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.

A-8

INSTALLATION

A-8

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
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

®

is a

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:

Trigger Input

+15 VDC for Trigger Group

1

2

A

B

4 Step Input

Dual Procedure Input

4

3

Cold Inch Forward

+15 VDC for Cold Inch Group

78

6

5

D

E

C

Gas Purge Input

Cold Inch Reverse

+15 for shutdown group

910

G

F

Shutdown1 input

Shutdown2 input (Water Fault)

11

12

H

I

Reserved for future use

•

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

12 3456 78

O

N

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.

POWER WAVE®655/R

A-9

INSTALLATION

A-9

DIP Switch Settings and Locations

DIP switches on the P.C. Boards allow for custom
configuration of the Power Wave®. To access the DIP
switches:

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.

Feed Head Board DIP Switch:

Switch 1 = Object Instance LISE (see table 3)
Switch 2 = Object Instance msp (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 LISE (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 msp (see table 3)

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-10

INSTALLATION

A-10

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

SWITCH 3

0000000
1000001
2000010
3000011
4000100
5000101
6000110
7000111
8001000
9001001
10001010
11001011
12001100
13001101
14001110
15001111
16010000
17010001

SWITCH 8

SWITCH 7

SWITCH 6

SWITCH 5

SWITCH 4

SWITCH 3

18010010
19010011
20010100
21010101
22010110
23010111
24011000
25011001
26011010
27011011
28011100
29011101
30011110
31011111
32100000
33100001
34100010
35100011
36100100
37100101
38100110
39100111
40101000
41101001
42101010
43101011
44101100
45101101
46101110

*

47101111
48110000
49110001
50110010
51110011
52110100
53110101
54110110
55110111
56111000
57111001
58111010
59111011
60111100
61111101
62111110
*Software Selectable (Line 0)
**Default Setting (Line 62)

**

POWER WAVE®655/R

B-1

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.

B-1

• 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-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

B-2

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

I

1

I

2

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING

POWER WAVE®655/R

B-3

OPERATION

B-3

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
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
intrigued 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).

power source is designed to be

RECOMMENDED EQUIPMENT

• Automatic Operation

All welding programs and procedures are set through
software for the robotic Power Wave®s. FAUN
robots equipped with RJ-3 controllers may communi­cate directly to the Power Wave
equipment such as ply or computers can communi­cate to the Power Wave®using DeviceNET.

All wire welding processes require a robotic Power

®

wire feeder.

Feed

• semiautomatic Operation

Operating the Power Wave®655/r in the semi-auto­matic mode requires an Arc-Link compatible wire
feeder and user interface.

®

. Other pieces of

REQUIRED EQUIPMENT

• Control Cables (22 pin to 22 pin), K1795-10ft.,-25ft.,-50ft.,

-100ft.

• Control Cables for use on FAUN robot arm, 22 pin to 14
pin, ft.(m), K1804-1

• Control Cables for use on FAUN robot arm, 22 pin to 14
pin, 18in.(457mm), K1805-1

• Control Cables for use on FAUN 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 Wave®s are not to be used in outdoor envi-

ronments.

• 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-4

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.

Light

Condition

Steady Green

Blinking
Green

Alternating
Green and
Red

®

.

TABLE 6

Meaning

System OK. Power source communicating normal­ly with wire feeder and its components.

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.

B-4

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.

5.

10 AMP AUXILIARY POWER CIRCUIT BREAKER:
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

13. AUXILIARY OUTPUT

FIGURE B.1

2

3

Steady Red

Blinking Red

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.

POWERWAVE

6

7

8

9

10

-

13

5

Case Front Layout

Power Wave 655/R (Domestic/Canadian Version)

®

4

+

1

11

12

POWER WAVE®655/R

B-5

OPERATION

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
the voltage correspondingly.

