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Lincoln Electric 655/R Welder User Manual

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1. i 45V Machine Control Power Supply R50 J42 7 Di D18 D4 2 T 6A 200V 13 200V 57 60v TEST es n em 5Volts 750 Amp E C39 i 10 55 VDC o o o D T 19 332 82 Operation 2000V 3 992 8 Vref 1 4 100K 100 N 10 0K R9 12 E E 100 30V R60 5 10 0 is 15Volts 55 4 dd g 2000 pea 750 Amp vee 10 0 1 5
2. cL L9 5 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED A 01 FROM X 4 MANUFACTURER No ajy ames i A ONTROL BOARD 58 B9222 9 RECTIFIER HARMONIC i lt __ 1 FILTER RS232 RECEIVE gt 3J2 gt 253 2 Am u 5 POS Pos gt 85232 TRANSMIT 9 4 2 gt 254 3 U we 022u c MAIN TRANSFORMER T1 80 ___ im 3 N A HD BD SWITCH BOARD 1 LEFT 206 1J9 ELECTRODE VOLTAGE SENSE 4 A AC2 NEG 1 D 12 ELECTRODE 2 5 i V o 1 D i 521 lt 3183 SOLENOID 40VDC e i OUTPUT DIODES Ww gt NEG NAN NE
3. Removal Removal Step 6 Step 6 aj AUXILIARY VOLTAGE DRIVER BD SENSE BD REMOVAL PROCEDURE 1 Remove input power to the POWER WAVE 655 R 2 Remove the case top and sides 3 Perform the Capacitor Discharge procedure Observe all static electricity precau tions 4 Remove the PC board compartment cover 5 Remove the two screws holding the rear of the Control Box in place See Figure 18 6 Clear the leads in the sleeving and the grom mets on the sides of the control box 7 Label and remove the molex plugs from the Control Board and the Feed Head Board 8 Tilt back the rear of the control box to access the PC board mountings 9 To remove the Voltage Sense Board use a nee dle nose pliers to carefully pinch the three plas tic standoffs to release the board 10 Use a Phillips screwdriver to remove the Auxiliary Driver Bd REPLACEMENT PROCEDURE 1 7 8 Install the replacement board using the original fasteners Connect the M
4. ES Oo oO ENGINEERING CONTROLLED CHANGE DETAIL REMOVED MFG OPERATION AND WIC TABLE ITEM QTY PART NO DESCRIPTION gt NOE MANUFACTURER NO P C BOARD BLANK REFERENCE INFORMATION X1 1 M13552 3 IC CONVERTER VIF 654 ELECTRONIC MODULES TO BE ASSEMBLED SOLDERED AND SEALED TO ENCAPSULATION MATERIAL MUST EXTEND BEYOND EDGES OF P C BOARD 12 12 00 BUY BLANK COMPLETE AS G3501 F 1 13000 46 TRANSFORMER PCB 5 iz VA EIECIRICIN SEE EHSA SEFOREHANDLNG 2 ocn ocr 9 N J THESE SURFACES MUST BE MAINTAINED CO PLANAR WITHIN 010 THICKNESS OF 20 4 LAYER BOARD PER E3281 ZEE REF ADI PEROT PC BOARD AND MODULE MOUNTING HOLES FREE OF ENCAPSULANT MATERIAL THROUGH ENTIRE SOLDERING AND SEALING PROCESS 4 PLACES N T ITEM 8 MOUNTS AND SOLDERS TO SAME HOLES AS ITEM 7 ITEM 8 IS MOUNTED ON 877 3162965 TRIMMER MT 12W 10K 10 LINEAR i FOR A CENTERED 0 50 MIN DIA AND 0 55 MAX DIA 8 HOLES MASK PER NON COMPONENT SIDE OF P C BOARD 2 c APPROPRIATE MANUFACTURING WORK INSTRUCTION
5. 5 L L 1925 ENGINEERING CONTROLLED J CHANGE DETAIL REVISED CB2 AND RECEPTACLE GRAPHICS 4 MANUFACTURER No 5 aie i A B ONTROL BOARD S3 85232 o gt i INPUT u EN CONNECTOR RECTIFIER HARMONIC gt lt __ 1 FILTER RS232 RECEIVE gt 3J2 gt 253 2 Am u 5 POS Pos gt 85232 TRANSMIT 9 4 2 gt 254 3 U s o 9224 270 e c A MAIN TRANSFORMER T1 800V SWITCH BOARD 1 LEFT 206 1J9 ELECTRODE VOLTAGE SENSE 4 5 iz A FEED HD BD ELECTRODE LL i T2 i 5 v o j D i 521 lt 3183 SOLENOID 40VDC e i OUTPUT DIODES Ww gt NEG NAN NEG 522 83 SOLENOID INPUT 11 Pm 270 D1 D8 RS232 COMMON 1J2 gt 251 7 206A 539 lt MOTOR 2800UF Z ps n lt 20 E 541 y 2088 MOTOR 9 Ri B B 3 TP3 J 5 mr MES Pa x4 841 lt 84 15VDC TACH Pm 270 TRANSDUCER 403 lt 340 IGBT DRIVE ii 202A 202 1 lt 339 ELECTRODE VOLTAGE SENSE 842 204 TACH 1A DIFF INPUT ELECTRODE
6. 11925 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROM X A 02 D i MANUFACTURER No NA INPUT PONTROL BOARD CONNECTOR RECTIFIER HARMONIC CR1 FILTER RS232 RECEIVE aye 253 2 Li POS POS 2 88232 TRANSMIT 4J2 254 3 MAIN TRANSFORMER 1 80 fow c c i N A SW ITC H BOAR D 1 LE FT 206 lt 149 ELECTRODE VOLTAGE SENSE i i 12 i ELECTRODE Les v 521 L 3383 SOLENOID 40VDC 4 j 6 NEG NEG M OUTPUT DIODES 522 483 SOLENOID INPUT POS e 11 01 08 5232 COMMON 132 251 7 Y 206 TP2 us 2800uF 320V 539 MOTOR sont 20 1 541 2J83 MOTOR 4 er e D R1 3 gt 500 5 CURRENT 841 1084 15VDC TACH 022 0221 TRANSDUCER 403 3240 IGBT DRIVE ij 202 3J9 ELECTRODE VOLTAGE SENSE 842 2388 TACH DIFF INPUT E ECTHODE 440 4 ertm D 4 TACH 1B DIFF INPUT e MAIN 52 VOLTAGE SENSE T INPUT BOARD gt RECEPTACLE 4 lt TACH COMMON 270
7. e x L 86rvE5 ENGINEERING CONTROLLED CHANGE DETAIL ADDED NOTE N E 4 D MANUFACTURER No 3 o 2 V TO AUX 2 TO J9 CONNECTED HERE olo 202 Y Y PM ON EARLIER MACHINES 4 Ld lt 1 lt YS 2 lt cle 542 CONTROL BOARD LEFT SIDE OF MACHINE A E C TOR Rie DE PEDO DIGITAL POWER SOLID J7 P gt NOTUSED 5A CIRCUIT oS miu N SUPPLY BOARD RELAY 8t6 2 AUXILIARY TRANSFORMER 1 BREAKER P pr diE Gige muss j 9 lt 66 B14 3 800 J72 2 223 y L5 ee 44 80 i4 21 1 A rh 12 lt 9 222 1 A TO J61 WORK 13 lt lt 10 S 00 A m CB3 lt 4 4 482 Jn 15 24 em J47 RECONNECT PANEL V JUMPER Aden M ota Lan 444 S1 H54 yee ae 539 D 4 lt 478 TO POWER BD RECTIFIER TO TO AUX 2 CB4 15 2 L b WIRE cre 67 lt 3 16 TO web um TO FAN TO AUXHI CRI 3 5A CIRCUIT FEEDER m cx 1 2 152 4 8 10 160 BREAKER RECEPTACLE D 52 eim Br 886 4 226 MAIN CHOKE i 6 lt
8. ADS 2 Mamme XA3 Fle Sa 9 gt olg E 5 oO cc Ds1644P 6 hs Hos 4 Dus NC ZLARI B tk R W O o c i GS EU UN EET TINI IO ee ee 1 z 9 E L _ f DATALO 5I DATAISI o 2 b EMEN 1 Ethernet 1 0 a T olo 227 s 4 0 E 5 151451 M vaw 4 91 S 5 X 3 4 amp gt E LT uw Ct wwun DO mes 5 E Oat X7 LCUM OF L TOUT a ee 0 EY vgagBgu sbs g E A E PAIR arri Lie 7 P a DID ANDO i rie tC BS tes SAN uu rE ADUL E STD 2 04 I t d atl FILTER n SOLaTe ADD b R W Saw Differential 1 0 du 4 RESET 6 MACE WIR s GET GRE UD Lec ani am 8 3 vo 18 18 UY
