switch 1 = Object Instance LSB1(see table 3) switch 2 = Object Instance
switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select switch 7 = reserved for future use switch 8 = work sense lead
1
LEASE SIGNIFICANT BIT
2
MOST SIGNIFICANT BIT
switch 8
off work sense lead not connected on work sense lead connected
work sense lead
MSB2(see table 3)
TABLE 3
Object Instance switch 2 switch 1 Instance
off off 0 (default) off on 1 on off 2 on on 3
POWER WAVE 655/R
Page 17
A-11 A-11
INSTALLATION
Bank (S2)
:
switch Description
1 Devicenet Baud Rate 2(see table 4)
TABLE 4
Prior to S24958-6 software switch 1 switch 2 baud rate
off off Programmable value on off 125K off on 250K on on 500K
S24958-6 and later software switch 1 switch 2 baud rate
off off 125K off on 250K on off 500K on on Programmable value
Bank (S2)
:
switch Description
3 Devicenet Mac ID
thru (see table 5)
8
TABLE 5
SWITCH 8
SWITCH 7
SWITCH 6
SWITCH 5
SWITCH 4
0000000 1000001 2000010 3000011 4000100 5000101 6000110 7000111 8001000 9001001 10 001010 11 001011 12 001100 13 001101 14 001110 15 001111 16 010000 17 010001
SWITCH 8
18 010010 19 010011 20 010100 21 010101 22 010110 23 010111 24 011000 25 011001 26 011010 27 011011 28 011100 29 011101 30 011110 31 011111 32 100000 33 100001 34 100010 35 100011 36 100100 37 100101 38 100110 39 100111 40 101000 41 101001 42 101010 43 101011 44 101100 45 101101
SWITCH 3
46 101110
*
47 101111 48 110000 49 110001 50 110010 51 110011 52 110100 53 110101 54 110110 55 110111 56 111000 57 111001 58 111010 59 111011 60 111100 61 111101 62 111110 *Software Selectable (Line 0) **Default Setting (Line 62)
POWER WAVE 655/R
SWITCH 7
SWITCH 6
SWITCH 5
SWITCH 4
SWITCH 3
**
Page 18
A-12 A-12
NOTES
POWER WAVE 655/R
Page 19
B-1 B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Recommended Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Duty Cycle and Time Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
TABLE OF CONTENTS - OPERATION SECTION
Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Welding Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Constant Voltage Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
POWER WAVE 655/R
Page 20
B-2 B-2
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized
several seconds after the welding ceases.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the beginning of this manual.
POWER WAVE 655/R
Page 21
B-3 B-3
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
INPUT POWER
ON
OFF
HIGH TEMPERATURE
MACHINE STATUS
CIRCUIT BREAKER
WIRE FEEDER
U
U
U
SMAW
GMAW
FCAW
GTAW
OPEN CIRCUIT
0
1
2
VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 PHASE INVERTER
INPUT POWER
THREE PHASE
DIRECT CURRENT
POWER WAVE 655/R
I
1
I
2
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVE GROUND
WARNING OR CAUTION
Page 22
B-4 B-4
OPERATION
GENERAL DESCRIPTION
The Power Wave power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes.
The Power Wave power source is designed to be used with the family of Power Feed wire feeders, operating as a system. Each component in the system has spe­cial circuitry to "talk with" the other system compo­nents, so each component (power source, wire feeder, electrical accessories) knows what the other is doing at all times. The components communicate with Arc-Link.
Robotic systems can communicate with other industri­al machines via DeviceNET. The result is highly intri­gated and flexible welding cell.
The Power Wave 655/R is a high performance, digital­ly controlled inverter welding power source capable of complex, high-speed waveform control. Properly equipped, it can support the GMAW, GMAW-P, FCAW, SMAW, GTAW and CAC-A processes. It carries an out­put rating of either 650 amps, 44 volts (at 100% duty cycle) and 800 amps, 44 volts (at 60% duty cycle).
RECOMMENDED EQUIPMENT
• Automatic Operation All welding programs and procedures are set through software for the robotic Power Waves. FANUC robots equipped with RJ-3 controllers may communicate directly to the Power Wave. Other pieces of equip­ment such as PLCʼs or computers can communicate to the Power Wave using DeviceNET. All wire welding processes require a robotic Power Feed wire feeder.
• Semi-Automatic Operation Operating the Power Wave 655/R in the semi-auto­matic mode requires an Arc-Link compatible wire feeder and user interface.
REQUIRED EQUIPMENT
• Control Cables (22 pin to 22 pin), K1795-10ft.,-25ft.,-50ft.,
-100ft.
• Control Cables for use on FANUC robot arm, 22 pin to 14 pin, 10ft.(3m), K1804-1
• Control Cables for use on FANUC robot arm, 22 pin to 14 pin, 18in.(457mm), K1805-1
• Control Cables for use on FANUC robot arm, 22 pin to 14 pin, 18in.(457mm), K1804-2
If the duty cycle is exceeded, a thermostat will shut off the output until the machine cools to a reasonable operating temperature.
RECOMMENDED PROCESSES AND EQUIPMENT
RECOMMENDED PROCESSES
The Power Wave 655/R can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is factory prepro­grammed with multiple welding procedures, typically including GMAW, GMAW-P, FCAW, GTAW,CAC-A, and SMAW for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum.
The Power Wave 655/R can be configured for either robotic or semi-automatic use.
LIMITATIONS
• Power Waves are not to be used in outdoor environ-
ments.
• Only Arc-Link Power Feed wire feeders and user
interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feeders cannot be used.
DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining system duty cycle capability. Note that the duty cycle is based upon a ten minute period. A 60% duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period.
POWER WAVE 655/R
Page 23
B-5 B-5
-
+
POWERWAVE
Case Front Layout
Power Wave 655/R (Domestic/Canadian Version)
S6
1
3
2
11
12
4
13
5
9
10
8
7
6
OPERATION
CASE FRONT CONTROLS
All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1)
1. POWER SWITCH: Controls input power to the Power Wave.
2. STATUS LIGHT: A two color light that indicates sys­tem errors. Normal operation is a steady green light. Error conditions are indicated per table 4.
NOTE: The robotic Power Waveʼs status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.
TABLE 6
Light
Condition
Steady Green
System OK. Power source communicating normal­ly with wire feeder and its components.
Meaning
3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temper­ature situation occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is enabled.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER: Protects 40 volt DC wire feeder power supply.
10 AMP AUXILIARY POWER CIRCUIT BREAKER:
5. Protects 110 volt AC case front receptacle auxiliary supply.
6. LEAD CONNECTOR S2 (SENSE LEAD)
7. 5-PIN ARC LINK S1
8. 5-PIN DEVICENET CONNECTOR S5
9. I / O CONNECTOR
10. NEGATIVE STUD
11. INTERFACE CONNECTOR S6
12. POSITIVE STUD
Blinking Green
Alternating Green and Red
Steady Red Blinking Red
Occurs during a reset, and indicates the PW­655/R is mapping (identifying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system con­figuration is changed during operation.
Non-recoverable system fault. If the PS Status light is flashing any combination of red and green, errors are present in the PW­655/R. Read the error code before the machine is turned off.
Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits are flashed in red with a long pause between digits. If more than one code is present, the codes will be separated by a green light.
To clear the error, turn power source off, and back on to reset. See Troubleshooting Section.
Not applicable. Not applicable.
13. AUXILIARY OUTPUT
FIGURE B.1
POWER WAVE 655/R
Page 24
B-6 B-6
Current
Time
Wave Control +10.0
Wave Control -10.0
Wave Control 0.00
OPERATION
WELDING MODE DESCRIPTIONS
CONSTANT VOLTAGE WELDING
For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft­ware at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed speed changes, the Power Wave will automatically adjust the corre­sponding voltage.
FIGURE B.2 – CV WAVE CONTROL CHARACTERISTICS
Wave control adjusts the inductance of the waveshape. (This adjustment is often referred to as "pinch". In ­ductance is inversely proportional to pinch.) In creasing wave control greater than 0 results in a harsher, colder arc, while decreasing the wave control to less than 0 provides a softer, hotter arc. (See Figure B.2.)
POWER WAVE 655/R
Page 25
B-7 B-7
OPERATION
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. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known. Using a preset voltage becomes impracti­cal, and instead the arc length is set by adjusting "trim".
Trim adjusts the arc length and ranges from 0.50 to
1.50, with a nominal value of 1.00. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease the arc length.
Most pulse welding programs are syngeric. As the wire feed speed is adjusted, the Power Wave will automati­cally recalculate the waveform parameters to maintain similar arc properties.
FIGURE B.3 - PULSE WAVE CONTROL CHARACTERISTICS
The Power Wave utilizes "adaptive control" to com­pensate for changes in electrical stick-out while weld­ing. (Electrical stick-out is the distance from the con­tact tip to the work piece.) The Power Wave waveforms are optimized for a 0.75" (19mm) stick-out. The adap­tive behavior supports a range of stickouts from 0.50" (13mm) to 1.25" (32mm). At very low or high wire feed speeds, the adaptive range may be less due to reach­ing physical limitations of the welding process.
Wave control in pulse programs usually adjusts the focus or shape of the arc. Wave control values greater than 0 increase the pulse frequency while decreasing the background current, resulting in a tight, stiff arc best for high speed sheet metal welding. Wave control values less than 0 decrease the pulse frequency while increasing the background current, for a soft arc good for out-of-position welding. (See Figure B.3)
Current
Time
POWER WAVE 655/R
Page 26
B-8 B-8
NOTES
POWER WAVE 655/R
Page 27
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Factory Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Field Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
TABLE OF CONTENTS - ACCESSORIES
POWER WAVE 655/R
Page 28
C-2 C-2
ACCESSORIES
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 outlet on the regulator to the proper 5/8-18 female gas inlet on the back panel of the wire drive. Secure fitting with flow adjuster key at top.
Voltage Sense Leads (K490-10, -25 or -50)
The voltage sense leads connect at the front of the machine.
Cool Arc 40 (K1813-1) * Water Flow Sensor (K1536-1)
Water cooled guns can be damaged very quickly if they are used even momentarily without water flow­ing. Recommend practice is to install a water flow sensor such as on the water return line of the torch. When fully integrated into the welding system, the sensor will prevent welding if no water flow is present.
• Dual Cylinder Undercarriage, K1570-1*
*The Dual Cylinder Undercarriage, K1570-1 is not
compatible in combination with the Power Wave Water Cooler K1767-1.
