Operator’s Manual POWER WAVE 655R · 2019-02-26 · SECTION A: WARNINGS C ALIFORNIA PROPOSITION...

POWER WAVE ® 655R

Operator’s Manual

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM713-C | Issue D ate Feb-19

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

10630, 10863, 11410, 11880

Register your 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 Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.comA Lincoln Service Representative will contact you no later than the following business day.

For Service outside the USA: Email: [email protected]

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.

This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followedto avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.

READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glarewith protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work areaAT ALL TIMES.

SPECIAL SITUATIONSDO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.

Additional precautionary measuresPROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 06/15/2016

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel EnginesDiesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and otherreproductive harm.

Gasoline EnginesThe engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or otherreproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. Foradditional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

1.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flamewelding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel fromvaporizing on contact with hot engine partsand igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 06/15/2016

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot 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 areaof physical contact with work and ground.

In addition to the normal safety precautions, ifwelding must be performed under electricallyhazardous conditions (in damp locations or whilewearing wet clothing; on metal structures such asfloors, gratings or scaffolds; when in crampedpositions such as sitting, kneeling or lying, if thereis a high risk of unavoidable or accidental contactwith the workpiece or ground) use the followingequipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enoughventilation and/or exhaust at the arc to keep fumes and gasesaway from the breathing zone. When welding hardfacing(see instructions on container or SDS) or on leador cadmium plated steel and other metals orcoatings which produce highly toxic fumes, keepexposure as low as possible and within applicableOSHA PEL and ACGIH TLV limits using localexhaust or mechanical ventilation unless exposureassessments indicate otherwise. In confinedspaces or in some circumstances, outdoors, arespirator may also be required. Additionalprecautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 06/15/2016

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings 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, specialprecautions should be used to prevent hazardous situations.Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.

FOR ELECTRICALLYPOWERED EQUIPMENT.

8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

Refer tohttp://www.lincolnelectric.com/safetyfor additional safety information.

SAFETY

Safety 04 of 04 - 06/15/2016

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.

c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications .......................................................................................A-1Safety Precautions.................................................................................................A-2Select Suitable Location ........................................................................................A-2

Lifting...............................................................................................................A-2Stacking ..........................................................................................................A-2

Machine Grounding ...............................................................................................A-2High Frequency Protection ....................................................................................A-2Input Connection....................................................................................................A-3Input Fuse and Supply Wire Considerations .........................................................A-3Input Voltage Changeover Procedure ...................................................................A-3Welding with Multiple Power Wave® s ...................................................................A-4Electrode and Work Cable Connections................................................................A-5

Cable Inductance and its Effects on Pulse Welding........................................A-5Negative Electrode Polarity ..................................................................................A-6Voltage Sensing ....................................................................................................A-6Power Wave® / Power Feed® Wire Feeder Interconnections .................................A-7

Control Cable Specifications ...........................................................................A-7External I/O Connector....................................................................................A-8High Speed Gear Box .....................................................................................A-8Dip Switch Settings and Locations.................................................................A-9Control Board Dip Switch ................................................................................A-9Feed Head Board Dip Switch..........................................................................A-9DeviceNET/Gateway Board Dip Switch, Bank (S1) ........................................A-9Bank (S2) ......................................................................................................A-10

________________________________________________________________________Operation .........................................................................................................Section B

Safety Precautions.................................................................................................B-1Graphic Symbols that appear on this machine or in this manual...........................B-2General Description ...............................................................................................B-3Recommended Processes and Equipment ...........................................................B-3Required Equipment ..............................................................................................B-3Limitations..............................................................................................................B-3

Duty Cycle and Time Period ...........................................................................B-3Case Front Controls ........................................................................................B-4Constant Voltage Welding...............................................................................B-5Pulse Welding .................................................................................................B-6

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Equipment ...............................................................................................C-1Factory Installed..............................................................................................C-1Field Installed..................................................................................................C-1

________________________________________________________________________Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1Routine, Periodic, Calibration Specification...........................................................D-1

________________________________________________________________________Troubleshooting ..............................................................................................Section E

How to use Troubleshooting Guide .......................................................................E-1Troubleshooting the Power Wave® / Power Feed System using the Status LED..E-2Troubleshooting Guide.............................................................................E-3 thru E-6Error Codes for the Power Wave®..................................................................E-7, E-8

________________________________________________________________________Diagrams ..........................................................................................................Section F

Wiring Diagramʼs.....................................................................................F-1, F-2, F-3Pin, Lead Connector, Connection Diagrams, and Dimension Print..........F-4 thru F-7

________________________________________________________________________Parts Lists ...................................................................................................P-392 Series

________________________________________________________________________

vivi

A-1INSTALLATION

POWER WAVE® 655/R

A-1

TECHNICAL SPECIFICATIONS - Power Wave® 655/r (K1519-1, K1519-2)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLYINPUT VOLTS

460/575V - 60HZ.

400V - 50HZ.

460/575V - 60HZ.

CODE NUMBERS

10630

10863

1141011880

OPENCIRCUIT

VOLTAGE

75 VDC

INPUTVOLTAGE /

FREQUENCY

460V - 60HZ.575V - 60HZ.

HEIGHT26.10 in663 mm

WIDTH19.86 in505 mm

DEPTH32.88 in835 mm

WEIGHT306 lbs.139 kg.

TYPE 75°C(SUPER LAG)OR BREAKERSIZE (AMPS)

7060

TYPE 75°CGROUND WIRE IN

CONDUIT AWG[MM2]SIZES

8 (10)10 (6)

TYPE 75°CCOPPER WIRE IN

CONDUIT AWG[MM2]SIZES

6 (16)6(16)

PROCESS CURRENT RANGES (DC)

MIG/MAGFCAWSMAWPulse

CURRENT

50-815 Average Amps 40-815 Average Amps30-600 Average Amps15-880 Peak Amps

PULSEVOLTAGE

RANGE

5 - 55 VDC

AUXILIARY POWER(CIRCUIT BREAKER

PROTECTED)

40 VDC AT10 AMPS

110 VAC AT10 AMPS

PULSE ANDBACKGROUNDTIME RANGE

100 MICRO SEC. -3.3 SEC.

CURRENTRANGE

20-815

PULSEFREQUENCY

0.15 - 1000 Hz

INPUTCURRENT

AMPS

43/34 53/42

40 51

41/33 53/42

IDLEPOWER

400 WattsMax.

POWER FACTOR@ RATED OUT-

PUT

.95 MIN.

EFFICIENCY@ RATEDOUTPUT

84%

OUTPUT CONDITIONS

[email protected]%815A@44V. 60%



OPERATING TEMPERATURE RANGE-20°C to +40°C

STORAGE TEMPERATURE RANGE-40°C to +40°C

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 together at the output ofthe solid state fan control relay, located on the back of theControl PC board enclosure.