9. 10987 6 8 76 5 54321 432 1 PROCEDURE 1 Disconnect the input power to the POWER 6 Remove input power to the POWER WAVE WAVE 655 8 655 R If any of the voltages are low or not pre sent perform the Input Contactor Test If that 2 Remove the case top checks out the Input Board may by faulty 3 Remove lead X4 from the coil terminal of main 7 Reconnect lead to the main input contactor input contactor CR 1 Insulate lead X4 Refer to CR 1 coil terminal Figure F 8 8 Carefully apply the correct input voltage to the 4 Carefully apply input power to the POWER POWER WAVE 655 R WAVE 655 R 9 Turn on the POWER WAVE 655 R Check for the presence of 24 VAC from lead X4 to lead WARNING 601 See Figure F 9 ELECTRIC SHOCK can kill This 24 VAC is the coil voltage for main input AR o contactor CR1 It will normally be present High voltage 5 present when input approximately 12 seconds after input line power is applied to the machine switch SW1 is activated 10 If the voltage is not present perform the Auxiliary Transformer 1 Test 5 Turn on the POWER WAVE 655 R Careful 11 Disconnect the input power and replace the test for the correct voltages according to Table case top POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
10. 45M a GENERAL INFORMATION LOST USED FI ECTRIDZM SYMAN lt PER F1537 C 185 1119 CAPACITORS MFO 822 504 UNLESS OTHERWISE SPECIFIED i 5 2 dut RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LARIS 9 27 Vee ss gt DIODES 1A amp 00V UNLESS OTHERWISE SPECIFIED ETAGE RET e gt MAD s 1 gt POWER SUPPLY POINT m 19 T 56 SYMBOL INDICATES WIERE TEST POINT PADS SHOULD 8 8 ADDED DM SECONDARY SIDE OF ARTWORK 57 COMHANN CONNECTING Vee PF TION Yl gt c70 gt EARTH GROUND CONNECTION Eg E ac EN 50v 485 485 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC MAY BE CUPLICATED COMMUNICATED 90 D lt sam PROPRIFTARY amp CONFIDFNITAL OTHER PANTIES USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PEDMISSION OF LINCOLN GLOBAL INC 5 SINCE COMPONENTS CIRCUITRY ON A Py T PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMAL EQUIPMENT TYPE LUMMUN CONTROLS PAGE 03 OF 03 gt ABILITY F a COMPLETE DOR TS m SUBJECT SCHEMATIC ETHERNEI GAIEWAY nonem E 0 P DIAGRAM MAY MOT SHOW THE EXACT ENGINEER ME m Uu ee NUMBER REVISION COMPONENTS OR CIRCU
11. G 17 Schematic FeedHead PC Board Sheet 1 G3823 3 G 18 Schematic FeedHead PC Board Sheet 2 63823 3 G 19 s Schematic FeedHead PC Board Sheet 3 G3823 3 G 20 5 Board 119528 do YE gs G 21 2 PC Board Assembly input PC Board L11396 2 uta ar a 6 22 5chemauc Switch PC Board 1016 aon ik ca RR RC UC o G 23 E PC Board Assembly Switch PC Board 83501 1 wy e on deed eda ce eg ads G 24 Schematic Voltage Sense PC Board 524779 G 25 PC Board Assembly Voltage Sense PC Board M19540 3 G 26 Scnemauc 40 VDC Bus PC Board M19330 iu Lese du d i Ue au a are r6 ades G 27 PC Board Assembly 40 VDC Bus PC Board L11745 G 28 Schematic Auxiliary Driver PC Board 524530 G 29 PC Board Assembly Auxiliary Driver PC Board L11067 1 G 30 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi layered and are therefore considered to be unserviceable Assembly drawings of these boards are no l
12. 03821 2 0 A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC pur o O 4 gt 4 Return to Section Return to Master TOC 4 o c 2 re did ELECTRICAL DIAGRAMS SCHEMATIC DEVICENET GATEWAY PC BOARD SHEET 2 DeviceNet Isolated Section His J76 Connect i to 3 for DeviceNet as MENT ned 29 d dr 40V 66 3 C lt 3 PROPRIETARY amp CONFIDENTIAL jdn i ZA COMMON DRAWN BY NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 OTHER PARTIES OR USED FOR ANY PARERE WITHOUT THE EXPRESS WRITTEN PERSON BF LINCOLN ROSA A RENE wr EQUIPMENT TYPE COMMON DIGITAL CONTROLS SCHEMATIC GATEWAY PCB DOCUMENT DOGCUME ENGINEER NOT 4 RUDER REVISION 85 53801 20 G 9 Return to Section TOC Return to Master TOC G 10 SCHEMATIC ETHERNET GATEWAY PC BOARD SHEET 1 15 55PF 55 5 8 70
13. 4 4 c 2 4 FEEDBACK INPUT VOLT 55 67B SENSE CONTACTOR AND PRECHARGE BOARD CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RELAY cs 115 VAC 52 VAC 50 65 VDC DC sonno BUS BOARD 40 VDC 40 VDC 40 VDC ARC LINK WIRE 9 FEEDER RECP DC BUS BOARD POWER BOARD FEED HEAD BOARD GATEWAY BOARD AND VOLTAGE SENSE BOARD The DC Bus Board receives approximately 65VDC from the Bus Board rectifier The DC Bus Board regu lates that 65VDC to 40VDC supply This regulated 40VDC is applied to the Feed Head Board the Ethernet Gateway Board the Power Board and the wire feeder receptacle The switching power supplies on the Power Board sup ply a variety of regulated DC voltages to the Control Board The Control Board uses these regulated volt ages to power the many circuits and communication functions incorporated within the Control Board VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT ARC LINK BOARD ROBOT CONNECTION se TO WIRE DRIVE Ojo GATEWAY BOARD AND VOLTAGE SENSE BOARD IGBT DRIVE MAIN TRANSFORMER eID POWER WAVE 655 R Bn MU EA cce CURRENT OUTPUT DIODES TRANSDUCER ELECTRODE gt D1 D4 TERMINAL ns C 5 CR1 INPUT 2 RECTIFIER HARMONIC e FILTER E IGBT DRIVE FROM CONTROL CURRENT BOARD
14. gt lt C DATAIO 5I MCL65407DW mM iw 09 M 9 1 2 j 2 21 a 1 t i mw A ES 1 49 i 5 50 A B CANH Rato 18 yz 8 m Bes Mc1454070W CONTROLLER cap DU Var s ee ns237 wn d Fle Sa 9 gt 091 29 5 M wma j 1 2 200 MC1454070W nd 5 MCLSAQ70W T 18 15 m 1 28 1728 Hg 10 0 0K 30V 100V T 1590 Lo 073 1607 dp MEL45407DW 000 S Low 1728 15 6 8006 vE MCL45407DW i f 10 gt PWREN 10 10 0 25V i5 807A6AM 16V i v Vite 1 too DND ss 155 2 4 id 15V 10Vn9232 2 iv l i 5 1 Ti Se mori y GENERAL INFORMATION _ MEI 3 ILL ELECTRICAL SYMBOLS PER E1537 O O CAPACITORS MFD 022 50Y UNLESS OTHERWISE SPECIFIED 1000 E 9 ies En RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 5 3 200 55v 1 v sov sov 50 39 9 SUPPLY VOLTAGE NE
15. 2 4 Return to Master NOTE Resistance checks of the Switch Boards in this machine will vary greatly depending on s e the type and model of meter being used Comparative readings between the two sides z of a board and or between the two S witch Boards will be more meaningful than the actu al numbers In all cases readings of all sets of test points should be approximately the 2 2 same If not using an auto ranging meter select the X1000 scale 9 9 cle The readings in Table F ljare representative of the meters available when this test was ale developed PROCEDURE 1 Disconnect the input power to the POWER 5 If any test fails replace the Switch Board See WAVE 655 R Switch Board Removal and Replacement 2 Remove the case sides NOTE Switch boards should have Identical base numbers and dash numbers elo 3 Perform the Capacitor Discharge P rocedure E 6 If the switch board resistance tests are OK cls 4 Using the Fd he n the resistance check the molex pin connections and associat tests detailed in Table F 1 The readings should ed wiring from the switch boards to the control 9 i all be similar One or more readings that vary board See the Wiring Diagram olo considerably will usually indicate a defective pa board Refer to Figures 2 for the test E points 2 amp POWER WAVE 655 R