• Coaxial welding Cable, K1796
POWER WAVE 655/R
Page 29
D-1 D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Main Assembly (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
TABLE OF CONTENTS - MAINTENANCE
POWER WAVE 655/R
Page 30
D-2 D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only Qualified personnel should perform this maintenance.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
ROUTINE MAINTENANCE
PERFORM THE FOLLOWING DAILY:
1. Check that no combustible materials are in the welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that could block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits or punc­tures in the cable jacket, or any condition that would affect the proper operation of the machine.
CALIBRATION SPECIFICATION
Calibration of the PW-655/R is critical to its opera­tion. The output Voltage and Current are calibrated at the factory and generally speaking the calibra­tion will not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance, the calibration of output Voltage and
Current should be checked yearly.
The calibration procedure itself requires the use of a grid (Resistive Load Bank), and certified actual meters for voltage and current. The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use. The Diagnostics Utility includes detailed instructions, and is available on the Power Wave Submerged Arc Utilities disc that comes with the machine, on the Service Navigator DVDʼs or on
Powerwavesoftware.com
calibrate properly see the troubleshooting section of this manual.
. If the system does not
PERIODIC MAINTENANCE
PERFORM PERIODICALLY:
Clean the inside of the machine with a low pressure air stream. Clean the following parts. Refer to Figure D.1.
• Transformer and output rectifier assembly.
• Electrode and work cable connections.
• PC board connections..
• Intake and outlet louvers on the machine case.
• Any obvious accumulations of dirt within the machine.
• Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
POWER WAVE 655/R
Page 31
D-3 D-3
11
77
77
77
33
44
55
22
66
22
22
FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW)
MAINTENANCE
1. CASE FRONT ASSEMBLY
2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBLY
3. INPUT ASSEMBLY
4. CONTROL BOX AND VERTICAL DIVIDER ASSEMBLY
5. BASE, LIFT BAIL AND FAN ASSEMBLY
6. SWITCH BOARD HEATSINK ASSEMBLY
7. CASE PARTS
POWER WAVE 655/R
Page 32
D-4 D-4
NOTES
POWER WAVE 655/R
Page 33
E-1 E-1
+
INPUT BOARD
LEFT SWITCH BOARD
RIGHT SWITCH BOARD
INPUT RECTIFIER
CR1
GATEWAY BOARD
DC BUS BOARD
FEED HEAD BOARD
POWER BOARD
CONTROL BOARD
OUTPUT CHOKE
ELECTRODE TERMINAL
THERMOSTATS
T1
T2
AUX RECONNECT
RELAY
WATER COOLER
115 VAC RECP.
115 VAC FAN
ARC LINK WIRE FEEDER RECP.
S1
S6
CONNECTION
TO WIRE
DRIVE
S1
S6
VOLT SENSE BOARD
MAIN TRANSFORMER
S5
CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD
FROM CONTROL BOARD
2 4 V A C
115 VAC
52 VAC
230 VAC
40 VDC
40 VDC
40 VDC
40 VDC
ARC LINK
CONNECTION TO ROBOT
VOLTAGE SENSE OUTPUT
C
AP. V/F
FEEDBACK
CAP. V/F
FEEDBACK
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT TO CONTROL BOARD
-15 V
+15 V
+5 V
+5 V ARC LINK
+5V RS232
+15V SPI
STATUS THERMAL
LIGHT LIGHT
S2 WORK SENSE
LEFT S.B. CAP. V/F
RIGHT S.B. CAP. V/F
S3 RS232
LEFT CT CURRENT FB
C U R R E N T
F B
ARC LINK
IGBT DRIVES
TO LEFT S.B.
TO RIGHT S.B.
67A
67B
SW1
BUS BOARD RECTIFIER
CURRENT TRANSDUCER
O
UTPUT DIODES
D1 -D4
115 VAC
40 VDC
DEVICE NET
VOLTAGE SENSE SELECT
IGBT DRIVE FROM CONTROL BOARD
+5V SPI
RIGHT CT CURRENT FB
TO FAN RELAY CONTACTOR AND
PRECHARGE CONTROL SIGNALS
65 VDC
WORK TERMINAL
POWER WAVE 655/R
380­ 415 440­ 460 550­ 575
+
ETHERNET/
A
A
HARMONIC FILTER
C
P
OS
NEG
Auxiliary Fan
TABLE OF CONTENTS - THEORY OF OPERATION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Voltage and Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Switch Boards and Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
DC Bus Board, Power Board, Feed Head Board, Gateway Board
and Voltage Sense Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Output Rectifier, and Output Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
Thermal Protection, Protective Circuits, Over Current Protection
and Under/Over Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-11
FIGURE E.1 — BLOCK LOGIC DIAGRAM.
POWER WAVE 655/R
Page 34
E-2 E-2
+
INPUT B
OARD
LEFT SWITCH B
OARD
RIGHT SWITCH BOARD
INPUT
R
ECTIFIER
C
R1
GATEWAY
BOARD
DC BUS BOARD
FEED HEAD BOARD
P
OWER
BOARD
CONTROL BOARD
OUTPUT C
HOKE
E
LECTRODE
TERMINAL
T
HERMOSTATS
T1
T2
AUX R
ECONNECT
R
ELAY
WATER C
OOLER
115 VAC RECP.
1
15 VAC
FAN
ARC LINK WIRE FEEDER RECP.
S1
S6
CONNECTION
TO WIRE DRIVE
S
1
S6
V
OLT SENSE B
OARD
MAIN TRANSFORMER
S5
CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD
FROM CONTROL BOARD
2 4 V A C
1
15 VAC
5
2 VAC
230 VAC
40 VDC
40 VDC
40 VDC
40 VDC
ARC LINK
CONNECTION TO ROBOT
VOLTAGE SENSE OUTPUT
CAP. V/F
FEEDBACK
CAP. V/F
FEEDBACK
IGBT DRIVE FROM CONTROL BOARD
CT CURRENT TO CONTROL BOARD
-15 V
+15 V
+
5 V
+5 V ARC LINK
+5V RS232
+
15V SPI
STATUS THERMAL
LIGHT LIGHT
S2 WORK SENSE
LEFT S.B. C
AP. V/F
R
IGHT S.B.
CAP. V/F
S3
RS232
L
EFT CT CURRENT FB
C U R R E N T
F B
ARC LINK
IGBT D
RIVES
TO LEFT S.B.
T
O
R
IGHT
S
.B.
67A
67B
SW1
B
US BOARD
R
ECTIFIER
CURRENT TRANSDUCER
O
UTPUT DIODES
D1 -D4
1
15 VAC
4
0 VDC
DEVICE NET
VOLTAGE SENSE SELECT
IGBT DRIVE FROM CONTROL BOARD
+
5V SPI
RIGHT CT CURRENT FB
TO FAN RELAY
C
ONTACTOR AND
P
RECHARGE
C
ONTROL SIGNALS
65 VDC
WORK T
ERMINAL
POWER WAVE 655/R
380-
415 440­ 460 550-
575
+
ETHERNET/
A
A
HARMONIC FILTER
C
POS
N
EG
Auxiliary Fan
THEORY OF OPERATION
FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE
GENERAL DESCRIPTION
The Power Wave 655/R power source is designed to be a part of a modular, multi-process welding system. It is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control.
The Power Wave 655/R is designed to be used with the family of Power Feed wire feeders, operating as a system. Each component in the system has special cir­cuitry to "talk with" the other system components, so
each component (power source, wire feeder, electrical accessories) knows what the other is doing at all times. The components communicate with Arc-Link.
Robotic systems can communicate with other industri­al machines via DeviceNET or Arc Link. The result is highly integrated and flexible welding cell.
Depending upon configuration, it can support constant current, constant voltage, and pulse welding modes. Each machine is factory preprogrammed with multiple welding procedures. Typically these procedures include GMAW, GMAW-P, FCAW, GTAW for a variety of materials such as mild steel, stainless steel, cored wires and aluminum.
The Power Wave 655/R has an output rating of either 650 amps at 44 (at 100% duty cycle) volts or 800 amps at 44 volts (at 60% duty cycle.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
Page 35
E-3 E-3
THEORY OF OPERATION
INPUT VOLTAGE AND PRECHARGE
The Power Wave 655/R can be connected for a variety of three-phase input voltages. Refer to Figure E.2. The initial input power is applied through a line switch located on the front of the machine. Two phases of the three-phase input power are applied simultaneously to the Input Board and both auxiliary transformers.
The various secondary voltages developed by trans­former T1 are applied to the Input Board, the fan motor (via a control relay) and the Bus Board rectifier. The 65VDC produced from the Bus Board rectifier is used by the Bus Board to provide various DC voltages for the Power Board, the Feed Head Board, the Ethernet/Gateway Board and the wire feeder recepta­cle.
The 115/230VAC developed on the secondary of auxil­iary transformer T2 is applied to the 115VAC receptacle and to the water cooler receptacle.
The 230VAC supply is also used to operate an auxil­iary cooling fan in the upper section of the machine. This fan runs whenever the power switch is ON.
The large fan in the lower section only runs when the machine is producing output. It is activated through a solid state relay that responds to a signal from the Control Board.
Two of the input lines are connected to the Input Board, by way of the input line switch SW1. They are then con­nected to the input rectifier through the precharge relay on the Input Board. During the precharge or "soft start" sequence, these two phases are current limited by resistord on the Input Board.
The AC input voltage is rectified, and the resultant DC voltage is applied through a harmonic filter to the input capacitors located on the right and left switch boards.
A Voltage to Frequency circuit on the Switch Boards sends a signal to the Control Board. When the capaci­tors have charged to an acceptable level, the Control Board signals the Input Board to energize the main input contactor (CR-1). At this point the Power Wave 655/R is in the "Run Mode" of operation. If the capaci­tors become undervoltaged, overvoltaged, or unbal­anced, the Control Board will signal the Input Board to de-energize the main input contactor, and the Power Wave 655/R will be disabled. See Figure E.2.
POWER WAVE 655/R
Page 36
E-4 E-4
+
INPUT BOARD
LEFT
S
WITCH
BOARD
RIGHT SWITCH BOARD
INPUT
RECTIFIER
C
R1
G
ATEWAY
BOARD
DC
BUS
BOARD
FEED HEAD BOARD
POWER B
OARD
C
ONTROL
BOARD
OUTPUT C
HOKE
ELECTRODE TERMINAL
THERMOSTATS
T
1
T2
AUX RECONNECT
RELAY
WATER COOLER
1
15 VAC
RECP.
115 VAC FAN
ARC LINK W
IRE
F
EEDER
R
ECP.
