SVM180-A View Safety Info Return to Master TOC RETURN TO MAIN MENU POWERWAVE TM 655/R January, 2008 For use with machines having Code Numbers: 10630, 10863, 11410 Return to Master TOC View Safety Info Return to Master TOC View Safety Info 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.
SAFETY Return to Master TOC i i WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause canchemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii SAFETY 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.
Return to Master TOC iii WELDING SPARKS can cause fire or explosion. SAFETY 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. 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. 7.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv PRÉCAUTIONS DE SÛRETÉ SAFETY 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.
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TOMAIN MAINMENU INDEX RETURN TO Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC A-1 TABLE OF CONTENTS - INSTALLATION SECTION A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION Return to Master TOC Return to Section TOC A-2 TECHNICAL SPECIFICATIONS - POWER WAVE 655/R (K1519-1, K1519-2) Return to Master TOC INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS CODE NUMBERS 10630 OUTPUT CONDITIONS 600A@44V.100% 460/575V - 60HZ. 815A@44V. 60% 10863 400V - 50HZ. 11410 Return to Section TOC A-2 550A@44V.100% 675A@44V. 60% 460/575V - 60HZ. 600A@44V.100% 815A@44V.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-3 SAFETY PRECAUTIONS INSTALLATION 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.
Return to Master TOC Return to Section TOC A-4 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM . Disconnect input power before . . . W / L3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC V / L2 Return to Section TOC A-4 U / L1 XA inspecting or servicing machine. Do not operate with covers removed. Do not touch electrically live parts.
INSTALLATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-5 WELDING WITH MULTIPLE POWER WAVES 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. Perform welding in the direction away from the work leads.
INSTALLATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-6 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.
INSTALLATION Return to Master TOC Return to Section TOC A-7 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 DIP switch 7 must be set to ON on the Wire Feed Head PC Board.
INSTALLATION Return to Master TOC Return to Section TOC A-8 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 to the work. Attach the sense lead to the work as close to the weld as practical. Enable the work voltage sensing in the Power Wave as follows: WARNING ELECTRIC SHOCK can kill.
EXTERNAL I/O CONNECTOR INSTALLATION 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 is a 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.
INSTALLATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-10 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.
INSTALLATION Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-11 Bank (S2): switch 1 2 Description Devicenet Baud Rate (see table 4) S24958-6 and later switch 1 switch 2 off off off on on off on on software baud rate 125K 250K 500K Programmable value 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
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC A-12 NOTES POWER WAVE 655/R A-12
Return to Master TOC B-1 TABLE OF CONTENTS - OPERATION SECTION B-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC B-2 OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING Return to Master TOC Return to Section TOC 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.
OPERATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-3 GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER SMAW ON GMAW OFF FCAW HIGH TEMPERATURE GTAW U0 MACHINE STATUS CIRCUIT BREAKER Return to Master TOC U1 U2 WIRE FEEDER Return to Section TOC B-3 POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER I1 I2 OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND INPUT POWER WA
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-4 OPERATION 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. GENERAL DESCRIPTION The Power Wave power source is designed to be used with the family of Power Feed wire feeders, operating as a system.
Return to Master TOC 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. Return to Master TOC 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.
OPERATION Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-6 WELDING MODE DESCRIPTIONS 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.
Return to Master TOC Return to Section TOC B-7 PULSE WELDING OPERATION 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-8 NOTES POWER WAVE 655/R B-8
TABLE OF CONTENTS - ACCESSORIES C-1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2 Factory Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC C-2 OPTIONAL EQUIPMENT ACCESSORIES 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.
TABLE OF CONTENTS - MAINTENANCE D-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2 Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC D-2 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. Return to Master TOC Return to Section TOC • Do not touch electrically hot parts. ROUTINE MAINTENANCE PERFORM THE FOLLOWING DAILY: 1. Check that no combustible materials are in the welding or cutting area or around the machine. 2.