16. 5 Siz ac 05 5170 isto ag EA ADDRIGI 5121 104 5 ADDR gt PWRON INT 100 p gt 208 TREG_MACE me TREQ MACE 99 pF3 ADDR 28 vm eed eig INT CAM gt ppa P ADORILAI 2 a SwWi CS EIS 75 Sipes 0 qq ADDRIT5I DATAILO gt br m 42 E A 70708 2 AUBYTE ADDR 171 le DATANG Ea Os in p iy PR PA Al prem At Pun cones 70V 50V TN jov m 24 A17 ADORTI ALBYTE gt BRE 14014 N jool 5 16 15 15 n 5 js Few o1w Vols Dok 20 ALD BANK L gt 5 51 52 52 55 5 A2 4 2 2 6 7 8 8 d 30 euch Ao B 7 XMT EOF gt CS 0 2 A 28 pal CARLOS 21 Fco B BIC RTC CS e 24 EDF RESP B id ZERC MAIN 23 5 SYS RESUT T svsnstT 5 10 5 UO DELTA PH ZA 00 539 z 138 l0 DELTA HZ 2 TPUCHLL ADR 2
17. g mE Re Fai e eee Ld 851 9 RID ho 9 aaa HF ie E i P vv Tros deus SHUTDOWN 1 tcr Li mer o Fiz ta Gee gt s D 1 T Hr T 85 15 ay omen AS S vs AUN S un 9 C 48511 ABS VALUE 4 TO 2 IMIIDRAD 170 V WV y V 7 5 5 OS 5 2 SHUTDOWN 2 c a te w J85 Beinen Bao ac ue Rae INPUT gt 485118 dus liic 51 as Rigs C AK 1 eet Y GENERAL INFORMATION ELECTRICAL SYMBOLS PER CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED RESISTORS NOTES THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL AND MAY NOT BE DUPLICATED COMMUNICATED NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY PROPRIETARY amp CONFIDENTIAL To OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC LA OI ENSE 5 CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE HUTACU NG TOLERANCE GO REFERENCEA EQUIPMENT TYPE COMMON DIGITAL CONTROLS PAGE or 3 8 BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR ONS PLAGE DECIMALS IS 40 FES 0923206 F DOCUMENT 2
18. INPUT RECTIFIER HARMONIC FILTER IGBT DRIVE FROM BOARD 9 OARD CAP V F FEEDBACK D VOLT ele SENSE CONTACTOR AND PRECHARGE BOARD CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BO RELAY Gc 115 VAC 52 VAG 50 65 VDC gt M BUS BOARD DC 11 RECTIFIER BUS Auxiliary Fan AUX 2 4 V A RECONNECT C BOARD 40 VDC 40 VDC 40 VDC ARC LINK IO RECP CONTROL BOARD The Control Board performs the primary interfacing functions to establish and maintain output control of the Power Wave 655R machine The function generator and weld files exist within the Control Board hardware and software Digital command signals and arc voltage and current feedback information is received and processed by software located on the Control Board The appropriate pulse width modulation P WM signals are then sent to the gates of the S witch Board IGBTs to create the high speed digitally controlled welding waveform See PULSE WIDTH MODULATION dis cussion in this section SWITCH CONTROL T CURRENT TO CONTROL B VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT ARC LINK CONNECTION se TO WIR DRIVE GATEWAY MAIN TRANSFORMER ECCE CURRENT OUTPUT DIODES TRANSDUCER ELECTRODE D1 D4 TERMINAL Ge IN WORK OUTPUT TERMINAL CHOKE 5 gt U R TO ETHERNET lerr RIGHT 5 SB SB T F B IGBT TO FAN RELAY
19. R82 58 10125 RET 8 orac 5 Md vu T eM PS EUF RESP __ _ aspe Ho PA p 3 DAFAILA Ald 008 1015 o gt 06 em 2 tois CRYSTAL apum mera DATAUO 1 b aoe A12 Dao 1017 ae gt gt AUR14 343 pais B iac BA 17 M ADDRES 2 po DATAN sv i XC9572 66 LBYTE 00 2 gt 1 b4 UBYTE ALS 0013 20 5 ev per 103 a p ERR g 32 E D 919 4 67 5171 3 BMIS 1050 Lt f ADDRI0 9 525 PER 5 E CS MACE RGY i 12 Olio 77 EOF 1606 2 0 0 23 hooi foor 23 fioo MCU XbA 22pF 021 gt ow 2 dw 944 260 51V jogp 66 REC EOF 7 amp st lt 16 VDDSYN m 1088 1090 19 Hs 753 C CRYSTAL i uS EXTAL CLOUT 10108 imen BL H S TAL olo 16K X 8 SWE 6 0128 1011074 HS MOST 2 1 q 2416 RESET RESET EEPROM PSW2 10120 B2 MISO 142 1051 MsO BERR CST 0 and OIS nr ROPWRON ANT 170 FREEZE TS gt 110168 10168 10150 8 IFETCH 19 66 SPI_CS1 ae 103 01 10178 1nt amp n Pu
20. 28 SS su N 404 16164 VIF 856 8 5 COLD IN FORWARD 54 273 ARCLINK d 13V 360 3 238 3076 gt 405 816 lt VF AUX RECONNECT 857 ss COLD IN REVERSE POS m 0 aioe C M SINGLE PHASE DETECT 231 28 00 504 56 lt VIF STATUS LED HI FOR RED gt 37 3 1w LOW 1 PHASE N sse ales GAS PURGE INPUT 500V 172 ARCLINK L a 5 gb 18 505 10J6 VF Se 5 440 460V 859 L sus SHUTDOWN 15VDC 7 lt 3J72 COMMON oo PAS o H6 550 575V 5 Ns 1 1 te 503 lt 3 50 IGBT DRIVE 4J72 40VDC 134 WIES ARG LINK A pan 10185 SHUTDOWN 1 INPUT Y w is arcunk STATUS LED HI FOR GREEN 5 1B 861 11088 SHUTDOWN 2 INPUT 504 450 VIF 894 5 75 424VDC i 505 5 50 893 lt 2 75 24V GND 301 1416 IGBT DRIVE 56 ROBOTIC ss 5 RECEPTACLE 506 DRIVE RED Wr 7882 CAN H 302 lt 66 lt IGBT DRIVE 9 S 7AUX DRIVER BD 154 282 ARCLINK H ica 891 lt 4756 CAN TACH 15VDC 5 841 J82 ARCLINKL mE
21. 4209 3893 140 A Return to Section Return to Master TOC LINCOLN amp ELECTRIC an ELECTRICAL DIAGRAMS G 11 SCHEMATIC ETHERENET GATEWAY PC BOARD SHEET 2 EXTERNAL STATUS LEQ RED ANODE 1 D 3 4 GREEN ANODE lt 2 2 on 750 01 MODULE Return to Section TOC Return to Master TOC DEVICENET ARCLINK STATUS 35 STATUS STATUS LEDs LEDs yt GRN 4 CAN m CONTROLLER 010 ma 05 60v xi axe TXO INT_CANI p25 PZA m P23 SYS RESEI AS82527 gt P21 pol CLOCKOUT PKs l READY MISO P10 AUG 1 b DATA p12 antoP DATAI101 p13 Ap 1 229 DATALO L51 P15 A013 3 PLO ADLE 1 15 25 5CANZ JBN 1 ta 3 for DeviceNet Return to Section TOC Return to Master TOC Connect 1 to 2 for Module INT CANZ lt RESET caw cs2 Mu P22 ADORLL 20 P20 CLOCKDUT READY MISQ RAMA ADDAL4 34 pana 2 5 36 MOSI 11 9 pl 0G 3 3 ADS PL2 AD10 20 AD amp SELK PE ADDALS 33 07 praan F3 PLS ADL PLT ADIS