LIFTING

Lift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift the Power Wave® with accessories attached to it.

STACKING

Power Wave® machines can be stacked to a maxi-mum of 3 high.

The bottom machine must always be placed on afirm, secure, level surface. There is a danger ofmachines toppling over if this precaution is nottaken.

-------------------------------------------------------------

MACHINE GROUNDING

The frame of the welder must be grounded. A groundterminal marked with the symbol is located insidethe reconnect/input access door for this purpose. Seeyour local and national electrical codes for propergrounding methods.

HIGH FREQUENCY PROTECTION

Locate the Power Wave® away from radio controlledmachinery.

The normal operation of the Power Wave® mayadversely affect the operation of RF controlledequipment, which may result in bodily injury ordamage to the equipment.

------------------------------------------------------------------------

A-2INSTALLATION

POWER WAVE® 655/R

A-2

SAFETY PRECAUTIONSRead this entire installation section before youstart installation.

ELECTRIC SHOCK can kill.

• Only qualified personnelshould perform this installa-tion.

• Turn the input power OFF atthe disconnect switch or fusebox before working on thisequipment. Turn off the inputpower to any other equipmentconnected to the welding sys-tem at the disconnect switchor fuse box before working onthe equipment.

• Do not touch electrically hot parts.

• Always connect the Power Wave® grounding lug(located inside the reconnect input access door)to a proper safety (Earth) ground.

-------------------------------------------------------------

SELECT SUITABLE LOCATIONDo not use Power Waves® in outdoor environments. ThePower Wave® power source should not be subjected tofalling water, nor should any parts of it be submerged inwater. Doing so may cause improper operation as wellas pose a safety hazard. The best practice is to keep themachine in a dry, sheltered area.

Do not mount the Power Wave® over combustible sur-faces. Where there is a combustible surface directlyunder stationary or fixed electrical equipment, thatsurface shall be covered with a steel plate at least.060" (1.6mm) thick, which shall extend not less than5.90" (150mm) beyond the equipment on all sides.

Place the welder where clean cooling air can freelycirculate in through the rear louvers and out throughthe case sides and bottom. Dirt, dust, or any foreignmaterial that can be drawn into the welder should bekept at a minimum. Do not use air filters on the airintake because the air flow will be restricted. Failure toobserve these precautions can result in excessiveoperating temperatures and nuisance shutdowns.

Machines above code 10500 are equipped with F.A.N.(fan as needed) circuitry. The fan runs whenever theoutput is enabled, whether under loaded or open cir-cuit conditions. The fan also runs for a period of time(approximately 5 minutes) after the output is disabled,to ensure all components are properly cooled.

WARNING

CAUTION

CAUTION

A-3INSTALLATION

POWER WAVE® 655/R

A-3

INPUT CONNECTION

Only a qualified electrician should connect theinput leads to the Power Wave®. Connectionsshould be made in accordance with all local andnational electrical codes and the connection dia-gram located on the inside of the reconnect/inputaccess door of the machine. Failure to do so mayresult in bodily injury or death.

------------------------------------------------------------------------

Use a three-phase supply line. A 1.75 inch (45 mm)diameter access hole for the input supply is located onthe upper left case back next to the input access door.Connect L1, L2, L3 and ground according to the InputSupply Connection Diagram decal located on theinside of the input access door or refer to Figure A.1 .

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONSRefer to the Technical Specifications at the beginningof this Installation section for recommended fuse andwire sizes. Fuse the input circuit with the recommend-ed super lag fuse or delay type breakers (also called“inverse time” or “thermal/magnetic” circuit breakers).Choose an input and grounding wire size according tolocal or national electrical codes. Using fuses or circuitbreakers smaller than recommended may result in“nuisance” shut-offs from welder inrush currents, evenif the machine is not being used at high currents.

INPUT VOLTAGE CHANGE OVER(FOR MULTIPLE INPUT VOLTAGEMACHINES ONLY)Welders are shipped connected for the highest inputvoltage listed on the rating plate. To move this con-nection to a different input voltage, see the diagramlocated on the inside of the input access door. If themain reconnect switch or link position is placed in thewrong position, the welder will not produce outputpower.

If the Auxiliary (A) lead is placed in the wrong position,there are two possible results. If the lead is placed in aposition higher than the applied line voltage, thewelder may not come on at all. If the Auxiliary (A) leadis placed in a position lower than the applied line volt-age, the welder will not come on, and the two circuitbreakers in the reconnect area will open. If thisoccurs, turn off the input voltage, properly connect the(A) lead, reset the breakers, and try again.

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

W / L3

V / L2

U / L1

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

XA S24190

use or service this equipment.

Do not touch electrically live parts.

removed.

Only qualified persons should install,

Do not operate with covers

inspecting or servicing machine.

Disconnect input power before

.

.

.

.

CR1

INPUT SUPPLY CONNECTION DIAGRAM

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure todo so will result in damage to the machine.

WARNING

A-4INSTALLATION

POWER WAVE® 655/R

A-4

WELDING WITH MULTIPLE PowerWaves®

Special care must be taken when more than onePower Wave® is welding simultaneously on a sin-gle part. Arc blow and arc interference may occuror be magnified.

Each power source requires a work lead from thework stud to the welding fixture. Do not combine all ofthe work leads into one lead. Performing welding inthe direction away from the work leads. Connect all ofthe work sense leads from each power source to thework piece at the end of the joint.

- +

POWERWAVE

- +

POWERWAVE

Connect All WorkSense

Electrode Lead Electrode Lead

Leads at the Endof the Joint

Connect All WeldingWork Leads at theBeginning of the Joint

TravelDirection

TWO Power Wave® S

For the best results when pulse welding, set the wiresize and wire feed speed the same for all the PowerWave® s.

When these parameters are identical, the pulsing fre-quency will be the same, helping to stabilize the arcs.

Every welding gun requires a separate shielding gasregulator for proper flow rate and shielding gas cover-age.

Do not attempt to supply shielding gas for two or moreguns from only one regulator.

If an anti-spatter system is in use then each gun musthave its own anti-spatter system. (See Figure A.2.)

CAUTION

FIGURE A.2

A-5INSTALLATION

POWER WAVE® 655/R

A-5

ELECTRODE AND WORK CABLECONNECTIONSConnect a work lead of sufficient size and length (PerTable 1) between the proper output terminal on thepower source and the work. Be sure the connection tothe work makes tight metal-to-metal electrical contact.To avoid interference problems with other equipmentand to achieve the best possible operation, route allcables directly to the work and wire feeder. Avoidexcessive lengths and do not coil excess cable.