S1
S6
CONNECTION
TO WIRE
DRIVE
S1
S6
VOLT
S
ENSE
B
OARD
MAIN
TRANSFORMER
S
5
CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD
FROM CONTROL BOARD
2 4 V A C
115 VAC
52 VAC
230 VAC
40 VDC
40 VDC
40 VDC
40 VDC
ARC LINK
CONNECTION T
O
ROBOT
VOLTAGE SENSE OUTPUT
CAP. V/F
FEEDBACK
CAP. V/F
FEEDBACK
IGBT DRIVE FROM CONTROL BOARD
CT CURRENT T
O CONTROL
BOARD
-15 V
+15 V
+5 V
+5 V ARC LINK
+
5V RS232
+15V SPI
STATUS THERMAL
LIGHT LIGHT
S2 WORK SENSE
LEFT S.B. CAP. V/F
RIGHT S.B. CAP. V/F
S3
RS232
LEFT CT CURRENT FB
C U R R E N T
F B
ARC LINK
IGBT
D
RIVES
TO LEFT S.B.
TO RIGHT S.B.
67A
67B
SW1
BUS BOARD RECTIFIER
CURRENT TRANSDUCER
OUTPUT DIODES D1 -D4
115 VAC
40 VDC
DEVICE NET
VOLTAGE SENSE SELECT
IGBT DRIVE FROM CONTROL BOARD
+5V SPI
RIGHT CT CURRENT FB
TO FAN RELAY CONTACTOR AND
PRECHARGE CONTROL SIGNALS
65 VDC
W
ORK
T
ERMINAL
POWER WAVE 655/R
3
80­ 415 440-
460
5
50­ 575
+
E
THERNET/
A
A
H
ARMONIC
FILTER
C
P
OS
NEG
A
uxiliary
Fan
THEORY OF OPERATION
FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER
SWITCH BOARDS AND MAIN TRANSFORMER
There are two switch boards in the Power Wave 655/R machine. Each contains two input capacitors and insu­lated gate bipolar transistor (IGBT) switching circuitry. Refer to Figure E.3. The input capacitors on each board are connected in parallel. The two paralleled pairs are then connected in series to accomodate the high DC voltage from the rectifier.
When the input capacitors are fully charged, they act as power supplies for the IGBT (insulated gate bipolar transistors) switching circuits. The IGBTʼs switch the
DC power from the input capacitors "on and off," thus supplying pulsed DC current to the main transformer primary windings. See IGBT OPERATION DISCUS- SION AND DIAGRAMS in this section.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
Each switch board feeds current to separate, opposite­ly wound primary coils in the Main Transformer. The reverse directions of current flow through the main transformer primaries, and the offset timing of the IGBT switch boards induce an AC square wave output signal at the secondary of the main transformer. Current transformers monitor the primary currents. If the pri­mary currents become abnormally high, the Control Board will shut off the IGBTs, thus disabling the machineʼs output. The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off. This is needed due to the inductance of the transformer pri­mary windings. The firing of the two switch boards occurs during halves of a 50-microsecond interval, cre­ating a constant 20 KHZ output. See the PULSE WIDTH MODULATION discussion in this section.
Page 37
E-5 E-5
+
I
NPUT
BOARD
LEFT SWITCH BOARD
RIGHT SWITCH BOARD
INPUT RECTIFIER
CR1
GATEWAY BOARD
DC BUS BOARD
FEED HEAD BOARD
POWER BOARD
CONTROL BOARD
OUTPUT CHOKE
ELECTRODE TERMINAL
T
HERMOSTATS
T
1
T2
AUX RECONNECT
RELAY
W
ATER
COOLER
115 VAC RECP.
115 VAC FAN
ARC LINK WIRE FEEDER RECP.
S1
S6
C
ONNECTION
T
O WIRE
DRIVE
S1
S6
VOLT SENSE BOARD
MAIN TRANSFORMER
S5
C
ONTACTOR AND PRECHARGE
C
ONTROL SIGNALS FROM
C
ONTROL BOARD
F
ROM CONTROL
B
OARD
2 4 V A C
1
15 VAC
5
2 VAC
2
30 VAC
4
0 VDC
4
0 VDC
40 VDC
40 VDC
ARC LINK
CONNECTION TO ROBOT
VOLTAGE SENSE OUTPUT
C
AP. V/F
F
EEDBACK
CAP. V/F
FEEDBACK
IGBT DRIVE FROM CONTROL BOARD
C
T CURRENT
T
O CONTROL
B
OARD
-15 V
+
15 V
+
5 V
+
5 V ARC LINK
+5V RS232
+15V SPI
STATUS THERMAL
LIGHT LIGHT
S
2 WORK
S
ENSE
L
EFT S.B.
CAP. V/F
RIGHT S.B. CAP. V/F
S3 RS232
L
EFT CT CURRENT FB
C U R R E N T
F B
A
RC LINK
IGBT DRIVES
TO LEFT S.B.
TO RIGHT S.B.
6
7A
67B
SW1
BUS BOARD RECTIFIER
CURRENT TRANSDUCER
OUTPUT DIODES D1 -D4
115 VAC
40 VDC
D
EVICE NET
V
OLTAGE SENSE SELECT
IGBT DRIVE FROM CONTROL BOARD
+
5V SPI
RIGHT CT CURRENT FB
T
O FAN RELAY
CONTACTOR AND PRECHARGE CONTROL SIGNALS
6
5 VDC
WORK TERMINAL
POWER WAVE 655/R
380­ 415 440­ 460 550­ 575
+
ETHERNET/
A
A
HARMONIC FILTER
C
POS
NEG
Auxiliary Fan
THEORY OF OPERATION
FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
GATEWAY BOARD AND VOLTAGE SENSE BOARD
DC BUS BOARD, POWER BOARD, FEED HEAD BOARD, GATEWAY BOARD AND VOLTAGE SENSE BOARD
The DC Bus Board receives approximately 65VDC from the Bus Board rectifier. The DC Bus Board regu­lates that 65VDC to a +40VDC supply. This regulated 40VDC is applied to the Feed Head Board, the Ethernet/Gateway Board, the Power Board, and the wire feeder receptacle.
The switching power supplies on the Power Board sup­ply a variety of regulated DC voltages to the Control Board. The Control Board uses these regulated volt­ages to power the many circuits and communication functions incorporated within the Control Board.
When the Feed Head Board activates the Voltage Sense Board, the actual arc voltage is sensed (lead
67), and this information is delivered through the volt­age sense board to the Control Board.
The Power Wave 655R uses two digital communication platforms. Internally the PC boards communicate via ArcLink. Externally the Power Wave 655R communi­cates using the industry standard Ethernet or Device Net protocol.The Ethernet/Gateway Board makes the translation between the platforms possible. The Power Wave 655R does not have a dedicated interface device or board. The robot (or other input device – PLC, etc.) acts as the user interface, issuing commands that are translated by the Gateway Board to ArcLink compatible messages. Figure E.5 depicts the flow of communica­tion information.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
Page 38
E-6 E-6
FIGURE E.5 – POWER WAVE 655/R COMMUNICATIONS
THEORY OF OPERATION
AArrcc LLiinnkk
Arc Link
CCoonnttrrool
BBooaarrd
Weld Controller / Sequencer
l
d
PW-655R
EEtthheerrnneett/
GGaatteewwaay
BBooaarrd
Translator
Robot
Controller
/
y
d
DDeevviiccee NNeett
Device Net
FFeeeed
d
HHeeaad
d
BBooaarrd
d
PF-10R
POWER WAVE 655/R
Page 39
E-7 E-7
+
INPUT BOARD
LEFT SWITCH B
OARD
RIGHT S
WITCH
BOARD
INPUT RECTIFIER
C
R1
GATEWAY BOARD
DC BUS B
OARD
FEED HEAD B
OARD
POWER BOARD
CONTROL
BOARD
OUTPUT CHOKE
ELECTRODE TERMINAL
THERMOSTATS
T1
T2
AUX
RECONNECT
RELAY
WATER C
OOLER
1
15 VAC
RECP.
1
15 VAC
FAN
ARC LINK WIRE FEEDER R
ECP.
S1
S6
CONNECTION
TO WIRE
DRIVE
S1
S6
VOLT
S
ENSE
B
OARD
MAIN T
RANSFORMER
S5
CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD
F
ROM CONTROL
BOARD
2 4 V A C
115 VAC
52 VAC
230 VAC
40 VDC
40 VDC
4
0 VDC
40 VDC
ARC LINK
CONNECTION T
O
ROBOT
VOLTAGE SENSE OUTPUT
CAP. V/F
F
EEDBACK
CAP. V/F
F
EEDBACK
IGBT DRIVE FROM CONTROL B
OARD
CT CURRENT TO CONTROL BOARD
-15 V
+15 V
+5 V
+
5 V ARC LINK
+5V RS232
+15V SPI
STATUS THERMAL
LIGHT LIGHT
S
2 WORK
SENSE
LEFT S.B. CAP. V/F
RIGHT S.B. CAP. V/F
S3 RS232
L
EFT CT CURRENT FB
C U R R E N T
F B
A
RC LINK
IGBT DRIVES
TO LEFT S.B.
TO RIGHT S.B.
6
7A
67B
S
W1
BUS BOARD RECTIFIER
CURRENT TRANSDUCER
O
UTPUT DIODES
D1 -D4
115 VAC
40 VDC
DEVICE NET
VOLTAGE SENSE SELECT
IGBT DRIVE FROM C
ONTROL
BOARD
+5V SPI
RIGHT CT CURRENT FB
TO FAN RELAY C
ONTACTOR AND PRECHARGE C
ONTROL SIGNALS
65 VDC
W
ORK
T
ERMINAL
POWER WAVE 655/R
380­ 415 440­ 460 550­ 575
+
ETHERNET/
A
A
HARMONIC FILTER
C
POS
NEG
Auxiliary Fan
THEORY OF OPERATION
FIGURE E.6 – CONTROL BOARD
CONTROL BOARD
The Control Board performs the primary interfacing functions to establish and maintain output control of the Power Wave 655R machine. The function generator and weld files exist within the Control Board hardware and software. Digital command signals and arc voltage and current feedback information is received and processed by software located on the Control Board. The appropriate pulse width modulation (PWM) signals are then sent to the gates of the Switch Board IGBTs to create the high-speed, digitally controlled welding waveform. (See PULSE WIDTH MODULATION dis- cussion in this section).
In addition, the Control Board monitors the ther­mostats, the main transformer primary currents and input filter capacitor voltages. Depending on the fault condition, the Control Board will activate the thermal and/or the status light and will either disable or reduce
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
the machine output. In some conditions the input con­tactor will be de-energized.