MAINTENANCE D-3 FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW) Return to Master TOC Return to Section TOC D-3 7 7 1 7 Return to Master TOC Return to Section TOC 3 Return to Master TOC Return to Section TOC 4 2 2 6 5 1. CASE FRONT ASSEMBLY 2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBLY Return to Master TOC Return to Section TOC 3. INPUT ASSEMBLY 4. CONTROL BOX AND VERTICAL DIVIDER ASSEMBLY 2 5. BASE, LIFT BAIL AND FAN ASSEMBLY 6. SWITCH BOARD HEATSINK ASSEMBLY 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC D-4 NOTES POWER WAVE 655/R D-4
TABLE OF CONTENTS - THEORY OF OPERATION Return to Master TOC E-1 E-1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2 Input Voltage and Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION POWER WAVE 655/R INPUT RECTIFIER HARMONIC FILTER SW1 Return to Master TOC Return to Section TOC 67B S6 CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT FROM CONTROL BOARD FEED HEAD BOARD 40 VDC 115 VAC FAN RELAY ETHERNET/ GATEWAY BOARD DEVICE NET S5 CONNECTION TO ROBOT TO LEFT S.B. TO RIGHT S.B.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC E-3 INPUT VOLTAGE AND PRECHARGE THEORY OF OPERATION The Power Wave 655/R can be connected for a variety of three-phase input voltages. Refer to Figure E.2. The initial input power is applied through a line switch located on the front of the machine.
THEORY OF OPERATION INPUT RECTIFIER HARMONIC FILTER SW1 Return to Master TOC Return to Section TOC 67B CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD VOLT SENSE BOARD VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT FROM CONTROL BOARD FEED HEAD BOARD 40 VDC 115 VAC FAN RELAY ETHERNET/ GATEWAY BOARD DEVICE NET S5 CONNECTION TO ROBOT TO LEFT S.B. TO RIGHT S.B.
THEORY OF OPERATION INPUT RECTIFIER HARMONIC FILTER SW1 Return to Master TOC Return to Section TOC 67B CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD VOLT SENSE BOARD VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT FROM CONTROL BOARD FEED HEAD BOARD 40 VDC 115 VAC FAN RELAY ETHERNET/ GATEWAY BOARD DEVICE NET S5 CONNECTION TO ROBOT TO LEFT S.B. TO RIGHT S.B.
THEORY OF OPERATION A rc L i nk Arc Link Control Board Return to Master TOC Return to Section TOC Weld Controller / Sequencer Ether net/ Gate way Board Translator Feed H ead Board PW-655R D e v ic e N et Device Net Return to Section TOC Return to Master TOC Return to Master TOC Robot Controller Return to Section TOC E-6 FIGURE E.
THEORY OF OPERATION INPUT RECTIFIER HARMONIC FILTER SW1 Return to Master TOC Return to Section TOC 67B S6 CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT FROM CONTROL BOARD FEED HEAD BOARD 40 VDC 115 VAC FAN RELAY ETHERNET/ GATEWAY BOARD DEVICE NET S5 CONNECTION TO ROBOT TO LEFT S.B. TO RIGHT S.B.
THEORY OF OPERATION POWER WAVE 655/R INPUT RECTIFIER HARMONIC FILTER SW1 Return to Master TOC Return to Section TOC 67B CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD VOLT SENSE BOARD VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT FROM CONTROL BOARD FEED HEAD BOARD 40 VDC 115 VAC FAN RELAY ETHERNET/ GATEWAY BOARD DEVICE NET S5 CONNECTION TO ROBOT TO LEFT S.B. TO RIGHT S.B.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC E-9 THEORY OF OPERATION THERMAL PROTECTION Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the control board. One of the thermostats is located on the heat sink of the output rectifier, one on the DC bus, and one on the output choke.
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-10 FIGURE E.9 – IGBT OPERATION POSITIVE VOLTAGE APPLIED SOURCE n+ GATE SOURCE n+ n+ Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC GATE n+ p BODY REGION p BODY REGION n- DRAIN DRIFT REGION n- DRAIN DRIFT REGION n+ BUFFER LAYER n+ BUFFER LAYER p+ INJECTING LAYER p+ INJECTING LAYER DRAIN DRAIN Return to Section TOC E-10 B. ACTIVE A.