Minimum work and electrode cable sizes are as follows:TABLE 1 (For cable length up to 100 ft, or 30 meters)CURRENT (60% Duty Cycle) MINIMUM COPPER

400 Amps 2/0 (67mm2)500 Amps 3/0 (85mm2)600 Amps 3/0 (85mm2)

When using inverter type power sources like thePower Waves®, use the largest welding (electrode andground) cables that are practical. At least 2/0 copperwire - even if the average output current would notnormally require it. When pulsing, the pulse currentcan reach very high levels. Voltage drops can becomeexcessive, leading to poor welding characteristics, ifundersized welding cables are used.

NOTE: K1796 coaxial welding cable is recommendedto reduce the cable inductance in long cable lengths.This is especially important when Pulse welding up to350 amps.

CABLE INDUCTANCE, AND ITS EFFECTSON PULSE WELDING

For Pulse Welding processes, cable inductance willcause the welding performance to degrade. For thetotal welding loop length less than 50ft.(15m), tradi-tional welding cables may be used without any effectson welding performance. For the total welding looplength greater than 50ft.(15m), the K1796 CoaxialWelding Cables are recommended. The welding looplength is defined as the total of electrode cable length(A) + work cable length (B) + work length (C) (SeeFigure A.3).

For long work piece lengths, a sliding ground shouldbe considered to keep the total welding loop lengthless than 50ft.(15m). (See Figure A.4.)

FOR A DETAILED CONNECTION DIAGRAM USINGK1796 COAXIAL CABLE (SEE PIN, LEAD CON-NECTOR IN DIAGRAM SECTION)

When pulsing, the pulse current can reach veryhigh levels. Voltage drops can become excessive,leading to poor welding characteristics, if under-sized welding cables are used.------------------------------------------------------------------------Most welding applications run with the electrode being posi-tive (+). For those applications, connect one end of the elec-trode cable to the positive (+) output stud on the powersource (located beneath the spring loaded output cover nearthe bottom of the case front). Connect the other end of theelectrode cable to the wire drive feed plate using the stud,lockwasher, and nut provided on the wire drive feed plate.The electrode cable lug must be against the feed plate. Besure the connection to the feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sizedaccording to the specifications given in the work cable con-nections section. Connect a work lead from the negative (-)power source output stud to the work piece. The work piececonnection must be firm and secure, especially if pulse weld-ing is planned. Excessive voltage drops caused by poor workpiece connections often result in unsatisfactory welding per-formance.

CAUTION

B

A

C

FIGURE A.3

POWERWAVE

WORK

A

C

B

POWERWAVE

FIGURE A.4

K1796 COAXIAL CABLE

MEASURE FROM ENDOF OUTER JACKET OFCABLE

C

A

B

WORK

SLIDING GROUND

VOLTAGE SENSINGThe best arc performance occurs when the PowerWaves® has accurate data about the arc conditions.Depending upon the process, inductance within theelectrode and work lead cables can influence the volt-age apparent at the contact tip. Voltage sense leadsimprove the accuracy of the arc conditions and canhave a dramatic effect on performance.

If the voltage sensing is enabled but the senseleads are missing or improperly connected,extremely high welding outputs may occur.

Do not tightly bundle the work sense lead to the worklead.

The ELECTRODE sense lead (67) is built into theK1795 control cable. The WORK sense lead (21) con-nects to the Power Wave® at the four-pin connectorlocated underneath the output stud cover. Enable the voltage sense leads as follows:

TABLE 2Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 leadGMAW 67 lead required 21 lead optional**GMAW-P 67 lead required 21 lead optional**FCAW 67 lead required 21 lead optional**GTAW Voltage sense at studs Voltage sense at studsSAW 67 lead required 21 lead optional**

* The electrode voltage 67 sense lead is part of thecontrol cable to the wire feeder.

** For consistent weld quality, work voltage sensing isrecommended.

CAUTION

A-6INSTALLATION

POWER WAVE® 655/R

A-6

NEGATIVE ELECTRODE POLARITYWhen negative electrode polarity is required, such asin some Innershield applications, reverse the outputconnections at the power source (electrode cable tothe negative (-) stud, and work cable to the positive(+) stud).

When operating with electrode polarity negative theswitch 7 must be set to ON on the Wire Feed HeadPC Board. The default setting of the switch is OFF torepresent positive electrode polarity.

Set the Negative Polarity switch on Wire Feed HeadPC board as follows:

ELECTRIC SHOCK can kill.• Do not touch electrically live parts

or electrodes with your skin or wetclothing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

------------------------------------------------------------------------1. Turn off power to the power source at the discon-

nect switch.

2. Remove the front cover from the power source.

3. The wire feed head board is on the rightside of the power source. Locate the 8-position DIP switch and look for switch 7of the DIP switch.

4. Using a pencil or other small object, slidethe switch right to the OFF position forpositive electrode polarity. Conversely,slide the switch left to the on position fornegative electrode polarity.

5. Replace the cover and screws. The PC board will“read” the switch at power up, and configure thework voltage sense lead appropriately.

WARNINGO N

12

34

56

78

POWER WAVE® / POWER FEEDWIRE FEEDERINTERCONNECTIONSConnect the control cable between the power sourceand wire feeder. The wire feeder connection on therobotic Power Waves® is located under the springloaded output cover, near the bottom of the case front.The control cable is keyed and polarized to preventimproper connect.

For convenience sake, the electrode and controlcables can be routed behind the left or right strainreliefs (under the spring loaded output cover), andalong the channels formed into the base of the PowerWave®, out the back of the channels, and then to thewire feeder.

Output connections on some Power Waves® are madevia 1/2-13 threaded output studs located beneath thespring loaded output cover at the bottom of the casefront. On machines which carry the CE mark, outputconnections are made via Twist-Mate receptacles,which also located beneath the spring loaded outputcover at the bottom of the case front.

A work lead must be run from the negative (-) powersource output connection to the work piece. The workpiece connection must be firm and secure, especiallyif pulse welding is planned.

Excessive voltage drops at the work piece con-nection often result in unsatisfactory pulse weld-ing performance.------------------------------------------------------------------------

CONTROL CABLE SPECIFICATIONSIt is recommended that genuine Lincoln control cablesbe used at all times. Lincoln cables are specificallydesigned for the communication and power needs ofthe Power Wave® / Power Feed® system.

The use of non-standard cables, especially inlengths greater than 25 ft(7.6m), can lead to com-munication problems (system shutdowns), poormotor acceleration (poor arc starting) and lowwire driving force (wire feeding problems).------------------------------------------------------------------------

Lincoln control cables are copper 22 conductor cablein a SO-type rubber jacket.

CAUTION

CAUTION

Work Voltage SensingThe Power Waves® are shipped from the factory withthe work sense lead enabled.

