Welder User Manual
INSTALLATION
A-8 A-8
POWER WAVE 655/R
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POWER WAVE / 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.
The control cable is keyed and polarized to prevent
improper connect.
For convenience, the electrode and control cables can
be routed behind the left or right strain reliefs (under
the spring loaded output cover), and along the chan-
nels formed into the base of the Power Wave, out the
back of the channels, and then to the wire feeder.
Output connections on some Power Waves are made
via 1/2-13 threaded output studs located beneath the
spring loaded output cover at the bottom of the case
front. On machines which carry the CE mark, output
connections are made via Twist-Mate receptacles,
which also located beneath the spring loaded output
cover at the bottom of the case front.
A work lead must be run from the power source output
stud to the work piece. The work piece connection
must be firm and secure, especially if pulse welding is
planned.
Excessive voltage drops at the work piece connec-
tion often result in unsatisfactory pulse welding
performance.
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CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave / Power Feed system.
The use of non-standard 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).
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Lincoln control cables are copper 22 conductor cable
in a SO-type rubber jacket.
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 sens-
ing in the Power Wave as follows:
ELECTRIC SHOCK can kill.
• 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.
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1. Turn off power to the power source at the disconnect
switch.
2. Remove the front cover from the power source.
3. The control board is on the left side of the power
source. Locate the 8-position DIP
switch and look for switch 8 of the DIP
switch.
4. Using a pencil or other small object,
slide the switch right to the OFF position
if the work sense lead is NOT connect-
ed. Conversely, slide the switch left to
the ON position if the work sense lead is
present.
5. Replace the cover and screws. The PC
board will “read” the switch at power up, and config-
ure the work voltage sense lead appropriately.
Electrode Voltage Sensing
Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead must be connected at the wire
feeder.
WARNING
O
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1 2 3 4 5 6 7 8
CAUTION
CAUTION