THEORY OF OPERATION E-11 FIGURE E.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC E-12 NOTES POWER WAVE 655/R E-12
Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR F-1 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2 PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR 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.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-3 PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
Return to Master TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR important if the user interface displays "Err 006" or "Err 100" . USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user interface, and feed head) has a status light, and when a problem occurs it is important to note the condition of each.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-5 The following is a list of possible error codes that the Power Wave 655 can output via the status light If connected to a PF-10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display. 11 12 Error Code # CAN communication bus off. User Interface time out error. 21 Unprogrammed Weld Mode. 23 Weld Table checksum error.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-6 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION Major physical or electrical damage is evident when the sheet metal covers are removed. Contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-7 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The machine is dead—no lights— no output—the machine appears to be off. 1. Make certain the input power switch SW1 is in the ON position. 1. Check the input power switch SW1 for proper operation. Also check the associated leads for loose or faulty connections.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-8 Observe Safety Guidelines detailed in the beginning of this manual. F-8 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The Power Wave 655/R does not have welding output. The main input contactor CR1 is not activating. 1.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-9 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) FUNCTION PROBLEMS The machine often "noodle welds" when running a particular process. The output is limited to approximately 100 amps. 1.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-10 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) The Auxiliary Receptacle is "dead." The 120VAC is not present at the receptacle. POSSIBLE AREAS OF MISADJUSTMENT(S) FUNCTION PROBLEMS 1. Check the 10 amp circuit breaker (CB2) located on the case front. Reset if necessary. 2. Check the 6 amp circuit breaker (CB4) located in the reconnect area. Reset if necessary.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-12 TROUBLESHOOTING & REPAIR F-12 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE SWITCH BOARD Return to Master TOC Return to Section TOC CAPACITOR TERMINALS PROCEDURE 1. Disconnect the input power to the POWER WAVE 655/R. 2. Remove the left and right case sides. 3. Remove the two High Voltage Protection shields.
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-14 SWITCH BOARD TEST PROCEDURE (CONTINUED) FIGURE F.2 – LEFT SIDE NOTE: Resistance checks of the Switch Boards in this machine will vary greatly depending on the type and model of meter being used. Comparative readings between the two sides of a board and/or between the two Switch Boards will be more meaningful than the actual numbers.
TROUBLESHOOTING & REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-15 SWITCH BOARD TEST PROCEDURE (CONTINUED) FIGURE F.3 – RIGHT SIDE AND TEST POINTS Return to Master TOC Return to Section TOC (LEFT) 11 (RIGHT) 16 Return to Master TOC NEG POS 13 12 NEG POS NEG POS 18 15 NEG POS 14 17 TABLE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-16 NOTES POWER WAVE 655/R F-16
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR F-18 INPUT RECTIFIER TEST PROCEDURE (CONTINUED) FIGURE F.4 – INPUT RECTIFIER TEST INPUT RECTIFIER NEG (-) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC POS (+) A B C PROCEDURE 1. Disconnect the input power to the POWER WAVE 655/R. 2. Remove the case top and Input Panel. 3. Perform the Capacitor Discharge Procedure. Return to Master TOC Return to Section TOC 4.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-19 F-19 INPUT RECTIFIER TEST PROCEDURE (CONTINUED) TABLE F.2 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS TEST POINT TERMINALS + Probe ANALOG METER X100 RANGE - Probe Acceptable Meter Readings A B C POS (D) POS (D) POS (D) Approx. 500 ohms Approx. 500 ohms Approx.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-20 NOTES POWER WAVE 655/R F-20
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-22 F-22 INPUT CONTACTOR TEST PROCEDURE (CONTINUED) FIGURE F.5 – INPUT CONTACTOR COIL INPUT CONTACTOR 601 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC X4 FIGURE F.5A CONTACTOR TEST POINTS PROCEDURE 1. Disconnect the input power to the POWER WAVE 655/R. 2. Remove the input access panel and case top. 3.
Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR DC BUS BOARD TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC TROUBLESHOOTING & REPAIR DC BUS BOARD TEST PROCEDURE (CONTINUED) F-24 FIGURE F.6 – DC BUS PC BOARD LED R4 R7 R5 R8 C14 C2 C16 R28 R21 R3 C17 J47 R22 C3 C11 R19 LED1 R20 D5 R23 X1 R14 R13 Return to Section TOC F-24 R26 5 6 J47 7 8 1 2 3 4 D3 C8 C9 C10 D4 R29 DZ5 R27 MOV1 C15 R15 C7 X2 C5 C1 L1 MOV2 R16 C6 R25 J46 C13 DZ6 3 4 1 2 J46 1A D1 R11 R9 D2 R12 DZ4 Return to Master TOC Return to Section TOC R10 Power Bd.