Wave control adjusts the inductance of the wave­shape. (This adjustment is often referred to as "pinch".
Inductance is inversely proportional pinch.)
Increasing 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)

®

will automatically adjust

B-5

Current

FIGURE B.2

Time

POWER WAVE®655/R

B-6

OPERATION

B-6

PULSE WELDING

Pulse welding procedures are set by controlling an
overall "arc length" variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. 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 synetic. As the wire
feed speed is adjusted, the Power Wave
matically recalculate the waveform parameters to
maintain similar arc properties.

®

will auto-

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
forms are optimized for a 0.75" (19mm) stick-out. The
adaptive behavior supports a range of stinkpots 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)

®

wave-

Current

FIGURE B.3

Time

POWER WAVE®655/R

C-1

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. (See “Voltage Sensing” in the Installation
Section for use and Wiring Diagram Section Codes
11410, 11880).

Cool Arc 40 (K1813-1)

(See Wiring Diagram Section Codes 11410, 11880)

®

.

C-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

(See Pin, Lead Connector Diagram Section)

®

POWER WAVE®655/R

D-1

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

Routine maintenance consists of periodically
blowing out the machine, using a low pressure
airstream, to remove accumulated dust and dirt
from the intake and outlet louvers, and the cool­ing channels in the machine.

D-1

PERIODIC MAINTENANCE

Calibration of the Power Wave®655/R is critical to
its operation. 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.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the
factory. Generally speaking the machine calibration
will not need adjustment. However, if the weld per­formance changes, or the yearly calibration check
reveals a problem, contact the Lincoln Electric
Company for the calibration software utility.

The calibration procedure itself requires the use
of a grid, 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. Detailed instructions
are available with the utility.

POWER WAVE®655/R

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that best
describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE®655/R

E-2

TROUBLESHOOTING

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS

The Status LED on the power source case front
can help diagnose problems down to the system
component (power source, wire feeder, wire
drive, etc.) level.

E-2

If, for any reason, the system does not appear to
be working properly, always check the color of
the Status LED, and refer to the following chart to
help you determine which system component
(power source, wire feeder, wire drive, etc.) may
be faulty. Replace the components identified as
potentially faulty with known good components,
and the system should operate normally.

Steady Green

Blinking Green

Alternating Green and Red

Steady Red

System OK. Power source communicating normally
with wire feeder and its components.

Occurs during a reset, and indicates the Power Wave
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 Power Wave

before the machine is turned off.

Error Code interpretation through the Status light is
detailed in the Service Manual. Individual code digits
are flashed in red with a long pause between digits. If
more than one code is present, the codes will be sepa­rated by a green light.

To clear the error, turn power source off, and back on
to reset.

Not applicable.

®

. Read the error code

®

Blinking Red

Not applicable.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE®655/R

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

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

Input fuses keep blowing, or input
breaker keeps tripping.

Machine will not power up (no
lights, no fan, etc.)

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Contact your local authorized
Lincoln Electric Field Service
facility for technical assistance.

1. Make certain that fuses or

breakers are properly sized.
See Installation section of this
manual for recommended
fuse and breaker sizes.

2. Welding procedure is drawing

too much output current, or
duty cycle is too high.
Reduce output current, duty
cycle, or both.

3. There is internal damage to

the power source. Contact an
authorized Lincoln Electric
Service facility.

1. Make certain that the Power

Switch (SW1) is in the “ON”
position.

2. Circuit breaker CB4(Codes

10630, 10863) (in reconnect
area) may have opened.
Reset.
10A Fuse(Code 11410,

11880) (in reconnect area)
may have blown out. Replace.
Also, check input voltage
selection, below.

3. Input voltage selection made

improperly. Power down,
check input voltage reconnect
according to diagram on
reconnect cover.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,

contact your local Lincoln
Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE®655/R

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Thermal LED is lit.

Machine wonʼt weld, canʼt get any
output. (CR1 will not pull in.)

