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

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 •
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
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
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
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
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
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
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.
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
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
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
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
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
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
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
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
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
**
A-12 A-12
NOTES
POWER WAVE 655/R
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
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
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
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
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
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
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
B-8 B-8
NOTES
POWER WAVE 655/R
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
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
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
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
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