For processes requiring work voltage sensing, con-nect the (21) work voltage sense lead from the PowerWave® to the work. Attach the sense lead to the workas close to the weld as practical. Enable the workvoltage sensing in the Power Wave® as follows:


• Do not touch electrically live partsor electrodes with your skin or wetclothing.

• Insulate yourself from the work and ground.


------------------------------------------------------------------------1. Turn off power to the power source at the discon-

nect switch.

2. Remove the front cover from the power source.

3. The control board is on the left side ofthe power source. Locate the 8-positionDIP switch and look for switch 8 of theDIP switch.

4. Using a pencil or other small object,slide the switch right to the OFF positionif the work sense lead is NOT connect-ed. Conversely, slide the switch left tothe ON position if the work sense lead ispresent.

5. Replace the cover and screws. The PC board will(read) the switch at power up, and configure thework voltage sense lead appropriately.

Electrode Voltage SensingEnabling or disabling electrode voltage sensing isautomatically configured through software. The 67electrode sense lead must be connected at the wirefeeder.

A-7INSTALLATION

POWER WAVE® 655/R

A-7

WARNING

O N1

23

45

67

8

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 and a low speedgears. As shipped from the factory, the low speed(high torque) gear is installed on the feeder. Tochange Gear ratio see Power Feed® 10/R Instruction

Manual.


• Do not touch electrically live parts orelectrodes with your skin or wetclothing.



------------------------------------------------------------------------

1. Set the High/Low switch code on Wire Drive PCboard as follows:

• Turn off power to the power source at the discon-nect switch.

• Remove the front cover from the powersource.

• The wire feed head board is on the rightside of the power source. Locate the 8-position DIP switch and look for position8 of the DIP switch.

• Using a pencil or other small object,slide the switch right to the OFF posi-t ion, when the low speed gear isinstalled. Conversely, slide the switch left to theON position when the high speed gear is installed.

• Replace the cover and screws. The PC board will“read” the switch at power up, automaticallyadjusting all control parameters for the speedrange selected.

O N1

2

3

4

5

6

7

8

WARNING

A-8INSTALLATION

POWER WAVE® 655/R

A-8

EXTERNAL I/O CONNECTOR

The Power Wave® is equipped with a port for makingsimple input signal connections. The port is dividedinto three groups: Trigger group, Cold Inch Group andShutdown Group. Because the Power Wave® is a‘slave’ on the DeviceNet network, the Trigger andCold Inch Groups are disabled when the DeviceNet /Gateway is active.

The shutdown group is always enabled. Shutdown 2is used for signaling low flow in the water cooler.Unused shutdowns must be jumpered. Machines fromthe factory come with the shutdowns alreadyjumpered. (See Figure A.5)

Shutdown 1 and shutdown 2 inputs are for weld sys-tem faults and should not be used as emergency orsafety shutdowns.

D

E

F

1 2 3 4 5

�

6 7 8 9 10 11 12

G

H

I

A

B

C

+15

VD

C fo

r T

rigge

r G

roup

Trig

ger

Inpu

t

Dua

l Pro

cedu

re In

put

4 S

tep

Inpu

t

+15

VD

C fo

r C

old

Inch

Gro

up

Col

d In

ch F

orw

ard

Col

d In

ch R

ever

se

Gas

Pur

ge In

put

+15

for

shut

dow

n gr

oup

Shu

tdow

n1 in

put

Shu

tdow

n2 in

put (

Wat

er F

ault)

Res

erve

d fo

r fu

ture

use

�

FIGURE A.5

A-9INSTALLATION

POWER WAVE® 655/R

A-9

DIP Switch Settings and LocationsDIP switches on the P.C. Boards allow for customconfiguration of the Power Wave®. To access the DIPswitches:

• Turn off power at the disconnect switch.------------------------------------------------------------------------

• Remove the top four screws securing the frontaccess panel.

• Loosen, but do not completely remove, the bottomtwo screws holding the access panel.

• Open the access panel, allowing the weight of thepanel to be carried by the bottom two screws. Makesure to prevent the weight of the access panel fromhanging on the harness.

• Adjust the DIP switches as necessary.• Replace the panel and screws, and restore power.

Control Board DIP Switch:Switch 1 = Object Instance LSB1 (see table 3)

Switch 2 = Object Instance MSB2 (see table 3)Switch 3 = Equipment Group 1 SelectSwitch 4 = Equipment Group 2 SelectSwitch 5 = Equipment Group 3 SelectSwitch 6 = Equipment Group 4 SelectSwitch 7 = reserved for future useSwitch 8 = work sense lead1 LEASE SIGNIFICANT BIT2 MOST SIGNIFICANT BIT

Switch 8 work sense leadOff work sense lead not connectedOn work sense lead connected

Feed Head Board DIP Switch:Switch 1 = Object Instance LISE (see table 3)Switch 2 = Object Instance msp (see table 3)Switch 3 = Equipment Group 1 SelectSwitch 4 = Equipment Group 2 SelectSwitch 5 = Equipment Group 3 SelectSwitch 6 = Equipment Group 4 SelectSwitch 7 = negative polarity switch

Switch 7 Electrode polarityOff Positive (default)On negative

Switch 8 = high speed gearSwitch 8 Wire drive gearOff Low speed gear (default)On high speed gear

DeviceNET/Gateway Board DIP Switch:

Bank (S1):Switch 1 = Object Instance LISE (see table3)Switch 2 = Object Instance msp (see table 3)Switch 3 = Equipment Group 1 SelectSwitch 4 = Equipment Group 2 SelectSwitch 5 = Equipment Group 3 SelectSwitch 6 = Equipment Group 4 SelectSwitch 7 = Reserved for future useSwitch 8 = Reserved for future use

TABLE 3Object InstanceSwitch 2 switch 1 InstanceOff Off 0 (default)Off On 1On off 2On on 3

WARNING

A-10INSTALLATION

POWER WAVE® 655/R

A-10

Bank (S2):Switch Description

1 Devicenet Baud Rate2 (see table 4)

TABLE 4Prior to S24958-6 softwareSwitch 1 switch 2 Baud rate

Off off Programmable valueOn off 125KOff on 250KOn on 500K

S24958-6 and later softwareSwitch 1 switch 2 Baud rate

Off off 125KOff on 250KOn off 500KOn on Programmable value

Bank (S2):Switch Description

3 Devicenet Mac IDThru (see table 5)

8

TABLE 5

0 0 0 0 0 0 01 0 0 0 0 0 12 0 0 0 0 1 03 0 0 0 0 1 14 0 0 0 1 0 05 0 0 0 1 0 16 0 0 0 1 1 07 0 0 0 1 1 18 0 0 1 0 0 09 0 0 1 0 0 110 0 0 1 0 1 011 0 0 1 0 1 112 0 0 1 1 0 013 0 0 1 1 0 114 0 0 1 1 1 015 0 0 1 1 1 116 0 1 0 0 0 017 0 1 0 0 0 1

