Lincoln Electric POWER WAVE 655/R Operator'S Manual Download Page 6

Thank You

For selecting a 

QUALITY

product by Lincoln Electric. We want

you to take pride in operating this Lincoln Electric Company prod-
uct ••• as much pride as we have in bringing this product to you!

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:

WARNING

This statement appears where the information 

must

be followed 

exactly

to avoid 

serious personal injury

or 

loss of life

.

This statement appears where the information 

must

be followed to avoid 

minor personal injury

or 

damage to this equipment

.

CAUTION

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 

WEB SITE at www. lincolnelectric.Com. 

Choose “Support” and then

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

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. 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 posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation 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.

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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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