POWER WAVE 655/R
Page 40
E-8 E-8
+
I
NPUT
BOARD
LEFT
S
WITCH
BOARD
RIGHT
S
WITCH
BOARD
INPUT
RECTIFIER
C
R1
GATEWAY
BOARD
DC BUS B
OARD
FEED HEAD B
OARD
P
OWER
B
OARD
CONTROL
BOARD
O
UTPUT
C
HOKE
ELECTRODE T
ERMINAL
THERMOSTATS
T1
T2
AUX RECONNECT
RELAY
WATER COOLER
115 VAC R
ECP.
115 VAC FAN
ARC LINK W
IRE
F
EEDER
RECP.
S1
S6
CONNECTION
T
O WIRE
DRIVE
S
1
S
6
VOLT
S
ENSE
BOARD
MAIN
T
RANSFORMER
S5
C
ONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD
F
ROM CONTROL
B
OARD
2 4 V A C
1
15 VAC
5
2 VAC
2
30 VAC
4
0 VDC
4
0 VDC
4
0 VDC
40 VDC
A
RC LINK
C
ONNECTION
T
O
R
OBOT
VOLTAGE SENSE OUTPUT
C
AP. V/F
FEEDBACK
CAP. V/F
FEEDBACK
IGBT DRIVE F
ROM
C
ONTROL
B
OARD
C
T CURRENT TO CONTROL BOARD
-15 V
+
15 V
+
5 V
+
5 V ARC LINK
+
5V RS232
+
15V SPI
S
TATUS THERMAL
LIGHT LIGHT
S
2 WORK
S
ENSE
L
EFT S.B.
C
AP. V/F
R
IGHT S.B.
C
AP. V/F
S3 RS232
L
EFT CT
CURRENT
FB
C U R R E N T
F B
A
RC LINK
IGBT DRIVES
TO L
EFT
S
.B.
TO R
IGHT
S
.B.
6
7A
67B
S
W1
BUS BOARD R
ECTIFIER
CURRENT T
RANSDUCER
OUTPUT DIODES D1 -D4
115 VAC
40 VDC
D
EVICE NET
VOLTAGE SENSE SELECT
I
GBT DRIVE
F
ROM
C
ONTROL
BOARD
+5V SPI
RIGHT CT
CURRENT
FB
T
O FAN RELAY
C
ONTACTOR AND
P
RECHARGE
CONTROL SIGNALS
6
5 VDC
W
ORK
T
ERMINAL
POWER WAVE 655/R
380­ 415 4
40­ 460 5
50­ 575
+
ETHERNET/
A
A
H
ARMONIC
FILTER
C
P
OS
NEG
Auxiliary Fan
THEORY OF OPERATION
FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD
OUTPUT RECTIFIER, OUTPUT CHOKE
The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. The output choke is in series with the negative leg of the output rectifier and also in series with the welding load. Due to the current "smoothing" capability of the output choke, a filtered DC output current is applied through the machine output termi­nals to the welding arc.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
Page 41
E-9 E-9
THEORY OF OPERATION
THERMAL PROTECTION
Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con­nected to the control board. One of the thermostats is located on the heat sink of the output rectifier, one on the DC bus, and one on the output choke. Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond its duty cycle or out­put rating. If excessive operating temperatures should occur, the thermostats will prevent output from the machine. The yellow thermal light, located on the front of the machine, will be illuminated. The thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and the reset should occur within a 15-minute period. If the fan is not turn­ing or the intake air louvers are obstructed, the power must be removed from the machine and the fan condi­tion or air obstruction corrected. On later production machines (above code 10500) the cooling fan runs only when necessary. The F.A.N. (fan as needed) sys­tem is controlled by the Control Board via a solid state relay.
OVER CURRENT PROTECTION
If the average weld current exceeds 880 amps, the peak current will be limited to 100 amps until the aver­age current decreases to under 50 amps or the system is re-triggered.
UNDER/OVER VOLTAGE PROTECTION
A protective circuit is included on the Control Board to monitor the voltage across the input capacitors. In the event that a capacitor voltage is too high, too low, or becomes unbalanced side-to-side, the protection cir­cuit will de-energize the input contactor. Machine out­put will be disabled, and the "soft start" mode will be repeated. The protection circuit will prevent output if any of the following circumstances occur.
1. Capacitor conditioning is required. (This may be required if the machine has been off for a long peri­od of time and is connected for high input voltage operation.)
2. Voltage across a capacitor exceeds 467 volts. (This could result from high line surges or improper input voltage connections.)
PROTECTIVE CIRCUITS
Protective circuits are designed into the Power Wave 655/R to sense trouble and shut down the machine before damage occurs to the machineʼs internal com­ponents. Error Codes will be flashed out by the Red/Green Status LED on the front panel and LEDʼs on the Control Board to help identify the reason for the shutdown. See the Troubleshooting Section for more information regarding Error Codes. Fault codes can also be seen by using the Diagnostic Software.
3. Voltage across a capacitor is under 70 volts. (This would be due to improper input voltage connec­tions.)
4. Internal component damage.
POWER WAVE 655/R
Page 42
E-10 E-10
DRAIN
SOURCE
GATE
I
NJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
DRAIN
SOURCE
GATE
INJECTING LAYER
BUFFER LAYER
D
RAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
P
OSITIVE VOLTAGE APPLIED
B. ACTIVE
A. PASSIVE
THEORY OF OPERATION
FIGURE E.9 – IGBT OPERATION
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semicon­ductors well suited for high frequency switching and high current applications.
Drawing A shows an IGBT in a passive mode. There is no gate signal, (zero volts relative to the source), and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not supply current to components connected to the source. The circuit is turned off like a light switch in the OFF position.
Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components cou­pled to the source. Current will flow through the con­ducting IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON a light switch.
POWER WAVE 655/R
Page 43
E-11 E-11
MINIMUM OUTPUT
50
sec
25
sec
MAXIMUM OUTPUT
sec
s
ec
sec
24
sec
24
sec
sec
1
50
sec
sec
1
THEORY OF OPERATION
FIGURE E.10 – TYPICAL IGBT OUTPUTS
PULSE WIDTH MODULATION
The term PULSE WIDTH MODULATION (PWM) is used to describe how much time is devoted to conduc­tion in the positive and negative portions of the cycle. Changing the pulse width is known as MODULATION. Pulse Width Modulation is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during a cycle. The top drawing shows the minimum output sig­nal possible over a 50-microsecond time period.
1
An IGBT group consists of the sets of IGBT modules grouped onto one switch board.
The shaded portion of the signal represents one IGBT
1
group
, conducting for 1 microsecond. The negative por­tion is the other IGBT group. The dwell time (off time) is 48 microseconds (both IGBT groups off). Since only 2 microseconds of the 50-microsecond time period are devoted to conducting, the output power is minimized.
MAXIMUM OUTPUT
By holding the gate signals on for 24 microseconds each and allowing only 2 microseconds of dwell or off time (one microsecond during each half cycle) during the 50 microsecond cycle, the output is maximized. The dark­ened area under the minimum output curve can be com­pared to the area under the maximum output curve. The more darkened area, the more power is present.
POWER WAVE 655/R
Page 44
E-12 E-12
NOTES
POWER WAVE 655/R
Page 45
F-1 F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures
Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Input Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21
DC Bus Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Input Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
Auxiliary Transformer No. 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
Auxiliary Transformer No. 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
Component Removal and Replacement Procedure
Input Rectifier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45
Input Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Auxiliary Transformer No. 1 Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
Auxiliary Transformer No. 2 Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .F-51
Control, Feed Head, or Voltage Sense PC Board Removal and Replacement . . . . . . . . . . . . . . . . .F-53
Ethernet/Gateway PC Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-55
Power Wave Current Transducer Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-57
Output Rectifier Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59
Switch Board and Filter Capacitor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-63
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-67
Retest after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F71
POWER WAVE 655/R
Page 46
F-2 F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: output problems, function prob­lems, wire feeding problems, and welding problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may con­tribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted with­out removing the case wrap-around cover.
Step 3. RECOMMENDED COURSE OF ACTION
The last column labeled “Recommended Course of Action” lists the most likely com­ponents that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject com­ponent is either good or bad. If there are a number of possible components, check the components in the order listed one possibility at a time until you locate the cause of your problem.
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the specified test points, components, terminal strips, etc. can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.
to eliminate
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
POWER WAVE 655/R
Page 47
F-3 F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
•
Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
CAUTION
Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards, please use the following procedure:
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
2. Check for loose connections at the PC board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC board can be damaged by static electricity.
- Remove your bodyʼs static charge before opening the static­shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.
ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations
- If you donʼt have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
- Remove the PC board from the static-shielding bag and place it directly into the equipment. Donʼt set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board canʼt be installed immediately, put it back in the static-shield­ing bag.
- If the PC board uses protective shorting jumpers, donʼt remove them until installation is complete.
- If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop­er failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.
NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.
a. If the original problem does not reappear by
substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.
POWER WAVE 655/R
Page 48
F-4 F-4
TROUBLESHOOTING & REPAIR
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS
The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter­face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. In addition, errors displayed on the user interface in most cases indicate only that a problem exists in the power source, not what the problem may be.
Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below. This is especially
LIGHT CONDITION
Status LED is solid green (no blinking).
Status LED is blinking green.
important if the user interface displays "Err 006" or "Err 100" .
Included in this section is information about the power source Status LED, and some basic troubleshooting charts for both machine and weld performance. The STATUS LIGHT is a two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated in the following chart.
NOTE: The Power Wave status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.
MEANING
1. System OK. Power source communicating normally with wire feeder and its components.
2. Occurs during a reset, and indicates the Power Wave 455M (CE) is mapping (identifying) each com­ponent in the system. Normal for first 1-10 seconds after power is turned on, or if the system configura­tion is changed during operation.
Status LED is blinking red and green.
Status LED is solid red (no blinking).
Status LED is blinking red.
3. Non-recoverable system fault. If the PS Status light is flashing any combination of red and green, errors are present in the Power Wave 455M (CE). Read
the error code before the machine is turned off.
Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits are flashed in red with a long pause between digits. If more than one code is present, the codes will be separated by a green light.
To clear the error, turn power source off, and back on to reset.
Not Applicable
Not applicable.
POWER WAVE 655/R
Page 49
F-5 F-5
TROUBLESHOOTING & REPAIR
ERROR CODES FOR THE POWER WAVE
The following is a list of possible error codes that the Power Wave 655 can output via the status light If connect­ed to a PF-10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user inter­face display.