22. 5 9 gt Bs 4 oio LINCOLN amp ELECTRIC EN 170 PROPRIETARY amp CONFIDENTIAL S DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED N TO IANUFACTURING TOLERANCE PER E PAN 2056 U M DRAWN BY DESIGN INFORMATION TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC lwimbley REFERENCE EQUIPMENT TYPE INVERTER WELDERS MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS DO NO A HIS DRAWING APPROVED ENGINEER KJUSTICE EAE SUBJECT MATERIAL DISPOSITION NA APPROVAL DATE 12 4 02 WIRING DIAGRAM PAGE 1 1 NOTE This diagram Is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code Is pasted inside one of the enclosure panels of your machine SOLID EDGE G 3 WIRING DIAGRAM CODE 10863 ELECTRICAL DIAGRAMS
23. EATER F 4 Test Procedures Input Filter Capacitor Discharge Procedure 11 teva E SERE ESRB SN F 13 Input Rectifier F 17 MPU CONECO TOS DC F 21 DC BUS BOGE TESE F 23 acudir F 25 E DOSE NOSE F 29 tae shen F 33 Reculer 1CSt qe r Pmrr F 37 Auxiliary Transtonmer L I8SE ar OE Crane ae Cie ie F 39 Auxiliary F 43 E Component Removal and Replacement Procedure E Input Rectifier Removal and Replacement F 45 Input Contactor Removal and Replacement F 47 5 Auxiliary Transformer 1 Removal and Replacement Procedure F 49 Auxiliary Transformer 2 Removal and Replacement Procedure F 51 Control Feed Head or Voltage Sense PC Board Removal and Replacement F 53 Ethernet Gateway PC Board Removal and Replacement F 55 Power Wave Current Transdu
24. VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT ARC LINK BOARD 56 DRIVE 40 VDC MAIN TRANSFORMER CURRENT OUTPUT DIODES TRANSDUCER D1 D4 ELECTRODE TERMINAL CHOKE DEVICE NET TO TO LEFT RIGHT S B S B ETHERNET GATEWAY coNNECTION TO IGBT TO FAN RELAY DRIVES CONTACTOR AND PRECHARGE CONTROL SIGNALS ARC LINK 5V RS232 THERMOSTATS CONTROL BOARD S2 WORK SENSE 53 RS232 LEFT S B CAP V F RIGHT S B CAP V F 5 V ARC LINK 5V SPI 15V SPI POWER BOARD LEFTCT RIGHT CT CURRENT CURRENT FB FB STATUS THERMAL LIGHT LIGHT Robotic systems can communicate with other industri al machines via DeviceNET or Arc Link The result is highly integrated and flexible welding cell Depending upon configuration it can support constant current constant voltage and pulse welding modes Each machine is factory preprogrammed with multiple welding procedures Typically these procedures include GMAW GMAW P FCAW GTAW for a variety of materials such as mild steel stainless steel cored wires and aluminum The Power Wave 655 R has an output rating of either 650 amps at 44 at 100 duty cycle volts or 800 amps at 44 volts at 60 duty cycle NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC
25. LL 10A CIRCUIT lt 2 12 e 512 MIA 65 475 J41 14 511 J82 18 BREAKER o 753 6 416 O 50 u 1 0 15 51 ya BL 1 2 REC 676 47 14 5 3 THERM 8 478 4 TOSW1 9 2 E E T ol i TP3 WORK r 1 5 lt 4 1 lt 3 id AIC c ELECTRODE aim x gc Ap c cc 634 m 220A ow _ T 45 440 460 gt LL lt 1e Drom J864 6 DOBOS LE E 2 c4 96 H6 e 550 575V EARLIER MODEL lt 5 ml iR THERM 3 NV 54 115V 9 lt 6 J40 ge MMN PRIMARY 11 13 12 14 115V RECEPTACLE LX 19 lt 1 J50 lt 9 1 292 BOTTOM C POS C POS TO AUX 1 NC RECEPTACLE NEUTRAL FLOATING x 1 471 5 em 10 292 LEFT _ NEUTRAL BONDED ed zn em lt 11 4 x 2 262 TO AUX 2 gt 3 5 lt 3 gt 4 32 eae 1 2 lt 1 15 lt m 5 H O268A B S S8 ie um bum lt URRENT et lt 1 8 RANSFORMER 414 4i8 WATER DopE J874 9 3 WHITE COOLER mar lt 3 08 EN INPUT BOARD rom ol pot 220 s BD NEG aba PEEP TAGEE T 12 lt 4 c LED Xi 24 DICEN 16 1 x LL m x 0 TRANSFORMER enn 21 4 L6 i 1 lt
26. NATIONAL ELECTRICAL CODE STATUS LED RIG ERN 4 UBI 36 HAA 325 111 JtVS J9 33 NE TP2 lt 4 us HOA 341346472 a Jag 42 J47 J60 J61 377 de QN wA CURRENT 352A lt 6 ae HA AUX 1 wey 179 186 5 THERMAL LED Y TORI TRANSDUCER 4 2 1 1 2 1 3 1 4 1 5 TO J7 206A TO TP3 TO 54 RH oo 0000 00000 5 e E AUXILIARY TRANSFORMER 2 aps 5 ELECTRODE AUX FAN A S 2 394 4 6 5 8 6 10 d TO RECONNECT PANEL TOP T J146 7 9 A 1 ELECTRICAL SYMBOLS PER E1537 pas 310 370 385 n 10 461 TO CONTACTOR NOTES RIGHT SIDE OF MACHINE LEAD COLOR CODING 1 6 1 7 J710 4 87 8 B BLACK 000000 0000000 8 00000000 12 Sun NA PIN NEAREST THE FLAT EDGE OF LED LENS CATHODE ALIGNS WITH BLACK LEAD OF LED SOCKET CURE i POWER 5 9 N B CTs MUST BE ORIENTED IN THE PROPER DIRECTION TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED 1 1 T 2 8 14 9 16 TOCB3 A SIDE OF CT TO THE SWITCH BOARD THE ARROW ON THE CT SHOULD POINT FROM THE SWITCH BOARD TO THE TRANSFORMER C Ni CAPACITORS iR toe cr EXT NUMBERING SEQUENCE 6128 PLACE LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 550 575V OPERATION W WHITE VIEWED FROM COMPONENT SIDE OF BOARD G3498 CLEVELAND OHIO U S A O o e
27. F Electrical Diagrams Section G POWER WAVE 655 R LINCOLN Return to Master TOC Return to Master TOC 4 4 c 2 4 Return to Master TABLE OF CONTENTS INSTALLATION SECTION t luti Fe D r rR A 1 T hni al Specifications Roo bee 0000 A 2 diei RP A 3 remos s aia 3 Gee 3 nea ee eae Ge ee ee ae hoa 3 Machine axe A 3 High Frequency Protection ua aue pod ipa dee Por dede ER ac abd A 3 ONS GOIN atin Ba dcn iue E SC ie DN RU die A 4 Input use and Supply Wire Considerations espis ux 9 auc Re RR A 4 Input Voltage Change Over For Multiple Input Voltage Machines Only A 4 Welding with Multiple Power Waves A 5 Electrode ana Work Cable CONNCCUONS ues des huc ace e Rok IRR RR ROC ees Coe Re hr A 6 Cable Inductance and it
28. GUN p Receiver mS gt STATUS POLARITY 33 TREQLMACE TOTREG HR H lt Bu 21 lt 5 0013 9 5 RUE vdd E M LAM 25 mak SN POTT di 3 i ss al 4 4 94 34 95 EA IPN 4 E c POM IDS gt 5 sms emen mL ay ETHERNET podeis 1 1 a MEN DIFF3 0 lt 6 12 it gt 5 5 HK 3 DF3LTIN 53 4550 R124 37 gt 9 9 PASS ara Hav Es 260 LE mrs sas S 5 5 EE Pi 42 DENY 3 T Me ojo MEM LL cau eee MEN 10 5 Riza 1 Bi s gem o 120 Voam mmo Cad 1458 8 i TAA 5 E 2 N 221K orga 907 Yol M 21 gt 3 GND2 Xe NS 54 lt 26 re 0 01 5 S 6 4 Isolated Vo Vin Daal Scc Fie els H AD CLOCK ES Non vata m Ll N 0 V 0 1 ti e S H A M Dr4 TIN HS lt 3 H5 LK
29. 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 33 TROUBLESHOOTING amp REPAIR F 33 CURRENT TRANSDUCER TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Current Transducer and associated wiring is function ing correctly MATERIALS NEEDED Misc Hand Tools Lap top Computer Diagnostic Utilities Software Resistive Load Bank Optional 50 ft 4 0 weld cable Calibrated Ammeter Volt Ohmmeter NOTE The Diagnostic Utility Software is on the Utilities Disc that was shipped with