18 0 1 0 0 1 019 0 1 0 0 1 120 0 1 0 1 0 021 0 1 0 1 0 122 0 1 0 1 1 023 0 1 0 1 1 124 0 1 1 0 0 025 0 1 1 0 0 126 0 1 1 0 1 027 0 1 1 0 1 128 0 1 1 1 0 029 0 1 1 1 0 130 0 1 1 1 1 031 0 1 1 1 1 132 1 0 0 0 0 033 1 0 0 0 0 134 1 0 0 0 1 035 1 0 0 0 1 136 1 0 0 1 0 037 1 0 0 1 0 138 1 0 0 1 1 039 1 0 0 1 1 140 1 0 1 0 0 041 1 0 1 0 0 142 1 0 1 0 1 043 1 0 1 0 1 144 1 0 1 1 0 045 1 0 1 1 0 146 1 0 1 1 1 047 1 0 1 1 1 148 1 1 0 0 0 049 1 1 0 0 0 150 1 1 0 0 1 051 1 1 0 0 1 152 1 1 0 1 0 053 1 1 0 1 0 154 1 1 0 1 1 055 1 1 0 1 1 156 1 1 1 0 0 057 1 1 1 0 0 158 1 1 1 0 1 059 1 1 1 0 1 160 1 1 1 1 0 061 1 1 1 1 0 162 1 1 1 1 1 0*Software Selectable (Line 0)**Default Setting (Line 62)

SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3SWITCH 8

SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3SWITCH 8

*

**

B-1OPERATIONB-1

POWER WAVE® 655/R

SAFETY PRECAUTIONS

Read this entire section of operating instructionsbefore operating the machine.


• Unless using cold feed feature, whenfeeding with gun trigger, the electrodeand drive mechanism are always elec-trically energized and could remainenergized several seconds after thewelding ceases.

• Do not touch electrically live parts or electrodeswith your skin or wet clothing.



FUMES AND GASES can be dan-gerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

WELDING SPARKS can cause fireor explosion.

• Keep flammable material away.

• Do not weld on containers that haveheld combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the begin-ning of this manual.

WARNING

B-2OPERATIONB-2

POWER WAVE® 655/R

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

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

PROTECTIVEGROUND

WARNING

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

U0

U1

U2

I1

I2

SMAW

RECOMMENDED EQUIPMENT• Automatic OperationAll welding programs and procedures are set throughsoftware for the robotic Power Wave® s. FAUNrobots equipped with RJ-3 controllers may communi-cate directly to the Power Wave®. Other pieces ofequipment such as ply or computers can communi-cate to the Power Wave® using DeviceNET.

All wire welding processes require a robotic PowerFeed® wire feeder.

• semiautomatic OperationOperating the Power Wave® 655/r in the semi-auto-matic mode requires an Arc-Link compatible wirefeeder and user interface.

REQUIRED EQUIPMENT• Control Cables (22 pin to 22 pin), K1795-10ft.,-25ft.,-50ft.,

-100ft.• Control Cables for use on FAUN robot arm, 22 pin to 14

pin, ft.(m), K1804-1 • Control Cables for use on FAUN robot arm, 22 pin to 14

pin, 18in.(457mm), K1805-1• Control Cables for use on FAUN robot arm, 22 pin to 14

pin, 18in.(457mm), K1804-2

LIMITATIONS• Power Wave® s are not to be used in outdoor envi-

ronments.• Only Arc-Link Power Feed® wire feeders and user

interfaces may be used. Other Lincoln wire feedersor non-Lincoln wire feeders cannot be used.

DUTY CYCLE AND TIME PERIODThe Power Feed® wire feeders are capable of weldingat a 100% duty cycle (continuous welding). The powersource will be the limiting factor in determining systemduty cycle capability. Note that the duty cycle is basedupon a ten minute period. A 60% duty cycle repre-sents 6 minutes of welding and 4 minutes of idling in aten minute period.

B-3OPERATIONB-3

GENERAL DESCRIPTIONThe Power Wave® power source is designed to be apart of a modular, multi-process welding system.Depending on configuration, it can support constantcurrent, constant voltage, and pulse welding modes.

The Power Wave® power source is designed to beused with the family of Power Feed wire feeders,operating as a system. Each component in the systemhas special circuitry to "talk with" the other systemcomponents, so each component (power source, wirefeeder, electrical accessories) knows what the other isdoing at all times. The components communicate withArc-Link.

Robotic systems can communicate with other industri-al machines via DeviceNET. The result is highlyintrigued and flexible welding cell.

The Power Wave® 655/r is a high performance, digital-ly controlled inverter welding power source capable ofcomplex, high-speed waveform control. Properlyequipped, it can support the GMAW, GMAW-P,FCAW, SMAW, GTAW and CAC-A processes. It car-ries an output rating of either 650 amps, 44 volts (at100% duty cycle) and 800 amps, 44 volts (at 60%duty cycle).

If the duty cycle is exceeded, a thermostat will shut offthe output until the machine cools to a reasonableoperating temperature.

RECOMMENDED PROCESSES ANDEQUIPMENT

RECOMMENDED PROCESSESThe Power Wave® 655/r can be set up in a number ofconfigurations, some requiring optional equipment orwelding programs. Each machine is factory prepro-grammed with multiple welding procedures, typicallyincluding GMAW, GMAW-P, FCAW, GTAW, CAC-A,and SMAW for a variety of materials, including mildsteel, stainless steel, cored wires, and aluminum.

The Power Wave® 655/r can be configured for eitherrobotic or semi-automatic use.

POWER WAVE® 655/R

B-4OPERATION

POWER WAVE® 655/R

B-4

CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave®. (See Figure B.1)

1. POWER SWITCH: Controls input power to thePower Wave®.

2. STATUS LIGHT: A two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated per table 4.

NOTE: The robotic Power Waveʼs® status light willflash green, and sometimes red and green, for up toone minute when the machine is first turned on. Thisis a normal situation as the machine goes through aself test at power up.

TABLE 6Light

ConditionSteady Green

BlinkingGreen

A l t e r n a t i n gGreen andRed

Steady Red

Blinking Red

Meaning

System OK. Power source communicating normal-ly with wire feeder and its components.

Occurs during a reset, and indicates the PW-655/R is mapping (identifying) each componentin the system. Normal for first 1-10 secondsafter power is turned on, or if the system con-figuration is changed during operation.

Non-recoverable system fault. If the PSStatus light is flashing any combination ofred and green, errors are present in the PW-655/R. Read the error code before themachine is turned off.

Error Code interpretation through the Statuslight is detailed in the Service Manual.Individual code digits are flashed in red witha long pause between digits. If more thanone code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off, andback on to reset. See TroubleshootingSection.