Error Code #
11 CAN communication bus off. 12 User Interface time out error.
21 Unprogrammed Weld Mode. 22 Empty Weld Table. 23 Weld Table checksum error.
31 Primary overcurrent error. 32 Capacitor "A" under voltage
(Left side facing machine)
33 Capacitor "B" under voltage
(Right side facing machine)
34 Capacitor "A" over voltage
(Left side facing machine)
35 Capacitor "B" over voltage
(Right side facing machine)
Indication
Probably due to excessive number of communication errors. UI is no longer responding to the Power Source. The most likely cause is a fault/bad connection in the communication leads or con­trol cable.
Contact the Service Department or instructions on reloading the Welding Software. Contact the Service Department or instructions on reloading the Welding Software. Contact the Service Department or instructions on reloading the Welding Software.. Excessive Primary current present. May be related to a short in the main transformer or output rectifier. Low voltage on the main capacitors. May be caused by improper input configuration. When accompanied by an overvoltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine. Excess voltage on the main capacitors. May be caused by improper input configuration.
When accompanied by an under voltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine.
powerwavesoftware.com powerwavesoftware.com powerwavesoftware.com
for for for
36 Thermal error
37 Soft start error 41 Secondary overcurrent error
43 Capacitor delta error
49 Single phase error
Other
Indicates over temperature. Usually accompanied by Thermal LED. Check fan operation. Be sure process does not exceed duty cycle limit of the machine.
Capacitor precharge failed. Usually accompanied by codes 32-35. The secondary (weld) current limit has been exceeded. When this occurs the machine output will phase back to 100 amps, typically resulting in a condition referred to as "noodle welding"
NOTE: The secondary limit is 570 amps for the standard stud, and 325 amps.
The maximum voltage difference between the main capacitors has been exceeded. May be accompanied by errors 32-35.
Indicates machine is running on single phase input power. Usually caused by the loss of the middle leg (L2). Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the PS Control Board. If cycling the input power on the machine does not clear the error, try reloading the latest version operating system (available at Service Department at 1-888-935-3877
powerwavesoftware.com
). If this fails, contact the
POWER WAVE 655/R
Page 50
F-6 F-6
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal covers are removed.

The input fuses repeatedly fail or the input circuit breakers keep trip­ping.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
Contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
1. Make certain the fuses or break­ers are properly sized.
2. Make certain the reconnect panel is configured properly for the applied voltage.
3. The welding procedure may be drawing too much input current or the duty cycle may be too high. Reduce the welding cur­rent and/or reduce the duty cycle.
RECOMMENDED
COURSE OF ACTION
Contact the Lincoln Electric Service Department at 1-888-935-3877
1. Check the reconnect switches and associated wiring. See the Wiring Diagram.
2. Perform the Input Rectifier
Test.
3. Perform the Switch Board Test.
4. Perform the Input Contactor Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
POWER WAVE 655/R
Page 51
F-7 F-7
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)

The machine is dead—no lights— no output—the machine appears to be off.

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Make certain the input power switch SW1 is in the ON posi­tion.
2. Check the main input fuses (or breakers). If open, replace or reset.
3. Check the 6 amp CB4 breaker located in the reconnect area. Reset if tripped.
4. Make certain the reconnect panel is configured correctly for the applied input voltage.
RECOMMENDED
COURSE OF ACTION
1. Check the input power switch SW1 for proper operation. Also check the associated leads for loose or faulty connections. See the Wiring Diagram.
2. Check circuit breaker CB4 for proper operation
3. Perform the T1 Auxiliary
Trans former Test.
4. The power board rectifier may be faulty. Check rectifier and associated wiring. See the Wiring Diagram.
5. Perform the DC Buss Board
Test.
6. Perform the Power Board Test.
7. The Control Board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
POWER WAVE 655/R
Page 52
F-8 F-8
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
The Power Wave 655/R does not have welding output. The main input contactor CR1 is not activat­ing.

The thermal light is lit. The machine regularly "overheats."

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Turn the input power off and make certain the reconnect panel is configured correctly for the applied input voltage.
2. If the Thermal light is lit, the unit may be overheated. Let the machine cool and adjust weld­ing load and/or duty cycle to coincide with the output limits of the machine.
1. The welding application may be exceeding the recommended duty cycle and/or current limits of the machine.
2. Dirt and dust may have clogged the cooling channels inside the machine. Refer to the Maint - enance Section of this manual.
RECOMMENDED
COURSE OF ACTION
1. Perform the Input Contactor
Test.
2. Perform the Input Board Test.
3. Perform the T1 Auxiliary
Transformer Test.
4. Perform the Input Rectifier
Test.
5. Perform the Switch Board
Test.
6. Perform the Power Board Test.
7. The Control Board may be faulty.
1. One of the thermostats may be faulty. Also check associated wiring for loose or faulty con­nections. See the Wiring Diagram.
3. Air intake and exhaust louvers may be blocked due to inade­quate clearance around the machine.
4. Make sure the fan is functioning correctly. Machines above code 10500 are equipped with F.A.N. (fan as needed) circuitry. The fan runs whenever the output is enabled, whether under load or open circuit conditions. The fan also runs for a period of time (approximately 5 minutes) after the output is disabled.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
POWER WAVE 655/R
Page 53
F-9 F-9
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
The machine often "noodle welds" when running a particular process. The output is limited to approxi­mately 100 amps.

The Power Wave 655/R will not produce full output.

POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. The machine may be trying to deliver too much power. When the average output current exceeds 570 amps, the machine will "phase back" to protect itself.
Adjust the procedure or reduce the load to lower the current draw from the Power Wave 655/R machine.
1. The input voltage may be too low, limiting the output capability of the machine. Make certain the input voltage is correct for the machine and the reconnect panel configuration.
2. Make sure all three phases of input power are being applied to the machine.
RECOMMENDED
COURSE OF ACTION
1. Perform the Current
Transducer Test.
2. The Control Board may be faulty.
1. Perform the Output Rectifier
Test.
2. Perform the Current Trans­ducer Test.
3. Perform the Power Board Test.
4. The Control Board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
POWER WAVE 655/R
Page 54
F-10 F-10
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)

The Auxiliary Receptacle is "dead." The 120VAC is not present at the receptacle.

The Power Wave 655/R is "trig­gered" for output but there is no welding output.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. Check the 10 amp circuit break­er (CB2) located on the case front. Reset if necessary.
2. Check the 6 amp circuit breaker (CB4) located in the reconnect area. Reset if necessary.
3. Make sure all three phases of input power are being applied to the machine.
1. Make sure that the triggering method and device is correct and operating properly.
2. Check circuit breaker CB4.
Reset if tripped.
RECOMMENDED
COURSE OF ACTION
1. Check the receptacle and asso­ciated wiring for loose or faulty connections. See the Wiring Diagram.
2. Perform the T2 Auxiliary
Trans former Test.
Use the Diagnostic Software to locate the problem. The latest soft­ware and the Diagnostic Utilities software is available at
power-
wavesoftware.com.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
POWER WAVE 655/R
Page 55
F-11 F-11
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This “safety” procedure should be performed before any internal maintenance or repair procedures are attempted on the POWER WAVE 655/R. Capacitors normally discharge within 2 minutes of removing input power. This procedure is used to check that the capac­itors have properly discharged.
MATERIALS NEEDED
Misc. hand tools Volt-ohmmeter 25-1000 ohms @ 25 watts (minimum) resistor Electrically insulated gloves and pliers
POWER WAVE 655/R
Page 56
SWITCH BOARD
CAPACITOR TERMINALS
F-12 F-12
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE
PROCEDURE
1. Disconnect the input power to the POWER WAVE 655/R.
2. Remove the left and right case sides.
3. Remove the two High Voltage Protection shields. Be careful not to touch the capacitor terminals that are located at the bottom of the left and right side switch boards.
4. With a voltmeter, carefully check for a DC volt­age at the capacitor terminals of both boards. Note the polarity as marked on the PC board.
5. If any voltage is present, proceed to Step #6. If no voltage is present, the capacitors are dis­charged.
NOTE: Normally the capacitors discharge with-in
about two minutes after input power is removed.
POWER WAVE 655/R
6. Using the high wattage resistor (25-1000 ohms @ 25 watts), with electrically insulated gloves and pliers, touch the resistor across the two capacitor terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS. NEVER USE A SHORTING STRAP
FOR THIS PROCEDURE.
7. Repeat procedure for the other capacitors.
8. Recheck the voltage across the capacitor termi­nals. The voltage should be zero. If any voltage remains, repeat the discharge procedure.
NOTE: If the capacitor voltage is present after the
discharge has been performed, this may indicate a faulty switch board.
Page 57
F-13 F-13
TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning cor­rectly. This test will NOT indicate if the entire PC board is functional. This resistance test is preferable to a voltage test with the machine energized because these boards can be damaged easily. In addition, it is dangerous to work on these boards with the machine energized.
MATERIALS NEEDED
Misc. Hand Tools Torque Wrench Volt-ohmmeter Wiring Diagram
POWER WAVE 655/R
Page 58
F-14 F-14
TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.2 – LEFT SIDE
NOTE: Resistance checks of the Switch Boards in this machine will vary greatly depending on
the type and model of meter being used. Comparative readings between the two sides of a board and/or between the two Switch Boards will be more meaningful than the actu­al numbers. In all cases, readings of all sets of test points should be approximately the same. If not using an ʻauto-rangingʼ meter, select the X1000 scale.
The readings in Table F.1 are representative of the meters available when this test was developed.
PROCEDURE
1. Disconnect the input power to the POWER WAVE 655/R.
2. Remove the case sides.
3. Perform the Capacitor Discharge Procedure.
4 Using the volt-ohmmeter, perform the resistance
tests detailed in Table F.1. The readings should all be similar. One or more readings that vary considerably will usually indicate a defective board. Refer to Figures F.2 and F.3 for the test points
5. If any test fails replace the Switch Board. See
Switch Board Removal and Replacement.
NOTE: Switch boards should have Identical
base numbers and dash numbers.
6. If the switch board resistance tests are OK, check the molex pin connections and associat­ed wiring from the switch boards to the control board. See the Wiring Diagram.
POWER WAVE 655/R
Page 59
(LEFT) 11 NEG POS 13 12 NEG POS 14 (RIGHT) 16 NEG POS 18 15 NEG POS 17
F-15 F-15
TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.3 – RIGHT SIDE AND TEST POINTS
TABLE F.1 – SWITCH BOARD RESISTANCE TEST POINTS
POSITIVE
METER PROBE
POS (19) 11(16) or 13(18)
POS (21) 12(15) or 14(17) 11(16) or 13(18) POS (19) 12(15) or 14(17) POS (21)
NEG (20) 11(16) or 13(18)
NEG (22) 12(15) or 14(17) 11(16) or 13(18) NEG (20) 12(15) or 14(17) NEG (22)
NOTE: A suspect board should be re-checked after removal from the machine. The actual readings may
be different at that time but all similar test points should be comparable. If not, the board is probably defective.