30. 026 027 ZA 92 oV 70V PCL gt 1 111 h en to E ELECTRICAL DIAGRAMS 5V TKS isl SiS qp lea TOO JOS ipic 11512 9 5 148 82 1022 gt OFL TOUT a 1 3 UNDERVOLTAGE RESET 5 1024K X 16 FLASH G 10 10188 ino PO 5 52 Psi S m Is ADORE ADERISI ADORE 18 NIE ACDRI9 zi VECES ATZE ADDRO FETCH ADORIL 20 2 zm 103C oF2_TOUT Alas 15 gt COM 12 lt lt 1 DF3 TOUT 3 100 CRANE 0 ae Cu D Wow 18 6 rose 22 TOUT ADBRIZI n 1 8 Ls TW 106C ac 196 0 7 82 gt Typeset 29 OATALO lt sc R33 R56 B3 xu 107C VA xy P CUR a MEN ace DNE n i p 109 18 d bp oe 18 TULC t o 9 R61 T ADDE 1 1gp HCAS ric ADORIS 0 Xx Ms indi ADURBI 18 ho DATAS A m 1 HS SPILCS
31. 404 TO J6 CONNECTOR Wu 7X DE El 55 gt _ 405 20 mE ao 8 m 51 4 si SECONDARY PRIMARY m 9 2 500 lt 6 lt lt i x3 50 TO 5 y EFT 1 52 10 lt 12 o OIS i TO 251 lt 11 lt 13 4 6 4 4 540 lt 84 o l LL 10A CIRCUIT L2 lt 26 830 12 Xi 5 1 415 Mb n O O O 9 5 BREAKER o 5 J iic 1 m memi 4 7 47 lt 2 16 L o E E B e s kd 4 D wiry 2 TP3 NE 1 252 2 Um 415V c O ELECTRODE ai 2 3 14 cae 54 a M e gt Cle c im lt 3 10W 800 440 460V 5 LL x4 DC BUS ET 9 2 c4 05 e 550 575V D3A is 5 EARLIER MODEL lt 5 21 THERM 23 Ld i S4 115V 6 100 83 PRIMARY 1 13 12 14 bw oc 115V RECEPTACLE 10 lt i lt 9 292 xil BOTTOM C POS C POS TO AUX 1 N C NEUTRAL FLOATING 10 292 oe RECEPTACLE a bi 5 mE NEUTRAL BONDED 3 lt m TO AUX 2 52 2 2 4 lt 12 lt 2 262 D3B 33 gt 3 A m4 5 13 lt gp 4 r 5 4 lt 14 268 53 7 lt 15 68 a NB b 32 34 8 46 6 CURRENT Q e 5
32. CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER mone C7 stn SUBJECT FEEDHEAD PC BOARD SCHEMATIC NUMBER E 8 9 2 WITH PUBLISHED STANDARDS DO NOT ES ETE 3828 360 JAPPROVED Wyte NONE Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 pur o O 4 gt 4 Return to Section c 2 4 Return to Master G 21 SCHEMATIC INPUT PC BOARD LINCOLN 8 VAC Input 6 eS J61 lt e 1 J61 6 ELECTRICAL DIAGRAMS PRE CHARGE CONNECTIONS CONTACTOR OUTPUT R9 R8 3 CR 660V 5 CR2 168 190 250 Jel 19W low 100 20 10W 10W TP4 2505 e J61 IE 108 128 ud PT IOW RS R3 oo 108 128 10W 10W 5 ix UNUSED PINS 46 B 3 760 R21 x e e e e e CENTER LEG TO OUTSIDE LEG OF INPUT CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED onc Jed ors RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 9 Ip NOTES DIOD
33. p OUTPUT SEMINA CHOKE DEVICE NET ETHERNET GATEWAY CONNECTION Ti TO TO LEFT RIGHT S B S B gt IGBT TO FAN RELAY DRIVES CONTACTOR AND PRECHARGE CONTROL SIGNALS ARC LINK 5V RS232 5 V ARC LINK POWER BOARD 7 15V THERMOSTATS CONTROL BOARD 52 WORK SENSE S3 RS232 LEFT S B CAP V F RIGHT S B CAP V F pow 4 LEFTCT RIGHT CT CURRENT CURRENT FB F STATUS THERMAL LIGHT LIGHT When the Feed Head Board activates the Voltage Sense Board the actual arc voltage is sensed lead 67 and this information is delivered through the volt age sense board to the Control Board The Power Wave 655R uses two digital communication platforms Internally the PC boards communicate via ArcLink Externally the Power Wave 655R communi cates using the industry standard Ethernet or Device Net protocol The Ethernet Gateway Board makes the translation between the platforms possible The Power Wave 655R does not have a dedicated interface device or board The robot or other input device PLC etc acts as the user interface issuing commands that are translated by the Gateway Board to ArcLink compatible messages Figure E 5 depicts the flow of communica tion information NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Secti
34. CURRENT a O 612 6J614 2461 Ti A hs xxi ae 201044 CT CURRENT i A 13V P P 853 lt DUAL PROC INPUT n j 514 lt 1v10 CT CURRENT THERMAL LED 8 7 gt 2B t gt 60 64 1 7 Ja MEE S BOARD 2 RIGHT ETHERNET BD ZS PRECHARGE RELAY i 518 lt 2J10B CT CURRENT oe 855 lt 5085 COLD INCH 15VDC mE ARCLINK THERMAL LED 737 2w 6128 gt T2 rc 53 lt 1784 ae M 404 16 64 VIF 856 6085 COLD IN FORWARD 54 2273 AUX RECONNECT sav 208 a yum ae vro C 957 s COLD IN REVERSE POS 66 6 19 20726 ARCLINK H x SINGLE PHASE DETECT 9160 gt 23i 2800uF 504 56 VIF STATUS LED HI FOR RED gt 327 3 1W LOW 1 PHASE B 858 siss GAS PURGE INPUT i sov T i 1726 ARCLINK L o a i gb ky 18 505 10J6 So 5 440 460V 859 L sus SHUTDOWN 15VDC 7 lt 3J72 COMMON oo PAS c c i 550 575V 5 j NW 154 un ARC LINK H s emo rum 503 lt 3950 IGBT DRIVE 4J72 40VDC rud 10185 SHUTDOWN 1 INPUT m is ar
35. N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER FILENAME G3631 2D2 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V RESISTORS Ohms DIODES 1A 400V UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED 1 4W UNLESS OTHERWISE SPECIFIED LAST NO USED R C LABELS d SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT COMMON CONNECTION 777 FRAME CONNECTION EARTH GROUND CONNECTION G 17 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U S A MANUFACTURING TOLERANCE PER E2056 X INFO Chg Sheet No DESIGN INFORMATION FEE 5 9 gt 8 EIS LINCOLN amp ELECTRIC EN 170 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 REFERENCE EQUIPMENT TYPE 6 2 2000A Digital Systems DRAWN BY JP TK ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS NOT SCALE 155 DRAWING NOTE This diagram is for reference on
36. Return to Master TOC POWER WAVE 655 R LINCOLN NOTES POWER WAVE 655 R LINCOLN amp F 20 NOL 491Se A uunjeH NOL 0 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 21 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the input contactor is functional and if the contacts are functioning correctly MATERIALS NEEDED Misc Hand Tools Volt ohmmeter External 24 VAC supply POWER WAVE 655 R LINCOLN F 2
37. cer birth defects and other reproductive harm The Above For Diesel Engines Return to Master TOC ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp 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 ARE Return to Master TOC 4 gt 4 c 2 4 Return to Master PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment l a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 2 XN 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors SN 1 Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 ing to prevent spilled fuel from vaporizing