Arc loss fault on robot

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Fan thermostat has opened.
Check for proper fan operation.
(Fan should run whenever main
power is on.) Check for material
blocking intake or exhaust lou­vers, or for excessive dirt clog­ging cooing channels in
machine.

2. Secondary rectifier thermostat
has opened. After machine has
cooled, reduce load, duty cycle,
or both. Check for material
blocking intake or exhaust lou­vers.

1. Input voltage is too low or too
high. Make certain that input
voltage is proper, according to
the Rating Plate located on the
rear of the machine.

2. If the Thermal LED is also lit,
see “Yellow Thermal LED is Lit”
section.

Possibly caused by wire feeding
problem. Possible causes/solu­tions are:

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,

contact your local Lincoln
Authorized Field Service Facility.

1. Problem - Conduit leading to the
wire feeder has bends or twists,
which can reduce the wire feed
speed.

Solution - Remove bends and
twists from conduit.

2. Problem – Conduit leading up to
the wire feeder from the wire reel
is too long.

Solution – Use a shorter length of
conduit

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE®655/R

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

PROBLEMS

(SYMPTOMS)

Machine often “noodle welds” (out­put is limited to approximately 100
amps) when running a particular
procedure

Machine wonʼt produce full output.

For no apparent reason, the weld-

ing characteristics have changed.

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Secondary current limit has

been exceeded, and the
machine has phased back to
protect itself. Adjust procedure
or reduce load to lower current
draw from the machine.

1. Input voltage may be too low,

limiting output capability of the
power source. Make certain
that the input voltage is proper,
according to the Rating Plate
located on the rear of the
machine.

2. Input may be “single phased”.

Make certain the input voltage
is proper on all three input
lines.

1. Check for proper Wire Feed

Speed setting. In CV MIG and
FCAW modes, check for prop­er Voltage setting. In the
MIG/MAG pulse modes, check
the Trim setting. These con­trols are on the wire feeder.

2. Check for proper shielding gas

mix and flow.

3. Check for loose or faulty weld

cables and cable connections.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,

contact your local Lincoln
Authorized Field Service Facility.

Auxiliary receptacle is “dead” — no

auxiliary voltage .

The PowerWave is triggered to
weld, but there is no output.

1. Circuit breaker CB2 (on case

front) may have opened.
Reset.

2. Circuit breaker CB4(Codes

10630, 10863) (in reconnect
area) may have opened.
Reset.
10A Fuse(Code 11410, 11880)
(in reconnect area) may have
blown out. Replace.

1. Check for fault signals from the

I/O connector. Possible faults
are lack of water flow

2. Circuit breaker CB4 (in recon-

nect area) may have opened.
Reset.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE®655/R

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

The PowerWave is triggered to weld,
but there is no output.

TROUBLESHOOTING

POSSIBLE

CAUSE

WELDING PROBLEMS

1. Check for fault signals from the
I/O connector. Possible faults are
lack of water flow/ water flow
turned off.

E-6

RECOMMENDED

COURSE OF ACTION

The feeder will not cold inch wire

Arc loss fault on robot

1. Check for fault signals from the
I/O connector. Possible faults are
lack of water flow/ water cooler
turned off.

1. Possibly caused by wire feeding
problem.

2 Problem - Conduit leading to the

wire feeder has bends or twists,
which can reduce the wire feed
speed.
Solution - Remove bends and
twists from conduit.

3. Problem – Conduit leading up to
the wire feeder from the wire reel
is too long.

Solution – Use a shorter length of
conduit.

If all recommended possible areas
of misadjustments have been
checked and the problem persists,

contact your local Lincoln
Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE®655/R

E-7

Observe all Safety Guidelines detailed throughout this manual

ERROR CODES FOR THE POWERWAVE

The following is a list of possible error codes that the PW-455 can output via the status light (see
"Troubleshooting the Power Wave®/ Power Feed®System Using the Status LED").