NEGATIVE
METER PROBE
DIGITAL
METER
(TYPICAL)
> .5 MΩ >5kΩ > .5 MΩ >5kΩ < .5 MΩ <2kΩ < .5 MΩ <2kΩ < .5 MΩ <2kΩ < .5 MΩ <2kΩ > .5 MΩ >5kΩ > .5 MΩ >5kΩ
ANALOG
METER (X1000)
TYPICAL
POWER WAVE 655/R
Page 60
F-16 F-16
NOTES
POWER WAVE 655/R
Page 61
F-17 F-17
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog volt-ohmmeter Misc. Hand Tools Wiring Diagram
POWER WAVE 655/R
Page 62
NEG (-)
A
B
C
INPUT
RECTIFIER
POS (+)
F-18 F-18
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST PROCEDURE (CONTINUED)
FIGURE F.4 – INPUT RECTIFIER TEST
PROCEDURE
1. Disconnect the input power to the POWER WAVE 655/R.
2. Remove the case top and Input Panel.
3. Perform the Capacitor Discharge Procedure.
4. Locate the Input Rectifier and lead locations. Refer to Figure F.4.
5. Use an ohmmeter to perform the tests detailed in Table F.2.
6. If the rectifier does not meet the expected read­ings,remove the POS. and NEG leads and re­test. If it still fails the test it should be replaced.
POWER WAVE 655/R
NOTE: Some of the RTV material will have to be
removed. The terminals should be re­sealed with RTV when testing or replace­ment is complete.
9. See the Input Rectifier Removal and Replacement procedure for proper torque set­tings when re-connecting the leads to the recti­fier.
10. Before installing a new rectifier, perform the
Switch Board test and the Input Contactor test.
11. Replace the case top and input panel.
Page 63
F-19 F-19
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST PROCEDURE (CONTINUED)
TABLE F.2 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS
TEST POINT TERMINALS
+ Probe - Probe
A B C
A B C
NEG NEG NEG
POS POS POS
NEG (F) NEG (F) NEG (F)
POS (D) POS (D) POS (D)
A B C
A B C
ANALOG METER X100
RANGE
Acceptable Meter Readings
Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms
Approx. 500 ohms Approx. 500 ohms Approx. 500 ohms
Approx. 500 ohms Approx. 500 ohms Approx. 500 ohms
Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms
NOTE: Digital meters may not provide enough current in the “ohms” mode to achieve the read-
ings indicated. They will, however, indicate whether the device is shorted (typical failure mode) or open. A ʻshortedʼ device will usually read a low resistance (<100Ω) in both
polarities. An ʻopenʼ device will read as if the meter leads were not connected to any­thing (typically “OL”) in both polarities.
POWER WAVE 655/R
Page 64
F-20 F-20
NOTES
POWER WAVE 655/R
Page 65
F-21 F-21
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input contactor is functional and if the contacts are functioning correctly.
MATERIALS NEEDED
Misc. Hand Tools Volt-ohmmeter External 24 VAC supply
POWER WAVE 655/R
Page 66
INPUT CONTACTOR
601
X4
F-22 F-22
L3
L2
L1
T3
T2
T1
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST PROCEDURE (CONTINUED)
FIGURE F.5 – INPUT CONTACTOR COIL
FFIIGGUURREE FF..55AA
CCOONNTTAACCTTOORR
TTEESSTT PPOOIINNTTSS
PROCEDURE
1. Disconnect the input power to the POWER WAVE 655/R.
2. Remove the input access panel and case top.
3. Locate, mark, and remove the two leads (601, X4) that are connected to the input contactor coil. Refer to Figure F.5.
4. Use an ohmmeter to check the resistance of the coil. It should be approximately 6Ω.
5. Check the resistance across the contacts: Refer to Figure F.5A
L1 to T1 , L2 to T2 and L3 to T3. All three readings should show “open”
If the resistance is low, the input contactor is
faulty.
POWER WAVE 655/R
6. Press in on the “test button” and recheck the contacts as in Step 5.
NOTE: If a 24 vac supply is available, it can be
connected to the coil terminals to activate the contactor, instead of using the Test Button.
All readings should be very close to 0Ω If the resistance is high, the input contactor is faulty.
7. Reconnect the two leads (601, X4) to the input contactor coil.
8. Replace the input access door and case top.
Page 67
F-23 F-23
TROUBLESHOOTING & REPAIR
DC BUS BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the DC Bus PC Board is receiving and processing the proper voltages.
MATERIALS NEEDED
Misc. Hand Tools Volt/ohmmeter Wiring Diagram
POWER WAVE 655/R
Page 68
A1
C13
L1
C15
R12
R9
R10
R11
R25
D1
D2
DZ4
C6
R4
R5
R7
R8
R19
X1
X2
C2
C3
C5
C7
C8
C9
C10
C11
MOV1
LED1
R3
R13
R14
R20
R21
R22
R23
DZ5
DZ6
R15 R16
D3
J47 J46
C14
C16
C17
D4
D5
MOV2
R26
R27
R28
R29
C1
LED
J47
J46
1 2
1 2 3 4
5 6 7 8
3 4
C3
Power Bd. Rectier
F-24 F-24
TROUBLESHOOTING & REPAIR
DC BUS BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.6 – DC BUS PC BOARD
PROCEDURE
1. Disconnect the input power from the machine.
2. Remove the case top.
3. Locate the DC Bus PC Board and plugs P46 and P47. See Figure F.6.
4. Carefully apply input power to the POWER WAVE 655/R.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present when input power is applied to the machine.
5. Turn on the POWER WAVE 655/R. The LED on the DC Bus Board should light.
If the LED does not light, check the input voltage to the board at the terminals of the capacitor C-3. It should read 65-75vdc.
6. If the input voltage is correct the DC Bus Board may be defective. If not, check the Power Board Rectifier and the Auxiliary Transformer T1.
7. Check the Bus Board output voltages at P47 per Table F.3.
TABLE F.3 - DC Bus Bd Output Voltages
Positive
Meter
Probe
Pin 7 Pin 6 38 to 42 to Power PC Bd.
Negative
Meter Probe
Voltage
Reading
(vdc)
Pin 8 Pin 6 38 to42 to Power PC Bd.
Pin 4 Pin 2 38 to 42 to Feed Head Bd.
Pin 3 Pin 1 38 to 42
to S1 - Wire Feeder
Receptacle
8. If any of the readings is incorrect, replace the board.
9. Disconnect the input power and replace the case top.
POWER WAVE 655/R
Page 69
F-25 F-25
TROUBLESHOOTING & REPAIR
POWER BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Power Board is receiving the correct voltages and also if the Power Board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
Misc. Hand Tools Volt-ohmmeter Wiring Diagram
POWER WAVE 655/R
Page 70
POWER PC BOARD
CAPACITOR C3
Power Bd. Rectier
6 5 4 4 3 12 11 10 9 8 7
3 2 1 2 1 6 5 4 3 2 1
F-26 F-26
TROUBLESHOOTING & REPAIR
POWER BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.7 – POWER BOARD TEST
PROCEDURE
1. Disconnect the input power to the POWER WAVE 655/R.
2. Remove the case top.
3. Locate the Power Board and plugs J42 and J43. Do not remove plugs or leads from the Power Board. Refer to Figure F.7.
4. Carefully apply input power to the POWER WAVE 655/R.
WARNING
ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine.
POWER WAVE 655/R
5. Turn on the POWER WAVE 655/R. Carefully test for the correct voltages at the Power Board according to Table F.4.
6. If either of the 40 VDC voltages is low or not present at plug J41, perform the DC Bus PC Board Test. See the Wiring Diagram. Also perform the T1 Auxiliary Transformer Test.
7. If any of the DC voltages are low or not present at plugs J42 and/or J43, the Power Board may be faulty.
8. Replace the case top.
Page 71
F-27 F-27
TROUBLESHOOTING & REPAIR
POWER BOARD TEST PROCEDURE (CONTINUED)
TABLE F.4 – POWER BOARD VOLTAGE CHECKS
CHECK POINT
LOCATION
POWER BOARD
CONNECTOR
PLUG J41
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J43
TEST
DESCRIPTION
CHECK 40 VDC
INPUT FROM
DC BUS BOARD
CHECK +15
VDC SUPPLY FROM
POWER BOARD
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD
CONNECTOR
PLUG PIN NO.
2 (+)
1 (-)
475 477
1 (+)
5 (-)
225
222
3 (+)
5 (-)
221
222
2 (+)
5 (-)
223
222
5 (+)
10 (-)
274
LEAD NO. OR
IDENTITY
477 (+)
475 (-)
225 (+)
222 (-)
221 (+)
222 (-)
222 (+)
223 (-)
274 (+)
273 (-)
NORMAL
ACCEPTABLE
VOLTAGE READING
38 – 42 VDC
+15 VDC
+5 VDC
-15 VDC
+5 VDC
POWER BOARD
CONNECTOR
PLUG J43
POWER BOARD
CONNECTOR
PLUG J43
POWER BOARD
CONNECTOR
PLUG J41
POWER BOARD
CONNECTOR
PLUG J43
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD
CHECK +15 VDC
SPI SUPPLY FROM
POWER BOARD
CHECK +40 VDC
INPUT FROM
DC BUS BOARD
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
CHECK +20 VDC STT
SUPPLY FROM
POWER BOARD
4 (+)
9 (-)
228
6 (+)
11 (-)
4 (+)
3 (-)
476 478
3 (+)
12 (-)
268A
7 (+)
346
1 (-)
345
273
226
266
267
262
226 (+)
228 (-)
266 (+)
267 (-)
478 (+)
476 (-)
268A (+)
262 (-)
345 (+)
346 (-)
+5 VDC
+15 VDC
38 – 42 VDC
+5 VDC
+20 VDC
POWER WAVE 655/R
Page 72
F-28 F-28
NOTES
POWER WAVE 655/R
Page 73
F-29 F-29
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Input Board is sending the correct voltages and also if the Input Board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
Misc. Hand Tools Volt-ohmmeter Wiring Diagram
POWER WAVE 655/R
Page 74
F-30 F-30
INPUT C
ONTACTOR
6
01
X
4
J
60
J
61
INPUT PC BOARD
8 7 6 5
4 3 2 1
10 9 8 7 6
5 4 3 2 1
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.8 – INPUT BOARD AND CONTACTOR
PROCEDURE
1. Disconnect the input power to the POWER WAVE 655/R.
2. Remove the case top.
3. Remove lead X4 from the coil terminal of main input contactor CR1. Insulate lead X4. Refer to Figure F.8.
4. Carefully apply input power to the POWER WAVE 655/R.
WARNING
5. Turn on the POWER WAVE 655/R. Carefully test for the correct voltages according to Table
F.5.