38. i ini 7 9 Time POWER WAVE 655 R LINCOLN B 8 NOTES POWER WAVE 655 R LINCOLN amp B 8 NOL 491Se A uunjeH NOL 0 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Master TOC Return to Master TOC 4 4 c 2 4 Return to Master E TABLE OF CONTENTS ACCESSORIES lm P eee ee eee eek C 1 Opuonal eset _____ _ ___ _ _ C 2 E we acs ane as ad a Geng C 2 msi C 2 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Cc gg x Of gt 0912 Return to Section Return to Master TOC d ACCESSORIES OPTIONAL EQUIPMENT 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 Install the 5 8 18 male outlet on the regulator to the proper 5 8 18 female gas inlet on the back panel of the
39. 26 1286016 ADDR 25 SRAM 30 21 D ORS 20 DI 205018 19 ho og 3 DATAZ ADDRI2 p H3 DA AEDRTT AA os 14 DATAS ADDE Td SAI ADDR15 2 Ald 07 08 0817 3915 A16 31 DATATE ADDRE H9 4 22 DATA1 4 PI m 35 82 adc 13 36 DATAUS NIE NAR 752 dre e Dis DAIS 2580 38 12 225140 4 541 689 1561612816 0 081 BANK 1 DATA G 15 INVERTER WELDER REFERENCE EQUIPMENT TYPE PLACE DECIMALS IS 002 DRAWN BY FEI G3789 1E2 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE ENGINEER SCALE WITH PUBLISHED STANDARDS APPROVAL DO NOT SCALE THIS DRAWING NONE pisPosimon DATE PAGE 1 oF 4_ SUBJECT SCHEMATIC DIGITAL CONTROL Nu PROJECT 10 26 2006 CRM22115 GA G3789 2FO SOLID EDGE G 13 Return to Section TOC Return to Section TOC Return to Master TOC O o Fle Sa 9 gt 912 5 cc Return to Section TOC Return to Master TOC Return to Master TOC G 14 SCHEMATIC CONTROL PC BOARD SHEET 2 LINCOLN amp ELECTRIC EN 170 03 68269 ENGINEERING CONTROLLED CHANGE DETAIL 3 R65 REVISED VALUE MANUFACTURER Yes a J4 9 14 1 d 1 54 0137 15M85931 74 14 444 z 7 NOISE_ SIGH 063 1 5w 02 A
40. ENGINEERING CONTROLLED CHANGE DETAIL PAGE 3 R65 REVISED VALUE 0 9 022 68 55 MANUFACTURER Yes 0 OIG 8 2 9 2 116 115 b cat E x 45 dz 43 RE i M 38V i 4 5 Gc USP 00 D CO 10 PA9 72 OUTPUT OH IA SP D3 nt ADCINTZID PATESS is i E cech Pd ML Bur iD DS tae ADCING 75 3 A 35 2 09 04 15 TT i pse 08 46 SRE Der eae D 17109 a 3 Ilos C76 SS 18 D7 cr ee o l Tesu DSP DS 22 E 515 alc 8 m els s ELI 88 9 m i Sig 8 alge D3P Di2 28 015 26 13 ADCINT3 055 614 x22 ape 55988 osr O15 28 Kal at Ead a 566 RESET im 42 201 15 DSP RESET 35 RS TMS320F240 TMRCLEAIGRB7 108 EEEE nme cu 8 ie BBB ESE 855555 99552 12 39 XTALi CL T3PWM T3CMP IOPBSLLE 2 2 4 m LECSOC IOPCO THPWM TICMPA
41. LLI 2 5 a IN n o lt E co g 2 S E a cn ma 5l e 2 E olo OO sils 8 5 5 5 2 lt lt Un un LO NOL 0 NOL 0 NOL uunjeH NOL Je1Se N 0 DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes A 12 NOTES POWER WAVE 655 R LINCOLN amp A 12 NOL 491Se A uunjeH NOL 0 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg ET TABLE OF CONTENTS OPERATION SECTION EST 5 ODGFdHOD B 1 2 visi PECA Ue cH ETT TEE IR TETTE TOOL 1 ee eee B 2 E Siren E E 3 d Generar Des a Pari bait E ae B 4 Recommended Processes and Equipment 4 PIOGSSSOS sax acc dads 4 Recommended ESUIDITIGIIE 3 2548 54 ROG DRGs EAS B 4 4 Mc p PTT B 4 5 DUY
42. POWER WAVE 655 R LINCOLN F 23 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC dod TROUBLESHOOTING amp REPAIR ree DC BUS BOARD TEST PROCEDURE CONTINUED FIGURE F 6 DC BUS PC BOARD LED Power Bd Rectifier PROCEDURE 1 Disconnect the input power from the machine 6 Ifthe input voltage is correct the DC Bus Board may be defective If not check the Power Board 2 Remove the case top Rectifier and the Auxiliary Transformer T1 3 Locate the DC Bus PC Board and plugs P46 and 7 Check Bus Board output voltages at P47 per P47 See Figure F 6 Table F 3 4 Carefully apply inout power to the POWER WAVE 655 R TABLE F 3 DC Bus Bd Output Voltages Positive Negative Voltage WARNING M
43. TRANS CARER 1 8 5 amp m PRIMARY em 5 o 5 i mh aT rr T Fal DEM il ral o 3 chri a Los Cr 3 5 5 eee To DI e HE 4 yeild m i i MA pn a 1 i FON PPP los mhi TEST POT ion mt E c ___ i T NE T O 163 ur 183 u D d 1 o_o 4 ay 42 pc EF IM ri L cm i y Y cla elzg oloo e F Lp e gt D v i T D fae TP L TE Ex Lowe HE hz o lt M w 2 m PRHARY rm e Lo 9 2 4 cjs l i EE sis v 21 5 1 LIES B Likes un F Dee en HA TADE Du HEEJ c aj Fu Ai E E EH IESI D e alre a 22 mr m r j 4 LI Ld an 1 ET T 11 Lt i m Ld wt il
44. X 1446 440VDC POWER gt 7447 gt 477 lt 2341 4 440V 226 i CB4 Gua POS POS 2446 COMMON 9o 647 476 4 40 common P9292 15V 9 y ET 65VDC 1 m 75232 COMMON gt 228 lt 544 85232 COMMON 51 WIRE FEEDER 1 x2 LE FO 612 H1 24000uF 100V RECEPTACLE NEG NEG lt 3246 d NEG 446 L2 52 L D 40VDC COMMON O9 147 51 51 0VDC AUXILIARY TRANSFORMER T2 440VDC FEEDER 3447 gt 50 amp 7 75 52 352A CB1 67 lt ELECTRODE SENSE i 10A M H6A 5 gt zu 2 58 WATER COOLER mus L5 L 6128 612A H5A gt 6 a m 33A 4 RECEPTACLE Lanm l ss lt A ARCLINK i M CB2 i X 40K n n 54 lt ARCLINK 33 4 33 6 oe i H3A 2 ov asd i S5 DEVICENET p eem CONNECTOR CB3 H2A 4 3 s 200 208 10A 32 31 NOTES Hia gt 1 gt t 1 894 2 24VDC SAM rcr 893 _ _ 3 24V GND 115V MER ARE NOT SHOWN ELECTRICAL SYMBOLS PER E1537 RECEPTACLE 97 CAN 80A gt 891 lt 5 CAN L PROPRIETARY amp CONFIDENTIAL DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC REFERENCE DRAWN BY
45. available from the Compressed Gas Association 1235 efferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturers recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturers recommendations Mar 95 PRECAUTIONS DE SURETE 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail quil est pratique de le faire Si on place la S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Return to Master TOC Return to Master TOC 4 4 c 2 4 Return to Master Les circuits a lectrode et a la pi ce sont sous tension quand la machine
