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Lincoln Electric POWER WAVE 655/R, Operator'S Manual, Page: 1 / 44

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POWER WAVE

 ®

 655R

Operator’s Manual

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Date Purchased

Code: 

(ex: 10859)

Serial: 

(ex: U1060512345)

IM713-C

   |   Issue D ate 12-Jan

© Lincoln Global, Inc.  All Rights Reserved.

For use with machines having Code Numbers: 

10630, 10863, 11410, 11880

Register your machine:   

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:   

www.lincolnelectric.com/locator

Need Help? Call 1.888.935.3877  

to talk to a Service Representative

Hours of Operation:  

8:00 AM to 6:00 PM (ET) Mon. thru Fri. 

After hours?  

Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you 
no later than the following business day.

For Service outside the USA:  

Email: [email protected]

Summary of Contents for POWER WAVE 655/R

Page 1: ...our machine www lincolnelectric com register Authorized Service and Distributor Locator www lincolnelectric com locator Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Opera...

Page 2: ...KER 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...

Page 3: ...r 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 welde...

Page 4: ...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...

Page 5: ...opri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pa...

Page 6: ...ortant 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 b...

Page 7: ...ral 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...

Page 8: ...NDUIT AWG MM2 SIZES 8 10 10 6 TYPE 75 C COPPER WIRE IN CONDUIT AWG MM2 SIZES 6 16 6 16 PROCESS CURRENT RANGES DC MIG MAG FCAW SMAW Pulse CURRENT 50 815 Average Amps 40 815 Average Amps 30 600 Average...

Page 9: ...ower to any other equipment connected to the welding sys tem at the disconnect switch or fuse box before working on the equipment Do not touch electrically hot parts Always connect the Power Wave grou...

Page 10: ...ne is not being used at high currents INPUT VOLTAGE CHANGE OVER FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY Welders are shipped connected for the highest input voltage listed on the rating plate To move...

Page 11: ...WAVE POWERWAVE Connect All Work Sense Electrode Lead Electrode Lead Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint Travel Direction TWO Power Wave S For the...

Page 12: ...al welding loop length greater than 50ft 15m the K1796 Coaxial Welding Cables are recommended The welding loop length is defined as the total of electrode cable length A work cable length B work lengt...

Page 13: ...rk voltage sensing is recommended CAUTION A 6 INSTALLATION POWER WAVE 655 R A 6 NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications revers...

Page 14: ...ard cables especially in lengths greater than 25 ft 7 6m can lead to com munication problems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems...

Page 15: ...slide the switch left to the ON position when the high speed gear is installed Replace the cover and screws The PC board will read the switch at power up automatically adjusting all control parameter...

Page 16: ...t Switch 7 reserved for future use Switch 8 work sense lead 1 LEASE SIGNIFICANT BIT 2 MOST SIGNIFICANT BIT Switch 8 work sense lead Off work sense lead not connected On work sense lead connected Feed...

Page 17: ...0 0 0 0 17 0 1 0 0 0 1 18 0 1 0 0 1 0 19 0 1 0 0 1 1 20 0 1 0 1 0 0 21 0 1 0 1 0 1 22 0 1 0 1 1 0 23 0 1 0 1 1 1 24 0 1 1 0 0 0 25 0 1 1 0 0 1 26 0 1 1 0 1 0 27 0 1 1 0 1 1 28 0 1 1 1 0 0 29 0 1 1 1 0...

Page 18: ...ceases Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dan gerous...

Page 19: ...WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTEC...

Page 20: ...e 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 Pow...

Page 21: ...em fault If the PS Status light is flashing any combination of red and green errors are present in the PW 655 R Read the error code before the machine is turned off Error Code interpretation through t...

Page 22: ...c programs when the wire feed speed changes the Power Wave will automatically adjust the voltage correspondingly Wave control adjusts the inductance of the wave shape This adjustment is often referred...

Page 23: ...ically recalculate the waveform parameters to maintain similar arc properties POWER WAVE 655 R The Power Wave utilizes adaptive control to com pensate for changes in electrical stick out while weld in...

Page 24: ...ee 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 POWER WAVE 655 R Water Flow Sensor...

Page 25: ...will not need adjustment However neglected or improperly calibrated machines may not yield sat isfactory weld performance To ensure optimal performance the calibration of output Voltage and Current sh...

Page 26: ...BLE 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 general...

Page 27: ...ponents 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...

Page 28: ...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 i...

Page 29: ...ng 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 lou vers 1 Input voltage is too...

Page 30: ...age 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 p...

Page 31: ...n robot 1 Check for fault signals from the I O connector Possible faults are lack of water flow water flow turned off 1 Check for fault signals from the I O connector Possible faults are lack of water...

Page 32: ...erface 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 reload...

Page 33: ...ed When this occurs the machine output will phase back to 100 amps typically result ing in a condition referred to as noodle welding NOTE For The Power Wave 655 the secondary limit is 880 Amps The max...

Page 34: ...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...

Page 35: ...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...

Page 36: ...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...

Page 37: ...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...

Page 38: ...guration WORK SENSE LEAD K940 WATERCOOLED TORCH ELECTRODE LEAD CONTROL CABLE K1795 WATER COOLER POWER CONNECTION SHIELDING GAS TO SHIELDING GAS DEVICENET CABLE TO PLC CONTROLLER DEVICENET CABLE TO PLC...

Page 39: ...User supplied electrode lead POWERWAVE CONTROL CABLE K1805 1 WORK SENSE LEAD K940 DEVICENET CABLE K1804 1 CONTROL CABLE OR K1804 2 AND ANY K1795 CONTROL CABLE CONTROL CABLE K1805 1 User supplied elec...

Page 40: ...F 7 DIAGRAMS F 7 POWER WAVE 655 R M18241 A 01 32 88 14 62 19 16 19 90 9 48 12 35 19 00 22 63 26 10 23 12 23 51 4 21 12 90 6 75 3 47 10...

Page 41: ...NOTES POWER WAVE 655 R...

Page 42: ...h 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 moja da Aislese del trabajo y...

Page 43: ...te Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentac...

Page 44: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

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