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P o w er W a ve 655/R ® OPERA TOR’S MANUAL IM713-B December, 2009 Safety Depends on You L i n c o l n a r c w e l d i n g a nd c u t t i n g equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation .
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.
ii SAFETY ii ARC R A Y S can bur n. 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.
iii SAFETY iii FOR ELECTRIC ALL Y pow er ed 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.
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 suiv- antes: Sûreté Pour Soudage A L’Arc 1.
V V T T h h a a n n k k Y Y o o u u 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.
Vi Vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave® 655/r .................................................
A-1 INST ALLA TION POWER WAVE® 655/R A-1 TECHNICAL SPECIFICA TIONS - Power W ave® 655/r (K1519-1, K1519-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 460/575V - 60HZ.
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. ST ACKING Power Wave® machines can be stacked to a maxi- mum of 3 high. The bottom machine must always be placed on a firm, secure, level surface.
A-3 INST ALLA TION POWER WAVE® 655/R A-3 INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power Wave®. Connections should be made in accordance with all local and national electrica l codes and the connection dia- gram located on the inside of the reconnect/input access door of the machine.
A-4 INST ALLA TION POWER WAVE® 655/R A-4 WELDING WITH MUL TIPLE Power W aves® Special care must be taken when more than one Power Wave® is welding simultaneously on a sin- gle 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.
A-5 INST ALLA TION POWER WAVE® 655/R A-5 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.
VOL T AGE SENSING T he b e st a r c p e r f o rm a n c e oc c u r s wh e n th e Po w e r Wave® s has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the contact tip.
POWER W A VE® / 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.
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.
A-9 INST ALLA TION POWER WAVE® 655/R A-9 DIP Switch Settings and L ocations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave®.
A-10 INST ALLA TION POWER WAVE® 655/R A-10 Bank (S2) : Switch Description 1 Devicenet Baud Rate 2( see table 4 ) T ABLE 4 Prior to S24958-6 software Switch 1 switch 2 Baud rate Off off Programmable v.
B-1 OPERA TION B-1 POWER WAVE® 655/R SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill.
B-2 OPERA TION B-2 POWER WAVE® 655/R INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT.
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 communi- cate directly to the Power Wave®. Other pieces of equipment such as ply or computers can communi- cate to the Power Wave® using DeviceNET.
B-4 OPERA TION POWER WAVE® 655/R B-4 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.
B-5 OPERA TION B-5 CONST ANT VOL T AGE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed.
B-6 OPERA TION 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.
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED There are no factory installed options available for the Power Wave®. FIELD INST ALLED Gas Guard Regulator (K659-1) The Gas Guard regulator is availabl e as an optional accessory for Power Feed™ Robotic wire drive unit.
D-1 MAINTENANCE D-1 POWER WAVE® 655/R SAFETY PRECAUTIONS 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.
E-1 TROUBLESHOOTING E-1 POWER WAVE® 655/R 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.
E-2 TROUBLESHOOTING E-2 POWER WAVE® 655/R USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Status LED on the power source case front can help diagnose problems down to the system c o m p o n e n t ( p o w e r s o u r c e , w i r e f e e d e r, w i r e drive, etc.
E-3 TROUBLESHOOTING E-3 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
E-4 TROUBLESHOOTING E-4 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
E-5 TROUBLESHOOTING E-5 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
E-6 TROUBLESHOOTING E-6 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual 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.
E-7 TROUBLESHOOTING E-7 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual 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.
E-8 TROUBLESHOOTING E-8 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual 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.
F-1 DIAGRAMS F-1 POWER WAVE® 655/R.
F-2 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.
F-3 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.
T ABLE 5 DEVICENET CONNECTOR S5 Pin Lead # Function 2 894 +24vdc Devicenet 3 893 Common Devicenet+ 4 892 Devicenet H 5 891 Devicenet L F-4 PIN, LEAD CONNECT OR DIAGRAMS F-4 POWER WAVE® 655/R T ABLE 1.
F-5 CONNECTION DIAGRAM F-5 POWER WAVE® 655/R Hard Automation and Electrode Positive Configuration - + WO R K SE NSE LEA D K940 W AT ERC O O LE D TO RCH E L E CTRO DE LE A D CO N NE C TI ON DI AG RA M.
F-6 CONNECTION DIAGRAM F-6 POWER WAVE® 655/R K1796 COAXIAL WELD CABLE User supplied work lead U ser supplied electrode lead - + PO WER W A VE CONTROL CABLE K1805-1 WORK SENSE LEAD K940 DEVICENET CABL.
F-7 DIAGRAMS F-7 POWER WAVE® 655/R M 182 41 A .01 32. 88 14. 62 19. 16 19. 90 9.4 8 12. 35 19. 00 22. 63 26 .10 23. 12 23 .51 4.2 1 12. 90 6.7 5 3.4 7 10°.
NOTES POWER WAVE® 655/R.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Sales 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.
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