46. fdjust gt tightis BLACK when OFF POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o zl x Of gt 912 dc Return to Section Return to Master TOC F 69 1 TROUBLESHOOTING amp REPAIR F 69 CALIBRATION PROCEDURE CONTINUED Calibration can only be done under static load conditions Do not attempt to calibrate while welding NOTE Incorrect calibration can and will affect welding performance Itis strongly recom mended 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 Refer to the Software Documentation for instructions on using the Snapshot feature CALIBRATION PROCEDURE Once in the Calibration screen make sure that the machine output is OFF light is BLACK and connect a resistive load bank to the output studs Set load bank for 300 amps On the Calibration screen select the 300 Amps Current Set Point NOTE If the meters on the load bank are not certi fied connect calibrated and traceable meters to the machine output See Needed gt the beginning of this section A WARNING The Output Studs of the Machine will be HOT during Steps 4 through 7 4 Click on the Turn Output ON button The BLACK light on the
47. il PP bond CONVERTER z E OUPUT ee OG 3 fs p ANPUT COMMON Say ves 516075 EEPROM e ia P T ATZS128 108 Oot B3 na M f 40V M AME a 7 t T ATES LM25TSHVS 5 0 A a gt 65232 ms VIN ER our a e gt 29 x iren apar 026 59 th IE aaa ANE Olo Du d NT GENERAL INFORMATION Licini tur ELECTRICAL SYMBOL FER 5557 da J81 3 Lr o DIMES 1AACDV UNLEGE OTHERWISE SPECIFIED 8 SuPLY VOLTAGE RET c POWER SUPPLY SOURGE POINT olo 82 3 i 57 OMON CONECTION 7 SWITCHING POWER SUPPLY 2 FILENAME Ay Prove CL EARTH GROUND CONNECTION O c NOTES PROPRIETARY 8 CONFIDENTIAL 1115 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED V gt NA SINCE COMPONENTS OR CIRCUITRY A PRINTED CIRCUIT BOARD MAY hie TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC JA al Lal z 4 al Al p olo CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE MANUFACTURING TOLERAAKE REFERENCE EQUIPMENT TYPE COMMON DIGITAL CONTROLS
48. olo O o x Of gt 0912 1 Remove input power to the POWER WAVE switch board Note placement of the shake 655 R proof washers and fiber spacers 2 Remove the case top and sides 11 Using a 3 16 allen wrench carefully remove 3 Perform the Capacitor Discharge procedure the four cap screws that mount the switch board to the heat sink 4 Remove the high voltage protective shield 12 Carefully remove the switch board from the 5 Remove molex plug 40 50 from the top of the heat d di switch board Refer to Figure F 22 13 Ifthe filter capacitors are to be removed care 6 Remove the mylar insulating shield covering fully slide them out of the mounting bracket leads 13 14 or 17 18 Cutthe cable tie 7 Remove leads 13 14 or 17 18 from the S witch Board Return to Section TOC Return to Master TOC POWER WAVE 655 R LINCOLN diis TROUBLESHOOTING amp REPAIR SWITCH BOARD AND FILTER CAPACITOR 210 REMOVAL AND REPLACEMENT PROCEDURE CONTINUED c 9 REPLACEMENT PROCEDURE olz 8 NOTE Any instructions that are shipped with the replacement part will supersede these 9 2 instructions 1 If the filter capacitors are to be replaced carefully 9 Connect leads 13 14 or 17 18 to the correct termi Slide the new capacitors into the mounting bracket nal Position the capacitors so the correct polarity termi 10 install the mylar insulating
49. 4 J lt lt 4 840 424 1 277 iE x U i TO AUX 2 FT 12 Hn WORK Zp Z PE I 1539 AUX 2 lt 4 4 J824 3 ar 500 Jn 1 475 15 lt lt 2 RECONNECT PANEL 12 540 J47 mlom lt 4 ul 2 41 470 TO 61 did cx ec x uc 1 else 5 444 cp 51 B 54 lt 15 e Bm 4 478 POWER BD RECTIFIER TO SAT A CB4 WIRE ce 3 lt 16 3 521 TO pk ie TOFAN TO AUX 1 CRI 612 6A CIRCUIT FEEDER ilm r 1i J 4 152 74 88 ee ke aa 460 H o BREAKER 5 2 5 886 TO AUX 1 RECEPTACLE 253 953 A TO tele x4 26 MAIN CHOKE 1c C 284 53 mi 24 111 L1 TO SOLID STATE RELAY lt 8 1 lt 1 841 M3 R5 gt 444 9 2 842 Z 224A 55 55 Cx 104 D 3 3 1 T 1 choke X3A TO AUXI 1 1 743 To lt 4 4 6 4 lt 844 S6 10 273 RECT THERM THERM TO SOLID STATE RELAY VOLTAGE 4 52 7417 lt 5 lt 5 lt 845 1 267 SENSE 3 pata mf 10 1 53 800 BY 6 6 lt 846 LX 12 26 0 291 J9 Lig 840 7 lt 7 847 D RECEPTACLE 27 4 53 ATO 8 THIS AREA VIEWED FROM LEFT SIDE OF MACHINE 2 54 51 9 lt NE Nils CONDUCTOR nen 134 3 a DC BUS SWITCH BOARD 1 LEFT i SMEG GROUND TO CASE 4 1 267 BOARD THIS AREA VIEW
50. 45 820p R241 2 16 0k A 2 pan A 54 amp 028 Y R49 RAB R44 1 DN NIV 7 m TAE R71 R68 1 88 tear 2 171816 2 676 S2 pF D34 BATS48 Y pes 7 CURRENT NODE CONTROL DISABLE THE ate FETS AS SOON AS PRIMARY CURRENT 2 IS GREATER THAN A REFERENCE LEVEL ADBAOSARUTO 2 c58 19 18 28 118 1uF 2j 1uF CURRENT TRANSDUCER eee R43 1 58k R112 1 00k SIGNAL IN w IANN G WAS 500A OUTPUT CURRENT TRANSDUCER aie Fig INPUT 2 1 00k R61 R69 1 00 R32 41701 He MC330745D ctw ADC417D0 26 7 4 mt Eus AA S MSE foul r Y vg n ze o 2 we gt FORSAS R73 R127 gt 10 0k STUP CURRENT FEEDBACK gt R140 108i MSELB nag MSEL 16 v DBAGGARUTO MSUEN oup 45 QATA45 D54 N MC33874AD R25 41514 8122 57 _______ 5 B4 8 no 1 2W MV FEET ADB 4OSARU TE SECONDARY CURRENT SENSE 108k R79 131518 8123 5 49 3 SP AA 12 22 i oplo 5 32 Sh 1 28 S46 5 168 3 MC33874AD X6 oy RII 49 6 19 0 Hv HEAL VOLTAGE 2 R126 28 7 R124 R139 105k 2 8 292 8 ANNO 1 z 1 2 3500 VOLTS Las amp 27uF ON CONNECTOR Te en 2 MC33074AD 2 MC33074AD Q IRF7103 1 lt GA
51. 69 a Ati m 28611 Hd 2 uo STATUSE Lue JASSSPI PICDTUSE tls e 18618 BB 7 MISO gt d V 5 fav 12 PT a ZN 286 3 5 ex pur i 86 9 BUSS LOW sj Hi TEE 48619 X031 LLLA J86 8 scx CEDIDO A coc mea ok ccs cH AE AS A A ao ACE BUS HIGH i A EE AULA 8112 2 AN M 183 ISOLATION BARRRIER CAN COMMUNICATION CIRCUITRY GENERAL INFORMATION ELECTRICAL SYHBOLS PER ike HFD 1 022 50V EGG OTHERWISE SPETIFTEDI U RESISTORS Dima LABELS 0 RIES 1 UNLESS OTIERNISE SPEDIFIETD SUPPLY VOLTAGE JET POWER SUPPLY SOURCE PEINT 57 COMMON CONNECTION FILENAME FRAME NOTES DOCUMENT CONTAING PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL ING AND MAY NOT BE DUPLICATED COMMUNICATED n PROPRI amp CONFIDENTIAL xo OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL JEQUPNENT TYPE COMMON DIGITAL CONTROLS ge SUBJECT FEEDHEAD PC BOARD SCHEMATIC er Ta G3823 3E0 A N A SINCE COMPONENTS OR CIRCU