Return to Master TOC Return to Section TOC F-25 TROUBLESHOOTING & REPAIR POWER BOARD TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
TROUBLESHOOTING & REPAIR POWER BOARD TEST PROCEDURE (CONTINUED) Return to Master TOC Return to Section TOC F-26 F-26 FIGURE F.7 – POWER BOARD TEST Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC POWER PC BOARD CAPACITOR C3 6 5 4 4 3 3 2 1 2 1 PROCEDURE 1. Disconnect the input power to the POWER WAVE 655/R. 2. Remove the case top. 3. Locate the Power Board and plugs J42 and J43. Do not remove plugs or leads from the Power Board. Refer to Figure F.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR F-27 POWER BOARD TEST PROCEDURE (CONTINUED) CHECK POINT LOCATION TABLE F.4 – POWER BOARD VOLTAGE CHECKS TEST DESCRIPTION CONNECTOR PLUG PIN NO. LEAD NO.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-28 NOTES POWER WAVE 655/R F-28
Return to Master TOC Return to Section TOC F-29 TROUBLESHOOTING & REPAIR INPUT BOARD TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC Return to Section TOC F-30 TROUBLESHOOTING & REPAIR F-30 INPUT BOARD TEST PROCEDURE (CONTINUED) FIGURE F.8 – INPUT BOARD AND CONTACTOR INPUT PC BOARD J61 J60 601 X4 Return to Master TOC Return to Section TOC INPUT CONTACTOR 1. Disconnect the input power to the POWER WAVE 655/R. Return to Master TOC Return to Section TOC PROCEDURE 2. Remove the case top. 3. Remove lead X4 from the coil terminal of main input contactor CR1. Insulate lead X4. Refer to Figure F.8. 4.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-31 INPUT BOARD TEST PROCEDURE (CONTINUED) TABLE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-32 NOTES POWER WAVE 655/R F-32
Return to Master TOC Return to Section TOC F-33 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) F-34 FIGURE F.9 – CURRENT TRANSDUCER TEST CONTROL BOARD J8 J9 J8 211 212 213 Return to Master TOC Return to Section TOC Return to Section TOC F-34 1 2 3 4 5 6 7 8 216 1234 P91 Return to Master TOC Return to Section TOC CURRENT TRANSDUCER PROCEDURE 1. Disconnect the input power to the POWER WAVE 655/R. 2. Remove the case top and the control box cover. 3.
Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR F-35 CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) FIGURE F.10 – RS 232 port Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC RS 232 PORT 6. Connect a laptop computer to the PW655-R via the RS232 port on the front of the machine. See Figure F.10. 7. Connect a Load Bank (or 50ʼ weld cable) to the Positive and Negative Output Studs of the PW655-R. 8.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-36 NOTES POWER WAVE 655/R F-36
Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-38 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER TEST PROCEDURE (CONTINUED) FIGURE F.11 – OUTPUT RECTIFIER TEST Return to Master TOC Return to Section TOC NEGATIVE (-) OUTPUT TERMINALS POSITIVE (+) OUTPUT TERMINALS PROCEDURE 1. Remove main input supply power to the POWER WAVE 655/R. 2. Remove the case sides and perform the Input Filter Capacitor Discharge procedure. 3.
Return to Master TOC Return to Section TOC F-39 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-40 F-40 AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED) FIGURE F.12 – AUXILIARY TRANSFORMER NO. 1 TEST + X1 INPUT CONTACTOR - X2 POWER BOARD RECTIFIER BRIDGE 601 FAN RELAY Return to Master TOC Return to Section TOC X4 WHITE X3 RED X5 444 X3A FAN MOTOR WINDING Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC AUXILIARY TRANSFORMER #1 PROCEDURE 1.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-41 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED) 7. Carefully apply the correct input voltage to the POWER WAVE 655/R. WARNING ELECTRIC SHOCK can kill. High voltage is present at primary of the Auxiliary Transformer. 8. Check for the correct secondary voltages according to Table F.7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-42 NOTES POWER WAVE 655/R F-42
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC Return to Section TOC F-44 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 TEST PROCEDURE (CONTINUED) F-44 FIGURE F.13 – AUXILIARY TRANSFORMER NO. 2 TEST 350 (WHITE) 3 1 4 2 (BLACK) 352 To WATER COOLER RECEPTACLE (S8) 33A (RED) Return to Master TOC Return to Section TOC H1 Return to Master TOC Return to Section TOC 1 2 5 3 6 H6 4 2 5 3 6 To AUX.ILIARY TRANSFORMER #2 PRIMARY (P50) To S4, CB2 & AUX. FAN 352A (BLACK) 1.
Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-46 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.14 – INPUT RECTIFIER REMOVAL AND REPLACEMENT Return to Master TOC NEG (-) INPUT RECTIFIER POS (+) A B C REMOVAL PROCEDURE 1. Remove input power to the POWER WAVE 655/R. 2. Remove the case top, sides, and input access panel. 3. Perform the Capacitor Discharge procedure.
Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC Return to Section TOC F-48 TROUBLESHOOTING & REPAIR F-48 INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.15 – INPUT CONTACTOR REMOVAL AND REPLACEMENT INPUT CONTACTOR 601 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC X4 REMOVAL PROCEDURE L3 T3 L2 T2 L1 T1 1. Remove input power to the POWER WAVE 655/R. REPLACEMENT PROCEDURE 3.
Return to Master TOC Return to Section TOC F-49 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-50 AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT + X1 INPUT CONTACTOR - X2 POWER BOARD RECTIFIER BRIDGE 601 FAN RELAY X4 WHITE X3 RED X5 Return to Master TOC Return to Section TOC 444 AUXILIARY TRANSFORMER #1 REMOVAL PROCEDURE 1. Carefully place the transformer into the POWER WAVE 655/R. 3.
Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-52 TROUBLESHOOTING & REPAIR F-52 AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT 350 (WHITE) 3 1 4 2 (BLACK) 352 To WATER COOLER RECEPTACLE (S8) Return to Master TOC Return to Section TOC 33A (RED) H1 1 4 2 5 3 6 H6 32 (WHITE) 33 (RED) 1 4 2 5 3 6 To AUX.ILIARY TRANSFORMER #2 PRIMARY (P50) To S4, CB2 & AUX.
Return to Master TOC Return to Section TOC F-53 TROUBLESHOOTING & REPAIR CONTROL, FEED HEAD, VOLTAGE SENSE, OR AUXILIARY DRIVER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
TROUBLESHOOTING & REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-54 CONTROL, FEED HEAD, VOLTAGE SENSE OR AUXILIARY DRIVER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.18 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT CONTROL BOARD FEED HEAD BOARD Removal Step 6 Removal Step 6 VOLTAGE SENSE BD. AUXILIARY DRIVER BD. REMOVAL PROCEDURE 1. Remove input power to the POWER WAVE 655/R. Return to Master TOC Return to Section TOC 2.
Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR ETHERNET/GATEWAY PC BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-56 TROUBLESHOOTING & REPAIR F-56 ETHERNET/GATEWAY PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.19 – GATEWAY BOARD REMOVAL AND REPLACEMENT Ethernet/ Gateway PC Board Return to Master TOC Return to Section TOC Support the Panel REMOVAL PROCEDURE REPLACEMENT PROCEDURE 2. Using a phillips head screw driver, remove the six screws from the case front cover.
Return to Master TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR F-58 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.20 – POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE THIS SIDE FACES REAR + Return to Section TOC Return to Section TOC F-58 Return to Master TOC Return to Section TOC CURRENT TRANSDUCER REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove input power to the POWER WAVE 655/R. 1. Slide the new Transducer over the 4/0 cable.
Return to Master TOC Return to Section TOC F-59 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-60 F-60 OUTPUT RECTIFIER MODULE REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.21 – ACCESSING THE RECTIFIER MODULE J48 J60 Fan Relay Front Horizontal Divider Panel Rear Horizontal Divider Panel Return to Master TOC Return to Section TOC Power Switch J40/50 Output Choke Connection Front Panel Screws Return to Master TOC Return to Section TOC ACCESSING THE RECTIFIER MODULE 1. Remove input power to the POWER WAVE 655/R. 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-61 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER AND RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.22 – RECTIFIER MODULE REPLACEMENT Copper Plate Original Modules may have 1/4-20 bolts in place of studs RECTIFIER MODULE TESTING Return to Master TOC Return to Master TOC Return to Section TOC 1. Remove the leads and copper plate from one of the Diode Module pairs. (See Figure F.22).