ELECTRIC SHOCK can kill.
High voltage is present when input power is applied to the machine.
6. Remove input power to the POWER WAVE 655/R. If any of the voltages are low or not pre­sent, perform the Input Contactor Test. If that checks out, the Input Board may by faulty.
7. Reconnect lead X4 to the main input contactor CR1 coil terminal.
8. Carefully apply the correct input voltage to the POWER WAVE 655/R.
9. Turn on the POWER WAVE 655/R. Check for the presence of 24 VAC from lead X4 to lead
601. See Figure F. 9.
9. This 24 VAC is the coil voltage for main input
contactor CR1. It will normally be present approximately 12 seconds after input line switch (SW1) is activated.
10. If the voltage is not present, perform the
Auxiliary Transformer #1 Test.
11. Disconnect the input power and replace the case top.
POWER WAVE 655/R
Page 75
F-31 F-31
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST PROCEDURE (CONTINUED)
TABLE F.5 – INPUT BOARD VOLTAGE CHECKS
TEST POINTS
PLUG J61 PIN 8 (H1D)
TO
PLUG J61 PIN 6 (612)
PLUG J61 PIN 10 (T3)
TO
PLUG J61 PIN 2 (T1)
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 4 (604)
NUMBERS
#612
T1
LEAD
J61
H1D
J61
J60
#238
T3
#604
EXPECTED
VOLTAGE
READINGS
SAME AS
INPUT
VOLTAGE
A LITTLE LESS
THAN INPUT
VOLTAGE
13 – 15 VDC
COMMENTS
Present when Input Switch SW1 is closed.
This is Pre-Charge Voltage and will normally be present 6 sec­onds after activating Input Switch SW1. The Pre-Charge Voltage should remain for approximately 6 seconds and then be removed.
This is the Coil Voltage for the Pre-Charge Relay. Normally this DC Voltage will be present 6 sec­onds after Input Switch SW1 is activated. This 13 - 15 VDC will remain for approximately 6 sec­onds and then be removed. The Relay is controlled by the Control Board. See the Wiring Diagram.
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 5 (232)
#232
J60
13 – 15 VDC
#238
POWER WAVE 655/R
This is the DC Coil Voltage for the Control Relay. Normally this DC Voltage will be present approxi­mately 12 seconds after Input Switch SW1 is activated. The Relay is controlled by the Control PC Board. See the Wiring Diagram.
Page 76
F-32 F-32
NOTES
POWER WAVE 655/R
Page 77
F-33 F-33
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Current Transducer and associated wiring is function­ing correctly.
MATERIALS NEEDED
Misc. Hand Tools Lap-top Computer Diagnostic Utilities Software Resistive Load Bank (Optional - 50 ft., 4/0 weld cable) Calibrated Ammeter Volt-Ohmmeter
NOTE: The Diagnostic Utility Software is on the Utilities Disc that was shipped with the
machine. It can also be accessed from the Lincoln Service Navigator or down­loaded from the “web” at
Powerwavesoftware.com.
POWER WAVE 655/R
Page 78
F-34 F-34
CURRENT
TRANSDUCER
J8
216
211
212
213
CONTROL BOARD
J8
5 6 7 8
1 2 3 4
P91
1234
J9
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED)
FIGURE F.9 – CURRENT TRANSDUCER TEST
PROCEDURE
1. Disconnect the input power to the POWER WAVE 655/R.
2. Remove the case top and the control box cover.
3. Locate the current transducer leads at Control Board plug J8. See Figure F.9.
4. Carefully apply input power to the POWER WAVE 655/R.
WARNING
ELECTRIC SHOCK can kill. High voltage is present when input
power is applied to the machine.
POWER WAVE 655/R
5. Turn on the POWER WAVE 655/R. Check for the correct DC supply voltage to the current transducer at plug J8. See Figure F.9.
A. Pin 2 (lead 212+) to pin 6 (lead 216-)
should read approximately +15 VDC.
B. Pin 3 (lead 213-) to pin 6 (lead 216+)
should read approximately -15 VDC.
NOTE: Do not attempt to check the voltages at the
Current Transducer connector. The termi­nals are small and delicate and may be damaged if probed with meter leads.
If the DC supply voltages are not present, the control board may be faulty. If the supply volt­ages are correct, procede to Step 6.
Page 79
F-35 F-35
RS 232 PORT
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED)
FIGURE F.10 – RS 232 port
6. Connect a laptop computer to the PW655-R via the RS232 port on the front of the machine. See Figure F.10.
7. Connect a Load Bank (or 50ʼ weld cable) to the Positive and Negative Output Studs of the PW655-R.
8. Using the “Diagnostic Utility Software:
Establish Communication with the PW655R Select the ʻCalibrateʼ tab. Select the ʻ50 ampʼ Current Set Point Select ʻTurn Output ONʼ Use an external calibrated ammeter to read actual current
9. Check the feedback voltage at the Control Board plug J8 per Table F.6. Pin 1 (lead 211 +) to pin 6 (lead 216 -).
10. Repeat the test at several other current levels. If the feedback voltage is correct for the actual
current, the Current Transducer is OK
TABLE F.6 - CURRENT FEEDBACK CHART
OUTPUT CURRENT (Actual)
If the feeback voltage is not present, check the wiring from the Control Board to the Current Transducer, See the Wiring Diagram.
CAUTION: If using a weld cable across the output
studs instead of a Load Bank, do not exceed the current rating of the cable.
11. If supply voltages are correct but feedback voltages are incorrect, the Current Transducer or wiring from P91 to the Control Board may be defective. See the Wiring Diagram.
If the ʻactualʼ (measured) current does not match the ʻsetʼ current but the feedback voltage is correct for the actual current, perform the Machine Calibration.
12. Click on “Turn Output Off”
13. Disconnect the computer.
14. Remove input power and replace the control box cover and case top.
EXPECTED FEEDBACK VOLTAGE
500 450 400 350 300 250 200 150 100
50
POWER WAVE 655/R
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
0.4
Page 80
F-36 F-36
NOTES
POWER WAVE 655/R
Page 81
F-37 F-37
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The test will help determine if any of the output rectifiers are shorted.
MATERIALS NEEDED
Misc. Hand Tools Analog Volt-Ohmmeter
POWER WAVE 655/R
Page 82
NEGATIVE (-) OUTPUT TERMINALS
POSITIVE (+) OUTPUT TERMINALS
R1
F-38 F-38
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST PROCEDURE (CONTINUED)
FIGURE F.11 – OUTPUT RECTIFIER TEST
PROCEDURE
1. Remove main input supply power to the POWER WAVE 655/R.
2. Remove the case sides and perform the Input Filter Capacitor Discharge procedure.
3. Remove any output cables that may be con­nected to the POWER WAVE 655/R.
4. Disconnect one end of lead 206A that connects R1 to the Positive Output Terminal.
5. With an ohmmeter, measure the resistance between the positive and negative output termi­nals. Refer to Figure F.11.
POWER WAVE 655/R
IMPORTANT: The positive (+) meter probe must
be attached to the positive (+) output terminal and the negative (-) meter probe must be attached to the nega­tive (-) output terminal.
6. If the reading is more than 200 ohms, the out­put rectifier modules are not shorted. If the reading is less than 200 ohms, one (or more) of the rectifier modules is shorted. Refer to the Output Rectifier Module Replacement proce­dure.
7. Reconnect lead 206A.
8. Replace the case sides.
Page 83
F-39 F-39
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 1 and also if the correct voltages are being induced on the secondary windings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter Misc. Hand Tools Wiring Diagram
POWER WAVE 655/R
Page 84
INPUT CONTACTOR
601
X4
POWER BOARD
RECTIFIER BRIDGE
X1
X2
+
-
X3
X5
AUXILIARY TRANSFORMER #1
WHITE RED
FAN MOTOR WINDING
FAN RELAY
444
X3A
F-40 F-40
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED)
FIGURE F.12 – AUXILIARY TRANSFORMER NO. 1 TEST
PROCEDURE
1. Remove the main input power to the POWER WAVE 655/R machine.
2. Remove the case top and sides.
3. Perform the Capacitor Discharge procedure.
POWER WAVE 655/R
4. Locate secondary leads X1 and X2 (at power board rectifier bridge). Refer to Figure F.12.
5. Locate secondary leads X3 and X5 (fan motor leads).
6. Locate secondary lead X4 (at main contactor).
Page 85
F-41 F-41
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED)
7. Carefully apply the correct input voltage to the POWER WAVE 655/R.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present at primary of the Auxiliary Transformer.
8. Check for the correct secondary voltages according to Table F.7.
NOTE: The secondary voltages will vary proportionally
if the input line voltage varies from nominal.
9. If the correct secondary voltages are present, the T1 auxiliary transformer is functioning properly. If any of the secondary voltages are missing or low, check to make certain the primary is configured correctly for the input voltage applied. See the Wiring Diagram.
10. If the correct input voltage is applied to the prima­ry, and the secondary voltage(s) are not correct, the T1 transformer may be faulty.
11. Replace any cables ties and insulation removed earlier.
12. Replace the case sides and top.
TABLE F.7 – SECONDARY VOLTAGES
LEAD IDENTIFICATION
X1 to X2 X3 to X5 X3 to X4
NORMAL EXPECTED VOLTAGE
52 VAC
115 VAC
24 VAC
POWER WAVE 655/R
Page 86
F-42 F-42
NOTES
POWER WAVE 655/R
Page 87
F-43 F-43
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 2 and also if the correct voltages are being induced on the secondary windings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter Misc. HAnd Tools Wiring Diagram
POWER WAVE 655/R
Page 88
1
2
5
3
4
3
2
1
5
2
6
3
6
4
4
1
350
(WHITE)
352
(BLACK)
33 (RED)
32 (WHITE)
352A (BLACK)
H6
33A
(RED)
H1
To WATER COOLER RECEPTACLE (S8)
To S4, CB2 & AUX. FAN
To AUX.ILIARY TRANSFORMER #2 PRIMARY (P50)
F-44 F-44
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST PROCEDURE (CONTINUED)
FIGURE F.13 – AUXILIARY TRANSFORMER NO. 2 TEST
PROCEDURE
1. Remove the main input power to the POWER WAVE 655/R machine.
2. Remove any load that may be connected to the 115 VAC receptacle.
3. Remove the case top and right side.
4. Locate plugs P52 and P50 at the Auxiliary Transformer No. 2. Refer to Figure F.13.
5. Carefully apply the correct input power.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present at both plugs.
POWER WAVE 655/R
6. Check for 115 VAC at plug P52 pins 1 and 4 (leads 350 to 33A). Check for 230 VAC at plug P52 pins 1 and 2 (leads 350 to 352).