Not applicable.

Not applicable.

3. HIGH TEMPERATURE LIGHT (thermal overload):A yellow light that comes on when an over temper-ature situation occurs. Output is disabled until themachine cools down. When cool, the light goes outand output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:Protects 40 volt DC wire feeder power supply.

5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER:Protects 110 volt AC case front receptacle auxiliarysupply.

6. LEAD CONNECTOR S2 (SENSE LEAD)

7. 5-PIN ARC LINK S1

8. 5-PIN DEVICENET CONNECTOR S5

9. I / O CONNECTOR

10. NEGATIVE STUD

11. INTERFACE CONNECTOR S6

12. POSITIVE STUD

13. AUXILIARY OUTPUT

- +

POWERWAVE

Case Front LayoutPower Wave 655/R (Domestic/Canadian Version)

1

32

11

12

4

135

9

10

8

7

6

®

FIGURE B.1

B-5OPERATIONB-5

CONSTANT VOLTAGE WELDING

For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The preprogrammed voltage is thebest average voltage for a given wire feed speed.With synergic programs, when the wire feed speedchanges the Power Wave® will automatically adjustthe voltage correspondingly.

Wave control adjusts the inductance of the wave-shape. (This adjustment is often referred to as "pinch".Inductance is inversely proportional pinch.)Increasing wave control greater than 0 results in aharsher, colder arc while decreasing the wave controlto less than 0 provides a softer, hotter arc. (SeeFigure B.2)

POWER WAVE® 655/R

FIGURE B.2

Current

Time

B-6OPERATIONB-6

PULSE WELDING

Pulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc voltage is highly dependent upon the waveform.The peak current, back ground current, rise time, falltime and pulse frequency all affect the voltage. Theexact voltage for a given wire feed speed can only bepredicted when all the pulsing waveform parametersare known. Using a preset voltage becomes impracti-cal, and instead the arc length is set by adjusting"trim".

Trim adjusts the arc length and ranges from 0.50 to1.50, with a nominal value of 1.00. Trim values greaterthan 1.00 increase the arc length, while values lessthan 1.00 decrease the arc length.

Most pulse welding programs are synetic. As the wirefeed speed is adjusted, the Power Wave® will auto-matically recalculate the waveform parameters tomaintain similar arc properties.

POWER WAVE® 655/R

The Power Wave® utilizes "adaptive control" to com-pensate for changes in electrical stick-out while weld-ing. (Electrical stick-out is the distance from the con-tact tip to the work piece.) The Power Wave® wave-forms are optimized for a 0.75" (19mm) stick-out. Theadaptive behavior supports a range of stinkpots from0.50" (13mm) to 1.25" (32mm). At very low or highwire feed speeds, the adaptive range may be less dueto reaching physical limitations of the welding process.

Wave control in pulse programs usually adjusts thefocus or shape of the arc. Wave control values greaterthan 0 increase the pulse frequency while decreasingthe background current, resulting in a tight, stiff arcbest for high speed sheet metal welding. Wave con-trol values less than 0 decrease the pulse frequencywhile increasing the background current, for a soft arcgood for out-of-position welding. (See Figure B.3)

Time

Current

FIGURE B.3

C-1ACCESSORIESC-1

OPTIONAL EQUIPMENT

FACTORY INSTALLEDThere are no factory installed options available for thePower Wave®.

FIELD INSTALLEDGas Guard Regulator (K659-1)The Gas Guard regulator is available as an optionalaccessory for Power Feed® Robotic wire drive unit.Install the 5/8-18 male outlet on the regulator to theproper 5/8-18 female gas inlet on the back panel ofthe wire drive. Secure fitting with flow adjuster key attop.Voltage Sense Leads (K490-10, -25 or -50)The voltage sense leads connect at the front of themachine. (See “Voltage Sensing” in the InstallationSection for use and Wiring Diagram Section Codes11410, 11880).

Cool Arc 40 (K1813-1)(See Wiring Diagram Section Codes 11410, 11880)

POWER WAVE® 655/R

* Water Flow Sensor (K1536-1)

Water cooled guns can be damaged very quickly ifthey are used even momentarily without water flow-ing. Recommend practice is to install a water flowsensor such as on the water return line of the torch.When fully integrated into the welding system, thesensor will prevent welding if no water flow is pre-sent.

• Dual Cylinder Undercarriage, K1570-1*

*The Dual Cylinder Undercarriage, K1570-1 is notcompatible in combination with the Power Wave®

Water Cooler K1767-1.

• Coaxial welding Cable, K1796 (See Pin, Lead Connector Diagram Section)

D-1MAINTENANCED-1

POWER WAVE® 655/R

SAFETY PRECAUTIONS


• Only Qualified personnel shouldperform this maintenance.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on this equipment.

• Do not touch electrically hot parts.

ROUTINE MAINTENANCE Routine maintenance consists of periodicallyblowing out the machine, using a low pressureairstream, to remove accumulated dust and dirtfrom the intake and outlet louvers, and the cool-ing channels in the machine.

PERIODIC MAINTENANCECalibration of the Power Wave® 655/R is critical toits operation. Generally speaking the calibrationwill not need adjustment. However, neglected orimproperly calibrated machines may not yield sat-isfactory weld performance. To ensure optimalperformance, the calibration of output Voltageand Current should be checked yearly.

CALIBRATION SPECIFICATIONOutput Voltage and Current are calibrated at thefactory. Generally speaking the machine calibrationwill not need adjustment. However, if the weld per-formance changes, or the yearly calibration checkreveals a problem, contact the Lincoln ElectricCompany for the calibration software utility.

The calibration procedure itself requires the useof a grid, and certified actual meters for voltageand current. The accuracy of the calibration willbe directly affected by the accuracy of the mea-suring equipment you use. Detailed instructionsare available with the utility.

WARNING

E-1TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing that bestdescribes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


POWER WAVE® 655/R

USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS

The Status LED on the power source case frontcan help diagnose problems down to the systemcomponent (power source, wire feeder, wiredrive, etc.) level.

If, for any reason, the system does not appear tobe working properly, always check the color ofthe Status LED, and refer to the following chart tohelp you determine which system component(power source, wire feeder, wire drive, etc.) maybe faulty. Replace the components identified aspotentially faulty with known good components,and the system should operate normally.

Steady Green

Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

System OK. Power source communicating normallywith wire feeder and its components.

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 changed during opera-tion

Non-recoverable system fault. If the PS Status light isflashing any combination of red and green, errors arepresent in the Power Wave®. Read the error codebefore the machine is turned off.

Error Code interpretation through the Status light isdetailed in the Service Manual. Individual code digitsare flashed in red with a long pause between digits. Ifmore than one code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off, and back onto reset.

Not applicable.