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-62 NOTES POWER WAVE 655/R F-62
Return to Master TOC Return to Section TOC F-63 TROUBLESHOOTING & REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-64 TROUBLESHOOTING & REPAIR F-64 SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.23 – SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT SWITCH BOARD Observe all static electricity precautions.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-65 TROUBLESHOOTING & REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) REPLACEMENT PROCEDURE NOTE: Any instructions that are shipped with the replacement part will supersede these instructions. 1. If the filter capacitors are to be replaced, carefully slide the new capacitors into the mounting bracket.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-66 NOTES POWER WAVE 655/R F-66
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-67 CALIBRATION PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-68 CALIBRATION PROCEDURE (CONTINUED) CALIBRATION SET-UP: 1. Load the Diagnostic Utility Software into the computer. 2. Use the Serial Modem or Ethernet cable to connect the computer to the PW655-R. NOTE: If the PW655-R is connected to an Ethernet network, you may use an ethernet cable to connect to the machine instead of the Serial Modem Cable. Return to Master TOC Return to Section TOC 3.
Return to Master TOC Return to Section TOC F-69 TROUBLESHOOTING & REPAIR CALIBRATION PROCEDURE (CONTINUED) Calibration can only be done under ʻstatic loadʼ conditions. Do not attempt to calibrate while welding. NOTE: Incorrect calibration can and will affect welding performance. It is strongly recommended to use the “Diagnostics” screen to run and save a “Snapshot” before making any calibration adjustments. This will allow returning to original settings if necessary.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-70 NOTES POWER WAVE 655/R F-70
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-71 RETEST AFTER REPAIR MATERIALS NEEDED Diagnostic Utilities Software Laptop or other Suitable Computer RS-232 Serial Modem Cable or Ethernet Cable Resistive Load Bank Two (2) Welding Cables - 20ft. -4/0 Calibrated Ammeter and Voltmeter Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TEST PROCEDURE Return to Section TOC F-71 1.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-72 NOTES POWER WAVE 655/R F-72
TABLE OF CONTENTS - DIAGRAM SECTION Return to Master TOC G-1 G-1 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram for Code 10630 (G3498)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2 Wiring Diagram for Code 10863 (G3498-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL DIAGRAMS ENGINEERING CONTROLLED MANUFACTURER: No TM POWER WAVE 655 (460/ 575 )WIRING DIAGRAM S1 WIRE FEEDER RECEPTACLE C S2 VOLTAGE SENSE RECEPTACLE FRONT OF MACHINE D 52 51 1 2 3 4 L4 21A J72 TO J9 J73 1 2 3 4 5 6 7 S3 RS232 CONNECTOR J71 253 254 J74 251 TO J2 J75 20 CB1 10A CIRCUIT BREAKER 52 TO L2 J47 50 J76 J2 743 741 800 840 53 54 892 893 891 894 TO J81 J3 TO S1 TO S5 J4 830 J5 TO WORK ELECTRODE TP3 PRINT TO 10 X 17 S4 115V RECEPTACLE 31 J6 32 32A TO
ELECTRICAL DIAGRAMS S2 VOLTAGE SENSE RECEPTACLE FRONT OF MACHINE 53 54 C 67A D 52 E 51 1 2 3 4 3 CONDUCTOR TWISTED/SHIELDED SHIELD GROUND TO CASE L4 21A J72 TO J9 J73 1 2 3 4 5 6 7 S3 RS232 CONNECTOR J71 253 254 J74 251 TO J2 J75 20 CB1 10A CIRCUIT BREAKER 52 TO L2 J47 50 J76 TO WORK ELECTRODE TP3 N.E.