7. If 115 VAC and 230 VAC are present, Auxiliary Transformer No. 2 is good.
8. If 115 is not present between pins 1 and 4, and 230 VAC is not present between pins 1 and 2, check the associated leads and plugs for loose or faulty connections.
9. Carefully test for the correct AC input voltage applied to the primary windings at plug P50. See the Wiring Diagram.
10. If the correct AC input voltage is applied to the primary of the Auxiliary Transformer No. 2 and the secondary voltage is not correct, the trans­former may be faulty. Replace.
11. Replace any cables ties and insulation removed earlier.
12. Replace the case top and side.
Page 89
F-45 F-45
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input rectifi­er module.
MATERIALS NEEDED
Misc. Hand Tools Torque Wrench
POWER WAVE 655/R
Page 90
NEG (-)
A
B
C
INPUT
RECTIFIER
POS (+)
F-46 F-46
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.14 – INPUT RECTIFIER REMOVAL AND REPLACEMENT
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE 655/R.
2. Remove the case top, sides, and input access panel.
3. Perform the Capacitor Discharge procedure.
4. Remove the RTV sealant from the input rectifi­er connection terminals. See Figure F. 14.
5. Label and carefully remove the five leads from the input rectifier terminals. Note placement for reassembly. See Figure F.14.
6. Using a 3/16” allen wrench, remove the two mounting screws and washers from the rectifier module.
7. Carefully remove the input rectifier module.
REPLACEMENT PROCEDURE
NOTE: Any instructions that are shipped with
the replacement part will supersede these instructions.
1. Clean heat sink surfaces.
2. Apply a thin, even film (.004” t0 .01”) of thermal compound (Penetrox A13) to the module. Keep the compound away from the mounting holes. Compound in the holes or on the threads of the screws will affect the ability to get the proper torque.
3. Mount the module to the heat sink and evenly torque the mounting screws (with washers) to 44 in/lbs.
4. Assemble the leads to the correct module ter­minals and torque to 31 in/lbs. See Figure F.14.
5. Apply RTV sealant to the rectifier connection terminals.
6. Replace the case top, sides, and input access panel.
POWER WAVE 655/R
Page 91
F-47 F-47
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input con­tactor.
MATERIALS NEEDED
Misc. Hand Tools
POWER WAVE 655/R
Page 92
INPUT CONTACTOR
601
X4
F-48 F-48
L3
L2
L1
T3
T2
T1
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.15 – INPUT CONTACTOR REMOVAL AND REPLACEMENT
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE 655/R.
2. Remove the case top, sides and input access panel.
3. Perform the Capacitor Discharge procedure
4. Locate the input contactor. Label and carefully remove the leads from the input contactor ter­minals. Note placement for reassembly. See Figure F.15.
5. With a 5/16” nut driver or socket, remove the three mounting screws. See Figure F.15.
6. Carefully remove the input contactor.
POWER WAVE 655/R
REPLACEMENT PROCEDURE
1. Mount the contactor and tighten the mounting screws.
2. Connect the leads to the correct terminals. See Figure F.15.
3. Replace the case top, sides and input access panel.
Page 93
F-49 F-49
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary trans­former No. 1.
MATERIALS NEEDED
Misc. Hand Tools Wire splicing or soldering equipment
POWER WAVE 655/R
Page 94
INPUT CONTACTOR
601
X4
POWER BOARD
RECTIFIER BRIDGE
X1
X2
+
-
X3
X5
AUXILIARY TRANSFORMER #1
WHITE RED
FAN MOTOR WINDING
FAN RELAY
444
X3A
F-50 F-50
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE 655/R.
2. Remove the case top, sides and input access panel.
3. Perform the Capacitor Discharge procedure.
4. Remove the case back.
5. Disconnect lead X4 from the input contactor coil.
6. Remove leads X1 and X2 from the power board rectifier bridge. Refer to Figure16.
7. Cut X3 and X5 from the fan motor leads. Leave enough length to splice in the new transformer leads.
8. Cut the X3 lead that is connected to the input board. Leave enough lead length to splice in the new transformer lead.
9. Locate, label, and remove primary lead H1 from circuit breaker CB4.
10. Label and remove primary leads H2, H3, H4,
and H5 from the terminals on the reconnect panel. Note lead placement for reassembly.
11. Cut cable ties as necessary and clear the
leads.
12. Remove the two mounting screws holding the
transformer to the fan baffle and the base.
13. Carefully remove the transformer from the
POWER WAVE 655/R.
POWER WAVE 655/R
REPLACEMENT PROCEDURE
1. Carefully place the transformer into the POWER WAVE 655/R.
2. Secure the transformer to the fan baffle and the base.
3. Connect the primary leads H2, H3, H4, and H5 to the proper terminals on the reconnect panel.
4 Connect primary lead H1 to circuit breaker
CB4.
5. Splice the X3 lead of the new transformer with the X3 lead connected to the input board.
6. Splice X3 and X5 leads of the new trans­former to the fan motor leads X3 and X5.
7. Connect lead X4 to the main contactor coil terminal.
8. Connect leads X1 and X2 to the power board rectifier bridge.
9. Reposition any wire leads and install cable ties as necessary.
10. Replace the case back, sides and top.
Page 95
F-51 F-51
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary trans­former No. 2.
MATERIALS NEEDED
Misc. Hand Tools
POWER WAVE 655/R
Page 96
1
2
5
3
4
3
2
1
5
2
6
3
6
4
4
1
350 (WHITE)
352
(BLACK)
33 (RED)
32 (WHITE)
352A (BLACK)
H6
33A
(RED)
H1
To WATER COOLER RECEPTACLE (S8)
To S4, CB2 & AUX. FAN
To AUX.ILIARY TRANSFORMER #2 PRIMARY (P50)
F-52 F-52
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE 655/R.
2. Remove the case top, sides and input access panel.
3. Perform the Capacitor Discharge procedure.
4. Remove the case back.
5. Disconnect the three Molex Connectors indi­cated in Figure 17.
7. Remove the transformer mounting screws from the Fan Baffle and the base.
8. Carefully remove the transformer from the POWER WAVE 655/R.
POWER WAVE 655/R
REPLACEMENT PROCEDURE
1. Carefully place the transformer into the POWER WAVE 655/R.
2. Install the two mounting screws that hold the transformer to the machine base using the 3/8” nut driver.
3. Connect leads 33 and 32 to circuit breaker CB4 and the 115 V receptacle.
4. Connect plugs P50 and P52.
5. Reposition any leads and install cable ties as necessary.
6. Replace the case back.
7. Replace the case top, sides, and input access panel.
Page 97
F-53 F-53
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, VOLTAGE SENSE, OR AUXILIARY
DRIVER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the Control Board the Feed Head Board, the Auxiliary Driver Board or the Voltage Sense Board.
MATERIALS NEEDED
Misc. Hand Tools Anti-static wrist strap
CAUTION PC Boards can be damaged by static electricity.
• Remove your bodyʼs static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 MΩ resistive cord con ­nected to a grounded part of the equipment frame.
• If you donʼt have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.
POWER WAVE 655/R
Page 98
CONTROL BOARD FEED HEAD BOARD
AUXILIARY DRIVER BD.
VOLTAGE
SENSE BD.
Step 6
Removal
Step 6
Removal
F-54 F-54
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, VOLTAGE SENSE OR AUXILIARY
DRIVER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.18 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE 655/R.
2. Remove the case top and sides.
3. Perform the Capacitor Discharge procedure.
Observe all static electricity precau­tions.
4. Remove the PC board compartment cover.
5. Remove the two screws holding the rear of the Control Box in place. See Figure 18.
6. Clear the leads in the sleeving and the grom­mets on the sides of the control box.
7. Label and remove the molex plugs from the Control Board and the Feed Head Board.
8. Tilt back the rear of the control box to access the PC board mountings.
9. To remove the Voltage Sense Board, use a nee­dle-nose pliers to carefully pinch the three plas­tic standoffs to release the board.
10. Use a Phillips screwdriver to remove the
Auxiliary Driver Bd.
REPLACEMENT PROCEDURE
1. Install the replacement board using the original fasteners
2. Connect the Molex plugs to the Control Board and the Feed Head Board. Be sure the lead harnesses are securely and properly posi­tioned.
3. Use a Phillips screwdriver to replace the Auxiliary Driver Board.
4. Press the Voltage Sense Board onto its stand­offs. Make sure the board snaps into place on all three standoffs.
5. Secure the rear of the control box in place using two screws. Be careful not to pinch any wires between the control box sheeet metal pieces.
6. Replace any cable ties that might have been removed.
7. Replace the PC board compartment cover.
8. Replace the case top and sides.
NOTE: If the Control Board is replaced it will be
necessary to do the Calibration
Procedure.
POWER WAVE 655/R
Page 99
F-55 F-55
TROUBLESHOOTING & REPAIR
ETHERNET/GATEWAY PC BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Gateway PC Board.
MATERIALS NEEDED
Misc, Hand Tools Anti-static wrist strap
CAUTION: PC Boards can be damaged by static electricity.
• Remove your bodyʼs static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 MΩ resistive cord con ­nected to a grounded part of the equipment frame.
• If you donʼt have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.
POWER WAVE 655/R
Page 100
Support the Panel
Ethernet/ Gateway PC Board
F-56 F-56
TROUBLESHOOTING & REPAIR
ETHERNET/GATEWAY PC BOARD
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.19 – GATEWAY BOARD REMOVAL AND REPLACEMENT
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE 655/R.
2. Using a phillips head screw driver, remove the six screws from the case front cover. Tilt the cover down and support it from below to avoid stressing the electrical connections. See Figure F.19.
Observe all static electricity precau-
.
tions
3. Disconnect the four molex plugs and the net­work cable from the Ethernet/Gateway Board.
4. Remove the self-locking mounting nuts and carefully remove the board. Refer to Figure F.19.
POWER WAVE 655/R
REPLACEMENT PROCEDURE
1. Install the new Ethernet/Gateway Board to the case front cover with the self-locking nuts.
2. Reconnect the molex plugs and the network cable.
3. Re-attach the cover to the case front, being careful not to stress or pinch the wires.
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