Not applicable.

CAUTIONIf 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.


POWER WAVE® 655/R

Observe all Safety Guidelines detailed throughout this manual


PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

OUTPUT PROBLEMSMajor physical or electrical damageis evident when the sheet metalcovers are removed.

Input fuses keep blowing, or inputbreaker keeps tripping.

Machine will not power up (nolights, no fan, etc.)

1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assistance.

1. Make certain that fuses orbreakers are properly sized.See Installation section of thismanual for recommendedfuse and breaker sizes.

2. Welding procedure is drawingtoo much output current, orduty cycle is too high.Reduce output current, dutycycle, or both.

3. There is internal damage tothe power source. Contact anauthorized Lincoln ElectricService facility.

1. Make certain that the PowerSwitch (SW1) is in the “ON”position.

2. Circuit breaker CB4(Codes10630, 10863) (in reconnectarea) may have opened.Reset.10A Fuse(Code 11410,11880) (in reconnect area)may have blown out. Replace.Also, check input voltageselection, below.

3. Input voltage selection madeimproperly. Power down,check input voltage reconnectaccording to diagram onreconnect cover.

If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local LincolnAuthorized Field Service Facility.


POWER WAVE® 655/R



PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


OUTPUT PROBLEMSThermal LED is lit.

Machine wonʼt weld, canʼt get anyoutput. (CR1 will not pull in.)

Arc loss fault on robot

1. Fan thermostat has opened.Check for proper fan operation.(Fan should run whenever mainpower is on.) Check for materialblocking intake or exhaust lou-vers, or for excessive dirt clog-ging cooing channels inmachine.

2. Secondary rectifier thermostathas opened. After machine hascooled, reduce load, duty cycle,or both. Check for materialblocking intake or exhaust lou-vers.

1. Input voltage is too low or toohigh. Make certain that inputvoltage is proper, according tothe Rating Plate located on therear of the machine.

2. If the Thermal LED is also lit,see “Yellow Thermal LED is Lit”section.

Possibly caused by wire feedingproblem. Possible causes/solu-tions are:

1. Problem - Conduit leading to thewire feeder has bends or twists,which can reduce the wire feedspeed.

Solution - Remove bends andtwists from conduit.

2. Problem – Conduit leading up tothe wire feeder from the wire reelis too long.

Solution – Use a shorter length ofconduit



POWER WAVE® 655/R



PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


OUTPUT PROBLEMSMachine often “noodle welds” (out-put is limited to approximately 100amps) when running a particularprocedure

Machine wonʼt produce full output.

For no apparent reason, the weld-ing characteristics have changed.

Auxiliary receptacle is “dead” — noauxiliary voltage .

The PowerWave is triggered toweld, but there is no output.

1. Secondary current limit hasbeen exceeded, and themachine has phased back toprotect itself. Adjust procedureor reduce load to lower currentdraw from the machine.

1. Input voltage may be too low,limiting output capability of thepower source. Make certainthat the input voltage is proper,according to the Rating Platelocated on the rear of themachine.

2. Input may be “single phased”.Make certain the input voltageis proper on all three inputlines.

1. Check for proper Wire FeedSpeed setting. In CV MIG andFCAW modes, check for prop-er Voltage setting. In theMIG/MAG pulse modes, checkthe Trim setting. These con-trols are on the wire feeder.

2. Check for proper shielding gasmix and flow.

3. Check for loose or faulty weldcables and cable connections.

1. Circuit breaker CB2 (on casefront) may have opened.Reset.

2. Circuit breaker CB4(Codes10630, 10863) (in reconnectarea) may have opened.Reset.10A Fuse(Code 11410, 11880)(in reconnect area) may haveblown out. Replace.

1. Check for fault signals from theI/O connector. Possible faultsare lack of water flow

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset.



POWER WAVE® 655/R



CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


The PowerWave is triggered to weld,but there is no output.

The feeder will not cold inch wire

Arc loss fault on robot

1. Check for fault signals from theI/O connector. Possible faults arelack of water flow/ water flowturned off.

1. Check for fault signals from theI/O connector. Possible faults arelack of water flow/ water coolerturned off.

1. Possibly caused by wire feedingproblem.

2 Problem - Conduit leading to thewire feeder has bends or twists,which can reduce the wire feedspeed.Solution - Remove bends andtwists from conduit.

3. Problem – Conduit leading up tothe wire feeder from the wire reelis too long.Solution – Use a shorter length ofconduit.

WELDING PROBLEMS



POWER WAVE® 655/R



CAUTION

ERROR CODES FOR THE POWERWAVEThe following is a list of possible error codes that the PW-455 can output via the status light (see"Troubleshooting the Power Wave® / Power Feed® System Using the Status LED").

Error Code #

11 CAN communication bus off.

12 User Interface time out error.

21 Un-programmed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.

32 Capacitor "A" under voltage (Left side facing machine)

33 Capacitor "B" under voltage (Right side facing machine)

34 Capacitor "A" over voltage (Left side facing machine)

35 Capacitor "B" over voltage (Right side facing machine)

36 Thermal error

37 Soft start error

Indication

Probably due to excessive number of communication errors.

User Interface is no longer responding to the Power Source. The mostlikely cause is a fault/bad connection in the communication leads orcontrol cable.

Contact the Service Department for instructions on reloading theWelding Software.



Excessive Primary current present. May be related to a switch board oroutput rectifier failure.

Low voltage on the main capacitors. May be caused by improper inputconfiguration. When accompanied by an overvoltage error on the same side, it indi-cates no capacitor voltage present on that side, and is usually the resultof an open or short in the primary side of the machine.

Excess voltage on the main capacitors. May be caused by improperinput configuration. When accompanied by an under voltage error on the same side, it indi-cates no capacitor voltage present on that side, and is usually the resultof an open or short in the primary side of the machine.

Indicates over temperature. Usually accompanied by Thermal LED.Check fan operation. Be sure process does not exceed duty cycle limitof the machine.

Capacitor precharge failed. Usually accompanied by codes 32-35.


POWER WAVE® 655/R



CAUTION

Error Code #

41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

Indication

The secondary (weld) current limit has been exceeded. When thisoccurs 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 maximum voltage difference between the main capacitors has beenexceeded. May be accompanied by errors 32-35.

Indicates machine is running on single phase input power. Usuallycaused by the loss of the middle leg (L2).

Error codes that contain three or four digits are defined as fatal errors.These codes generally indicate internal errors on the PS Control Board.If cycling the input power on the machine does not clear the error, tryreloading the operating system. If this fails, replace the control board.

