Lincoln Electric IM713 User Manual

IM713-C

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Power Wave 655/R

For use with machines having Code Numbers:

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.

®

10630; 10863; 11410; 11880

January, 2012

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www. lincolnelectric. com

EN 60974-1

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

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

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

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.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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

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.c. Do not add the fuel near an open flame
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.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

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.

ii

SAFETY

ii

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 within applicable OSHA PEL and
ACGIH TLV limits 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 manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and hot
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.

the welding sparks from starting a fire.

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. Alway s 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. Re ad and foll ow the inst ru ctions o n c ompressed 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 manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales 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.

v

Thank You

v

For selecting a QUALITY product by Lincoln Electric. We want
you to take pride in operating this Lincoln Electric Company prod­uct ••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www. lincolnelectric.
com for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For fazing: Complete the form on the back of the warranty statement included in the literature packet
Accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Register Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www. lincolnelectric.Com. Choose “Support” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

vi

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications .......................................................................................A-1

Safety Precautions.................................................................................................A-2

Select Suitable Location ........................................................................................A-2

Lifting...............................................................................................................A-2

Stacking ..........................................................................................................A-2

Machine Grounding ...............................................................................................A-2

High Frequency Protection ....................................................................................A-2

Input Connection....................................................................................................A-3

Input Fuse and Supply Wire Considerations .........................................................A-3

Input Voltage Changeover Procedure ...................................................................A-3

Welding with Multiple Power Wave

Electrode and Work Cable Connections................................................................A-5

Cable Inductance and its Effects on Pulse Welding........................................A-5

Negative Electrode Polarity ..................................................................................A-6

Voltage Sensing ....................................................................................................A-6

®

Power Wave

/ Power Feed®Wire Feeder Interconnections .................................A-7

Control Cable Specifications ...........................................................................A-7

External I/O Connector....................................................................................A-8

High Speed Gear Box .....................................................................................A-8

Dip Switch Settings and Locations.................................................................A-9

Control Board Dip Switch ................................................................................A-9

Feed Head Board Dip Switch..........................................................................A-9

DeviceNET/Gateway Board Dip Switch, Bank (S1) ........................................A-9

Bank (S2) ......................................................................................................A-10

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precautions.................................................................................................B-1

Graphic Symbols that appear on this machine or in this manual...........................B-2

General Description...............................................................................................B-3

Recommended Processes and Equipment ...........................................................B-3

Required Equipment..............................................................................................B-3

Limitations..............................................................................................................B-3

Duty Cycle and Time Period ...........................................................................B-3

Case Front Controls ........................................................................................B-4

Constant Voltage Welding...............................................................................B-5

Pulse Welding .................................................................................................B-6

________________________________________________________________________

Accessories.....................................................................................................Section C

Optional Equipment...............................................................................................C-1

Factory Installed..............................................................................................C-1

Field Installed..................................................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine, Periodic, Calibration Specification...........................................................D-1

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to use Troubleshooting Guide .......................................................................E-1

Troubleshooting the Power Wave

Troubleshooting Guide.............................................................................E-3 thru E-6

Error Codes for the Power Wave®..................................................................E-7, E-8

________________________________________________________________________

Diagrams ..........................................................................................................Section F

Wiring Diagramʼs.....................................................................................F-1, F-2, F-3

Pin, Lead Connector, Connection Diagrams, and Dimension Print..........F-4 thru F-7

________________________________________________________________________

Parts Lists...................................................................................................P-392 Series

________________________________________________________________________

®

s ...................................................................A-4

®

/ Power Feed System using the Status LED ..E-2

vi

A-1

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 OUT-

PUT

EFFICIENCY

@ RATED

OUTPUT

A-1

11410
11880

OPEN

CIRCUIT

VOLTAGE

75 VDC

PROCESS CURRENT RANGES (DC)

460/575V - 60HZ.

CURRENT

RANGE

20-815

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[MM2]

SIZES

TYPE 75°C

GROUND WIRE IN

CONDUIT AWG[MM2]

SIZES

.95 MIN.

PROTECTED)

40 VDC AT

10 AMPS

110 VAC AT

10 AMPS

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

84%

460V - 60HZ.
575V - 60HZ.

PHYSICAL DIMENSIONS

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)

DEPTH

32.88 in
835 mm

STORAGE TEMPERATURE RANGE

-40°C to +40°C

70
60

WEIGHT

306 lbs.

139 kg.

A-2

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
(located inside the reconnect input access door)
to a proper safety (Earth) ground.

-------------------------------------------------------------

®

grounding lug

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.

A-2

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 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.

Do not mount the Power Wave®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.

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.

HIGH FREQUENCY PROTECTION

Locate the Power Wave®away from radio controlled
machinery.

CAUTION

®

The normal operation of the Power Wave
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.

------------------------------------------------------------------------

may

POWER WAVE®655/R

A-3

INSTALLATION

A-3

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

INPUT SUPPLY CONNECTION DIAGRAM

.

Disconnect input power before

inspecting or servicing machine.

.

Do not operate with covers
removed.

.

Do not touch electrically live parts.

.

Only qualified persons should install,
use or service this equipment.

W / L3

V / L2

U / L1

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

XA

CR1

S24190

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.

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.

------------------------------------------------------------------------

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 .

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

INPUT FUSE AND SUPPLY WIRE

(A) lead, reset the breakers, and try again.

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 recommend­ed 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.

POWER WAVE®655/R

A-4

INSTALLATION

WELDING WITH MULTIPLE Power
Waves

®

A-4

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power

®

Wave

s.

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. Performing 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 Wave®S

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.)

POWERWAVE

-

Electrode Lead

POWERWAVE

+

Travel

Direction

Connect All Welding
Work Leads at the
Beginning of the Joint

-

Connect All Work
Sense

of

+

Electrode Lead

Leads at the End

the Joint

POWER WAVE®655/R

A-5

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.

A-5

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.)

FOR A DETAILED CONNECTION DIAGRAM USING
K1796 COAXIAL CABLE (SEE PIN, LEAD CON­NECTOR IN DIAGRAM SECTION)

POWER
WAVE

FIGURE A.4

WORK

A

C

A

C

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

K1796 COAXIAL CABLE

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.

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 elec-

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.

trode 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.

CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING

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

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

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.

length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See
Figure A.3).

MEASURE FROM END
OF OUTER JACKET OF
CABLE

CAUTION

B

SLIDING GROUND

B

POWER
WAVE

FIGURE A.3

A

C

WORK

B

POWER WAVE®655/R

A-6

INSTALLATION

A-6

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
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.

3. The wire feed head board is on the right
side of the power source. Locate the 8­position DIP switch and look for switch 7
of the DIP switch.

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
located underneath the output stud cover.
Enable the voltage sense leads as follows:

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**

* 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.

67 lead required 21 lead optional**

Voltage sense at studs Voltage sense at studs

®

at the four-pin connector

TABLE 2

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.

12 3456 78

O

N

POWER WAVE®655/R

A-7

INSTALLATION

A-7

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
as close to the weld as practical. Enable the work
voltage sensing in the Power Wave

to the work. Attach the sense lead to the work

®

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.

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.

12 3456 78

O

N

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 sake, 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.

A work lead must be run from the negative (-) power
source output connection 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.

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.

POWER WAVE®655/R

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.