ELECTRICAL DIAGRAMS S2 VOLTAGE SENSE RECEPTACLE FRONT OF MACHINE 53 54 C 67A D 52 E 51 1 2 3 4 3 CONDUCTOR TWISTED/SHIELDED SHIELD GROUND TO CASE L4 21A J72 TO J9 J73 1 2 3 4 5 6 7 S3 RS232 CONNECTOR J71 253 254 J74 TO J2 251 J75 20 CB1 10A CIRCUIT BREAKER 52 TO L2 J47 50 J76 TO WORK ELECTRODE TP3 N.E.
ELECTRICAL DIAGRAMS ENGINEERING CONTROLLED MANUFACTURER: No G-5 CHANGE DETAIL: RELEASED FROM X A.02 N.A. INPUT RECTIFIER CR1 AC3 L1 POS T1 POS POS U N.A. AC2 L2 N.A. FEED HD BD .022u 800V MAIN TRANSFORMER T1 SWITCH BOARD #1 (LEFT) S3 RS232 CONNECTOR CONTROL BOARD HARMONIC FILTER RS232 RECEIVE 3J2 253 2 RS232 TRANSMIT 4J2 254 3 2.
ELECTRICAL DIAGRAMS G-6 CHANGE DETAIL: REVISED CB2 AND RECEPTACLE GRAPHICS ENGINEERING CONTROLLED MANUFACTURER: No N.A. INPUT RECTIFIER CR1 AC3 L1 POS T1 POS POS U N.A. AC2 L2 N.A. FEED HD BD .022u 800V MAIN TRANSFORMER T1 SWITCH BOARD #1 (LEFT) S3 RS232 CONNECTOR CONTROL BOARD HARMONIC FILTER RS232 RECEIVE 3J2 253 2 RS232 TRANSMIT 4J2 254 3 2.
ELECTRICAL DIAGRAMS G-7 CHANGE DETAIL: RELEASED A.01 FROM X. ENGINEERING CONTROLLED MANUFACTURER: No N.A. INPUT RECTIFIER CR1 AC3 L1 POS T1 POS POS U N.A. AC2 L2 N.A. FEED HD BD .022u 800V MAIN TRANSFORMER T1 SWITCH BOARD #1 (LEFT) S3 RS232 CONNECTOR CONTROL BOARD HARMONIC FILTER RS232 RECEIVE 3J2 253 2 RS232 TRANSMIT 4J2 254 3 2.
Return to Master TOC SCHEMATIC - DEVICENET/GATEWAY PC BOARD (SHEET 1) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-8 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC SCHEMATIC - DEVICENET/GATEWAY PC BOARD (SHEET 2) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-9 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC SCHEMATIC - ETHERNET/GATEWAY PC BOARD (SHEET 1) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-10 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC SCHEMATIC - ETHERENET/GATEWAY PC BOARD (SHEET 2) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-11 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC SCHEMATIC ETHERNET/GATEWAY PC BOARD (SHEET 3) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-12 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ENGINEERING CONTROLLED MANUFACTURER: Yes ELECTRICAL DIAGRAMS G-13 CHANGE DETAIL: PAGE 3, R65, REVISED VALUE 23 UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 G3789-1E2 SCALE: SUBJECT: ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS.
Return to Master TOC ENGINEERING CONTROLLED MANUFACTURER: Yes ELECTRICAL DIAGRAMS G-14 CHANGE DETAIL: PAGE 3, R65, REVISED VALUE UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 G3789-1E2 SCALE: SUBJECT: ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS.
ELECTRICAL DIAGRAMS ENGINEERING CONTROLLED MANUFACTURER: Yes G-15 CHANGE DETAIL: PAGE 3, R65, REVISED VALUE 47.5K UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 G3789-1E2 SCALE: SUBJECT: ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS.
Return to Master TOC ENGINEERING CONTROLLED MANUFACTURER: Yes ELECTRICAL DIAGRAMS G-16 CHANGE DETAIL: PAGE 3, R65, REVISED VALUE UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 G3789-1E2 SCALE: SUBJECT: ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS.
ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL POWER SUPPLY PC BOARD G-17 +5V Machine Control Power Supply R50 D18 6A 200V 10 R9 10.0K D22 1.0A 30V 11 Vref 1 12 D3 1A 600V 2 OUT 6 8 VREF VFB 2 4 RT/CT COMP 1 5 GND CS J41 3 100K 100K J42 X8 2 4 R8 OV1 C11 22 35V T1 Vfb1 475 C14 0.1 50V C47 1.0 35V 1.21K .33W R52 1.82K 221K R14 D21 1.0A 30V R3 6.19K 7 4 6 C45 150p 100V R39 R12 56.2K 5.62K 3W 0.05 C32 10p 100V J41 C42 R11 C7 0.1 50V C6 4.
Return to Master TOC SCHEMATIC - FEED HEAD PC BOARD (SHEET 1) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-18 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC SCHEMATIC - FEED HEAD PC BOARD (SHEET 2) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-19 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC SCHEMATIC - FEED HEAD PC BOARD (SHEET 3) ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-20 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-21 SCHEMATIC - INPUT PC BOARD ELECTRICAL DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS Return to Master TOC PC BOARD ASSEMBLY - INPUT PC BOARD L11396-2 Return to Section TOC G-22 G-22 CHANGE DETAIL: REVISED MAKE SPECIFICATION ENGINEERING CONTROLLED MANUFACTURER: No REFERENCES C1 CR1, CR2 D1, D3 D2 N.C. J60 N.C. J61 OCI1 R1, R2, R3, R6, R7, R8, R9, R10 R4 R5 R11, R17, R23, TP1, P.C. BOARD BLANK INFORMATION BUY COMPLETE AS L11396-B ( 2 LAYER BOARD PER E3281) Return to Master TOC N.D. 4.50 ±.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-23 SCHEMATIC - SWITCH PC BOARD ELECTRICAL DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS Return to Master TOC PC BOARD ASSEMBLY - SWITCH PC BOARD G3501-1 Return to Section TOC G-24 CHANGE DETAIL: REMOVED MFG OPERATION AND W/C TABLE ENGINEERING CONTROLLED MANUFACTURER: No NOTES: N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454 BEFORE HANDLING. N.B. PC BOARD AND MODULE MOUNTING HOLES TO BE FREE OF ENCAPSULANT MATERIAL FOR A CENTERED 0.50” MIN. DIA. AND 0.55” MAX. DIA. (8 HOLES). MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
Return to Master TOC SCHEMATIC - VOLTAGE SENSE PC BOARD ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-25 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS Return to Master TOC PC BOARD ASSEMBLY - VOLTAGE SENSE PC BOARD M19540-3 Return to Section TOC G-26 G-26 CHANGE DETAIL: REVISED MAKE SPECIFICATION ENGINEERING CONTROLLED MANUFACTURER: No N.A. N.A. REQD C1 D1 1 1 S20500-4 T12199-1 .0047 1000V 1N4004 J1 J2 L1 1 1 1 S24020-6 S24020-2G T12218-7 HEADER HEADER 330uH OCI1,OCI2 R1,R2 R3 TP1,TP2 2 2 1 2 S15000-20 S19400-4750 S18380-1 T13640-18 PHOTO FET 475 1/4W THERMISTOR,PTC 160J PART NO.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-27 SCHEMATIC - 40VDC BUS PC BOARD ELECTRICAL DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS Return to Master TOC PC BOARD ASSEMBLY - 40VDC BUS PC BOARD L11745-1 Return to Section TOC G-28 ENGINEERING CONTROLLED MANUFACTURER: No G-28 ITEM PART NO. 1 M19559 L11078-2 S25930-1 2 S9262-23 CF000017 E2529 * 3 E1777-2 T13359-12 4 S8025-80 E2529 CHANGE DETAIL: NEW NOTES: DESCRIPTION HEAT SINK 40V DC BUS P.C. BD.
Return to Master TOC SCHEMATIC - AUXILIARY DRIVER PC BOARD ELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-29 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS Return to Master TOC PC BOARD ASSEMBLY - AUXILIARY DRIVER PC BOARD L11067-1 Return to Section TOC G-30 ENGINEERING CONTROLLED MANUFACTURER: No G-30 CHANGE DETAIL: RELEASED FROM X A.03 ITEM 1 2 3 P.C. BOARD BLANK REFERENCE INFORMATION MAKE FROM S19399 (MAKES 14 BOARDS PER PANEL. SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION) REQ'D 1 1 1 OZ. PART No. SEE BLANK S24016-10 E2861 DESCRIPTION P. C.