F-1DIAGRAMSF-1

POWER WAVE® 655/R

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

on

ly.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hin

es c

ove

red

by

this

man

ual

. T

he

spec

ific

dia

gra

m f

or

a p

arti

cula

r co

de

is p

aste

din

sid

e th

e m

ach

ine

on

on

e o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

th

e S

ervi

ce D

epar

tmen

t fo

r a

rep

lace

men

t. G

ive

the

equ

ipm

ent

cod

e n

um

ber

.

F-2DIAGRAMSF-2

POWER WAVE® 655/R

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

on

ly.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hin

es c

ove

red

by

this

man

ual

. T

he

spec

ific

dia

gra

m f

or

a p

arti

cula

r co

de

is p

aste

din

sid

e th

e m

ach

ine

on

on

e o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

th

e S

ervi

ce D

epar

tmen

t fo

r a

rep

lace

men

t. G

ive

the

equ

ipm

ent

cod

e n

um

ber

.

F-3DIAGRAMSF-3

POWER WAVE® 655/R

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

on

ly.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hin

es c

ove

red

by

this

man

ual

. T

he

spec

ific

dia

gra

m f

or

a p

arti

cula

r co

de

is p

aste

din

sid

e th

e m

ach

ine

on

on

e o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

th

e S

ervi

ce D

epar

tmen

t fo

r a

rep

lace

men

t. G

ive

the

equ

ipm

ent

cod

e n

um

ber

.

TABLE 5 DEVICENET CONNECTOR S5

Pin Lead # Function2 894 +24vdc Devicenet3 893 Common Devicenet+4 892 Devicenet H5 891 Devicenet L

F-4PIN, LEAD CONNECTOR DIAGRAMSF-4

POWER WAVE® 655/R

TABLE 1 INTERFACE CONNECTOR S6

Pin Lead # FunctionA 841 +15vdc Tach voltageB 844 Tach commonC 842 Tach 1A differential signalD 843 Tach 1B differential signal E 845 Tach 2A differential signal F 846 Tach 2B differential signalG 847 Single Tach InputH Reserved for future useI 67B Voltage sense leadJ 539 Motor "+"K 541 Motor "-"L Reserved for future useM Reserved for future useN 521 +40vdc for solenoidP 522 solenoid inputR Reserved for future useS Reserved for future useT 855A Shield ground to caseU Reserved for future useV Reserved for future useW Reserved for future useX Reserved for future use

TABLE 2 WIRE FEEDER RECEPTACLE S1

Pin Lead # FunctionA 53 Arclink LB 54 Arclink HC 67A Electrode Voltage SenseD 52 Ground(0v) E 51 +40vdc

TABLE 6 EXTERNAL I/O S7

Pin Lead # Function1 851 +15vdc for Trigger group2 852 Trigger input3 853 Dual procedure input4 854 4 Step input5 855 +15vdc for cold inch group6 856 cold inch forward7 857 cold inch reverse8 858 gas purge input9 859 +15vdc for shutdown group10 860 shutdown1 input11 861 shutdown2 input12 862 input B

TABLE 4 RS232 CONNECTOR S3

Pin Lead # Function2 253 RS232 Receive3 254 RS232 Transmit4 # S3 Pin55 # S3 Pin46 ## S3 Pin2020 ## S3 Pin67 251 RS232 Common

TABLE 3 VOLTAGE SENSE RECEPTACLE S2

Pin Lead # Function3 21A Work Voltage Sense

F-5CONNECTION DIAGRAMF-5

POWER WAVE® 655/R

Hard Automation and Electrode PositiveConfiguration

- +

WORKSENSELEADK940

WATERCOOLEDTORCH

ELECTRODE LEAD

CONTROL CABLE K1795

WATER COOLERPOWERCONNECTION

SHIELDING GAS

TO SHIELDING GAS DEVICENET CABLETO PLC/CONTROLLER

DEVICENET CABLETO PLC/CONTROLLER

ELECTRODE LEAD

CONTROL CABLE K1795

COOL ARC 40 POWER CORD

WATER CONNECTIONS

F-6CONNECTION DIAGRAMF-6

POWER WAVE® 655/R

K1796 COAXIAL WELD CABLE

User suppliedwork lead

User suppliedelectrode lead

- +

POWERWAVE

CONTROL CABLE K1805-1

WORK SENSE LEAD K940

DEVICENET CABLE

K1804-1 CONTROL CABLE ORK1804-2 AND ANY K1795 CONTROL CABLE

CONTROL CABLE K1805-1

User suppliedelectrode lead

User suppliedwork lead

Robotic Set Up, Electrode Positive, CV/PulseConfiguration

F-7DIAGRAMSF-7

POWER WAVE® 655/R

M18

241

A.0

1

32.8

8

14.6

2

19.1

6

19.9

0

9.48

12.3

5

19.0

0

22.6

326

.10

23.1

223

.51

4.21

12.9

0

6.75

3.47

10°

NOTES

POWER WAVE® 655/R

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THECONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DEESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SUSUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENTET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTREEMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERSSIND EBENFALLS ZU BEACHTEN.

• Do not touch electrically live parts orelectrode with skin or wet clothing.

• Insulate yourself from work andground.

• No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

• Aislese del trabajo y de la tierra.

• Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

• Isolez-vous du travail et de la terre.

• Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

• Isolieren Sie sich von denElektroden und dem Erdboden!

• Não toque partes elétricas e electro-dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Keep flammable materials away.

• Mantenga el material combustiblefuera del área de trabajo.

• Gardez à l’écart de tout matérielinflammable.

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-dos.

• Wear eye, ear and body protection.

• Protéjase los ojos, los oídos y elcuerpo.

• Protégez vos yeux, vos oreilles etvotre corps.

• Tragen Sie Augen-, Ohren- und Kör-perschutz!

• Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTESDE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• Keep your head out of fumes.• Use ventilation or exhaust to

remove fumes from breathing zone.

• Los humos fuera de la zona de res-piración.

• Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

• Gardez la tête à l’écart des fumées.• Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

• Vermeiden Sie das Einatmen vonSchweibrauch!

• Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

• Mantenha seu rosto da fumaça.• Use ventilação e exhaustão para

remover fumo da zona respiratória.

• Turn power off before servicing.

• Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

• Débranchez le courant avant l’entre-tien.

• Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öffnen;Maschine anhalten!)

• Não opere com as tampas removidas.• Desligue a corrente antes de fazer

serviço.• Não toque as partes elétricas nuas.

• Do not operate with panel open orguards off.

• No operar con panel abierto oguardas quitadas.

• N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

• Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

• Mantenha-se afastado das partesmoventes.

• Não opere com os paineis abertosou guardas removidas.

• 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.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Operator’s Manual POWER WAVE 655R · 2019-02-26 · SECTION A: WARNINGS C ALIFORNIA PROPOSITION...

Documents

Transcript of Operator’s Manual POWER WAVE 655R · 2019-02-26 · SECTION A: WARNINGS C ALIFORNIA PROPOSITION...