TROUBLESHOOTING

E-7

Error Code #

11 CAN communication bus off.

12 User Interface time out error.

21 Un-programmed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.

32 Capacitor "A" under voltage

(Left side facing machine)

33 Capacitor "B" under voltage

(Right side facing machine)

Indication

Probably due to excessive number of communication errors.

User Interface is no longer responding to the Power Source. The most
likely cause is a fault/bad connection in the communication leads or
control cable.

Contact the Service Department for instructions on reloading the
Welding Software.

Contact the Service Department for instructions on reloading the
Welding Software.

Contact the Service Department for instructions on reloading the
Welding Software.

Excessive Primary current present. May be related to a switch board or
output rectifier failure.

Low voltage on the main capacitors. May be caused by improper input
configuration.
When accompanied by an overvoltage error on the same side, it indi­cates no capacitor voltage present on that side, and is usually the result
of an open or short in the primary side of the machine.

34 Capacitor "A" over voltage

(Left side facing machine)

35 Capacitor "B" over voltage

(Right side facing machine)

36 Thermal error

37 Soft start error

Excess voltage on the main capacitors. May be caused by improper
input configuration.
When accompanied by an under voltage error on the same side, it indi­cates no capacitor voltage present on that side, and is usually the result
of an open or short in the primary side of the machine.

Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle limit
of the machine.

Capacitor precharge failed. Usually accompanied by codes 32-35.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE®655/R

E-8

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-8

Error Code #

41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

Indication

The secondary (weld) current limit has been exceeded. When this
occurs the machine output will phase back to 100 amps, typically result­ing in a condition referred to as "noodle welding"
NOTE: For The Power Wave

The maximum voltage difference between the main capacitors has been
exceeded. May be accompanied by errors 32-35.

Indicates machine is running on single phase input power. Usually
caused by the loss of the middle leg (L2).

Error codes that contain three or four digits are defined as fatal errors.
These codes generally indicate internal errors on the PS Control Board.
If cycling the input power on the machine does not clear the error, try
reloading the operating system. If this fails, replace the control board.

®

655 the secondary limit is 880 Amps.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE®655/R

F-1

Enhanced Diagram

DIAGRAMS

F-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

POWER WAVE®655/R

F-2

Enhanced Diagram

DIAGRAMS

F-2

POWER WAVE®655/R

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-3

Enhanced Diagram

DIAGRAMS

F-3

POWER WAVE®655/R

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-4

PIN, LEAD CONNECTOR DIAGRAMS

F-4

TABLE 1 INTERFACE CONNECTOR S6

Pin Lead # Function

A 841 +15vdc Tach voltage

B 844 Tach common
C 842 Tach 1A differential signal
D 843 Tach 1B differential signal
E 845 Tach 2A differential signal
F 846 Tach 2B differential signal
G 847 Single Tach Input
H Reserved for future use
I 67B Voltage sense lead
J 539 Motor "+"
K 541 Motor "-"
L Reserved for future use
M Reserved for future use
N 521 +40vdc for solenoid
P 522 solenoid input
R Reserved for future use
S Reserved for future use
T 855A Shield ground to case
U Reserved for future use
V Reserved for future use
W Reserved for future use
X Reserved for future use

TABLE 2 WIRE FEEDER RECEPTACLE S1

Pin Lead # Function

A 53 Arclink L

B 54 Arclink H
C 67A Electrode Voltage Sense
D 52 Ground(0v)
E 51 +40vdc

TABLE 3 VOLTAGE SENSE RECEPTACLE S2

TABLE 4 RS232 CONNECTOR S3

Pin Lead # Function

2 253 RS232 Receive
3 254 RS232 Transmit
4 # S3 Pin5
5 # S3 Pin4
6 ## S3 Pin20
20 ## S3 Pin6
7 251 RS232 Common

