Power Wave 655/R ®OPERATORʼS MANUALIM713-CJanuary, 2012Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safe
A-3INSTALLATION POWER WAVE®655/RA-3INPUT CONNECTIONOnly a qualified electrician should connect theinput leads to the Power Wave®. Connectionsshould
A-4INSTALLATION POWER WAVE®655/RA-4WELDING WITH MULTIPLE PowerWaves®Special care must be taken when more than onePower Wave®is welding simultaneousl
A-5INSTALLATION POWER WAVE®655/RA-5ELECTRODE AND WORK CABLECONNECTIONSConnect a work lead of sufficient size and length (PerTable 1) between the pro
VOLTAGE SENSINGThe best arc performance occurs when the PowerWaves®has accurate data about the arc conditions.Depending upon the process, inductance w
POWER WAVE®/ POWER FEEDWIRE FEEDERINTERCONNECTIONSConnect the control cable between the power sourceand wire feeder. The wire feeder connection on the
HIGH SPEED GEAR BOXChanging the ratio requires a gear change and a PCboard switch change. The Power Feed®Wire Feedersare shipped with both high speed
A-9INSTALLATION POWER WAVE®655/RA-9DIP Switch Settings and LocationsDIP switches on the P.C. Boards allow for customconfiguration of the Power Wave®
A-10INSTALLATION POWER WAVE®655/RA-10Bank (S2):Switch Description1 Devicenet Baud Rate2(see table 4)TABLE 4Prior to S24958-6 softwareSwitch 1 swit
B-1OPERATIONB-1POWER WAVE®655/RSAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can kil
B-2OPERATIONB-2POWER WAVE®655/RINPUT POWERONOFFHIGH TEMPERATUREMACHINE STATUSCIRCUIT BREAKERWIRE FEEDERPOSITIVE OUTPUTNEGATIVE OUTPUT3 PHASE INVERTERI
FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
RECOMMENDED EQUIPMENT• Automatic OperationAll welding programs and procedures are set throughsoftware for the robotic Power Wave®s. FAUNrobots equippe
B-4OPERATIONPOWER WAVE®655/RB-4CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave®. (See Figure B
B-5OPERATIONB-5CONSTANT VOLTAGE WELDINGFor each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at
B-6OPERATIONB-6PULSE WELDINGPulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc volt
C-1ACCESSORIESC-1OPTIONAL EQUIPMENTFACTORY INSTALLEDThere are no factory installed options available for thePower Wave®.FIELD INSTALLEDGas Guard Regul
D-1MAINTENANCED-1POWER WAVE®655/RSAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Only Qualified personnel shouldperform this maintenance.• Turn the inpu
E-1TROUBLESHOOTINGE-1POWER WAVE®655/RIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, co
E-2TROUBLESHOOTINGE-2POWER WAVE®655/RUSING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMSThe Status LED on the power source case frontcan help diagnose
E-3TROUBLESHOOTINGE-3POWER WAVE®655/RObserve all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understand the t
E-4TROUBLESHOOTINGE-4POWER WAVE®655/RObserve all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understand the t
iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld
E-5TROUBLESHOOTINGE-5POWER WAVE®655/RObserve all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understand the t
E-6TROUBLESHOOTINGE-6POWER WAVE®655/RObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro
E-7TROUBLESHOOTINGE-7POWER WAVE®655/RObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro
E-8TROUBLESHOOTINGE-8POWER WAVE®655/RObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro
F-1DIAGRAMSF-1POWER WAVE®655/RNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specif
F-2DIAGRAMSF-2POWER WAVE®655/RNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specif
F-3DIAGRAMSF-3POWER WAVE®655/RNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specif
TABLE 5 DEVICENET CONNECTOR S5Pin Lead # Function2 894 +24vdc Devicenet3 893 Common Devicenet+4 892 Devicenet H5 891 Devicenet LF-4PIN, LEAD CONNECTOR
F-5CONNECTION DIAGRAMF-5POWER WAVE®655/RHard Automation and Electrode PositiveConfiguration- +WORKSENSELEADK940WA TERCOOLEDTORCHELECTRODE LEADCONTROL
F-6CONNECTION DIAGRAMF-6POWER WAVE®655/RK1796 COAXIAL WELD CABLEUser suppliedwork leadUser suppliedelectrode lead-+POWERWAVECONTROL CABLE K1805-1WORK
iiiSAFETYiiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b.
F-7DIAGRAMSF-7POWER WAVE®655/RM18241 A.0132.8814.6219.1619.909.4812.3519.0022.6326.1023.1223.514.2112.906.753.4710°
NOTES POWER WAVE®655/R
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ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra
Thank YouFor selecting a QUALITY product by Lincoln Electric. We wantyou to take pride in operating this Lincoln Electric Company prod-uct ••• as much
TABLE OF CONTENTSPageInstallation ...Section ATech
A-1INSTALLATION POWER WAVE®655/RA-1TECHNICAL SPECIFICATIONS - Power Wave®655/r (K1519-1, K1519-2)OUTPUTRECOMMENDED INPUT WIRE AND FUSE SIZESPHYSICA
If desired, the F.A.N. feature can be disabled (causing thefan to run whenever the power source is on). To disableF.A.N., connect leads 444 and X3A to
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