TABLE 5 DEVICENET CONNECTOR S5

Pin Lead # Function

2 894 +24vdc Devicenet
3 893 Common Devicenet+
4 892 Devicenet H
5 891 Devicenet L

TABLE 6 EXTERNAL I/O S7

Pin Lead # Function

1 851 +15vdc for Trigger group
2 852 Trigger input
3 853 Dual procedure input
4 854 4 Step input
5 855 +15vdc for cold inch group
6 856 cold inch forward
7 857 cold inch reverse
8 858 gas purge input
9 859 +15vdc for shutdown group
10 860 shutdown1 input
11 861 shutdown2 input
12 862 input B

Pin Lead # Function

3 21A Work Voltage Sense

POWER WAVE®655/R

F-5

CONNECTION DIAGRAM

Hard Automation and Electrode Positive
Configuration

F-5

SHIELDING GA S

TO SHIEL DING GAS DE VICENE T CABLE

DEVICENET CABLE

TO PLC/CO NTROLLER

TO PLC/CONTROLLER

CONTROL CABLE K1795

- +

ELECTRODE LEAD

CONTROL CABLE K1795

WATER COOLER

COOL ARC 40 POWER CORD

POWER
CONNECT ION

ELE CTRODE LEAD

WATERCOOL ED
TORCH

WATER
CONNECTIONS

WORK
SENSE
LEAD
K940

POWER WAVE®655/R

F-6

CONNECTION DIAGRAM

Robotic Set Up, Electrode Positive, CV/Pulse
Configuration

CONTROL CABLE K1805-1

CONTROL CABLE K1805-1

User supplied

User supplied

electrode lead

electrode lead

F-6

K1804-1 CONTROL CABLE OR
K1804-2 AND ANY K1795 CONTROL CABLE

POWERWAVE

DEVICENET CABLE

User supplied
User supplied

work lead
work lead

WORK SENSE LEAD K940

-

K1796 COAXIAL WELD CABLE

+

POWER WAVE®655/R

F-7

DIAGRAMS

A.01

F-7

M18241

14.62

32.88

10°

12.90

26.10

23.51

23.12

22.63

9.48

19.16

19.90

4.21

6.75

3.47

12.35

19.00

POWER WAVE®655/R

NOTES

POWER WAVE®655/R

WARNING

Spanish

AVISO DE

PRECAUCION

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground.

• No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

• Aislese del trabajo y de la tierra.

• Keep flammable materials away.

• Mantenga el material combustible

fuera del área de trabajo.

• Wear eye, ear and body protection.

• Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

• Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

• Isolez-vous du travail et de la terre.

• Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

• Isolieren Sie sich von den

Elektroden und dem Erdboden!

• Não toque partes elétricas e electro-

dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Gardez à l’écart de tout matériel

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-

inflammable.

dos.

• Protégez vos yeux, vos oreilles et

votre corps.

• Tragen Sie Augen-, Ohren- und Kör-

perschutz!

• Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU
SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO­DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

• Turn power off before servicing.

• Do not operate with panel open or

guards off.

WARNING

• Los humos fuera de la zona de res-

piración.

• Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

• Gardez la tête à l’écart des fumées.

• Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

• Vermeiden Sie das Einatmen von

Schweibrauch!

• Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

• Mantenha seu rosto da fumaça.

• Use ventilação e exhaustão para

remover fumo da zona respiratória.

• Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

• Débranchez le courant avant l’entre-

tien.

• Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)

•

Não opere com as tampas removidas.

•

Desligue a corrente antes de fazer
serviço.

•

Não toque as partes elétricas nuas.

• No operar con panel abierto o

• N’opérez pas avec les panneaux

• Anlage nie ohne Schutzgehäuse

• Mantenha-se afastado das partes

• Não opere com os paineis abertos

guardas quitadas.

ouverts ou avec les dispositifs de
protection enlevés.

oder Innenschutzverkleidung in
Betrieb setzen!

moventes.

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES

DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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