52. If the Auxiliary A lead is placed in the wrong position there are two possible results If the lead is placed in a position higher than the applied line voltage the welder may not come on at all If the Auxiliary A lead is placed in a position lower than the applied line volt age the welder will not come on and the two circuit breakers in the reconnect area will open If this occurs turn off the input voltage properly connect the A lead reset the breakers and try again POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC Return to Master TOC INSTALLATION lid WELDING WITH MULTIPLE POWER WAVES A 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 direc tion away from the work leads Connect all of the work sense leads from each power source to the work piece at the end of the joint For the best results when pulse welding set the wire size and wire feed speed the same for all the Power Waves When these parameters are identical the pulsing fre quency will be the same helpi
53. Remove your bodys static charge before opening the static shielding bag Wear an anti static wrist strap For safety usea 1 Meg ohm resistive cord connected to a grounded part of the equipment frame f you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Dont set the PC board on or near paper plastic or cloth which could have a static charge If the PC board cant be installed immediately put it back in the static shield ing bag f the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substit
54. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie x Of 9 gt 912 Return to Section Return to Master TOC B 5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave See Figure B 1 1 POWER SWITCH Controls input power to the Power Wave 2 STATUS LIGHT A two color light that indicates sys tem errors Normal operation is a steady green light Error conditions are indicated per table 4 NOTE The robotic Power Wave s 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 TABLE 6 condition Condition Steady Green 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 component in the system Normal for first 1 10 seconds after power is turned on or if the system con figuration is changed during operation Alternating Green and Red Non recoverable system fault If the PS Status light is flashing any combination of red and green errors are present in the PW 655 R Read the error code before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manua
55. Tr 3 T 7 1 r E s 7 M4 1 all TRANSFORMER MI vm UO 189 Hi E rm PRIMARY X 1 on d Tr m a RE 1 FO inu 2 mu T si is a jUET amp bk PRETI E n s a ni T b DAT m ECL Ez ET Et Eh ita da LLL 1 4 1 L Em jen em er k m oe ae O O o gt cig cic sis 2 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp es ELECTRICAL DIAGRAMS G 24 PC BOARD ASSEMBLY SWITCH PC BOARD
56. c m aF 8 b IDENTIFICATION CODE 1 S NS NN NP NR a A i T p C26 gt Um 1 023 i T E Py Dito e E C25 cc of JE D D gt 7 E e 8 a N b C24 cc lt dL LoL 2 i 21 SCHEMATIC REFERENCE 11016 10 I R67 i I 1 15 2 25 2 25 R64 R65 R66 R41 IQ R42 R64 R65 R66 DO NOT OPERATE WITH PANELSREMOVED DISCONNECTINPUT POWER AND DISCHARGE n 7 NK INPUT CAPACITORS BEFORE NG 98 SERVICING DO NOTTOUCH 2 ELECTRICALLY LIVE PARTS 8 HIGH VOLTAGE CAN GH VOLTAGEC Bu N FOR PARTS ORDERS OR SUBSIDIARY ORDERS INCLUDE 1 25254PRINT 1 25191 1PRINT 5 j 2 1 T12837 1 AND 4 525347 2 D a R a THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED 2 PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 0 9 00 04 MANUFACTURING TOLERANCE PER Eu DESIGN INFORMATION INFORMATION REFERENCE EQUIPMENT TYPE INVERTER WELDERS PAGE 1 OF 1 EX i PLACE DECIMALS IS 002 DRAWNBY Wimbley 1 DOCUMENT DOCUMENT 8 puru D aor SUBJECT SWITCH P C BD
57. s r NOL Je1Se N 0 uunjeH NOL uunjeH NOL uunjeH NOL 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes D 4 NOTES POWER WAVE 655 R LINCOLN amp D 4 NOL 491Se A uunjeH NOL 0 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg E TABLE OF CONTENTS THEORY OF OPERATION ES Theory of Operation E 1 o General DescrDHOlli Ped wees RRS shee eee CASES EIER ERE E 2 Voltage and eed keds Car eae ea RR cari ra E 3 x Switch Boards anda Main ivecneskacive eretada etm do aaa EDS IEEE AI a E 4 DC Bus Board Power Board Feed Head Board Gateway Board and Voltage Sense x x dicic i 9 ee dri ew kad he ea dea dra E 5 DOIG gc aie Geese be ee oe E 7 Output Rectifier and Output Choke x3 3 d E 8 Thermal Protection Protective Circuits Over Current Protection v ana Under Over voltage ae tae ae
58. souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le cable de soudage etla machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans leau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines f Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le cable lectrode autour de n importe quelle partie du COrps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ge
59. 404 490 nrm CO lt 3 4 TACH 18 DIFF INPUT e 2 52 VOLTAGE SENSE t INPUT BOARD 4858 CHOKE RECEPTACLE 844 96 TACH COMMON 20 216 68 lt CONTROL BOARD COMMON 406 lt 6 40 IGBT DRIVE 800V iow L1 ei E 845 lt 5555 320V lt gt 260 gt x3 5 84 TACH 2A DIFF INPUT Jl Pot d 4 oV 160J 211 138 lt CURRENT FEEDBACK 1 13V i 11 LIA 4 Ose Kame lt o 23 lt se lt 15V L4 C i i ea VERE 212 Md 415 WORK VOLTAGE SENSE gt 6 9 3 21A 7777 3 MAIN CONTACTOR CONTROL 847 7384 SINGLE TACH INPUT 2 i f i i 500V 12 4 POWER Y HID 5 10761 2 851 lt 1485 TRIGGER 15VDC 14 414 4J10A CURRENT e e O orm T 4 J as TRIGGER INPUT CT CURRENTS j i O 13V P 853 lt DUAL PROC INPUT n 514 lt 1 0 CT CURRENT THERMAL LED 8J7 gt 2B gt 41605 604 N A SZA 485 YELLOW 5 D pA ATERN SSWITCH BOARD 2 RIGHT ETHERNET BD 518 CURRENT 9 gun 855 lt 5 85 COLD INCH 15VDC n ARCLINK THERMAL LED 737 2w D 5128
60. 62V 5 IN4735A IUS EO ENCAPSULATION c j Tho D7 D8 D9 D10 D11 D12 D13 Oo oO FU Tu 014 015 016 017 018 019 20 12705 32 DIODE T220 15A 600V FR MUR1560 D iJ D20 D21 D22 D23 D24 D25 D26 Olcg N D D1 D2 D3 D4 112705 44 DIODE AXLDS 1A 1000V FR 818 h RAT R42 RAS RAA RAS R63 i res ees 40 14648 9 o gt 14285 R64 R65 R66 67 RESISTOR WW 5W 2 5K 5 SQ 4 275 OPPOSITE COMPONENT cjg SIDE 2 50 D 1 32 12 116 MAX CRIMP HEIGHT CAPACITORS MFD VOLTS p 2 00 i RESISTORS OHMS 10 75 04 n 5 PW 655 wr Ti R 045 9 switch FR 1 D d RS p Tc AM EYELET DETAIL 09 00 i ap 23 D NB qo ITEM QTY PARTNO DESCRIPTION 2 1 1 BLANK L4 i NA NHL NL M16100 46 ELECTRONIC MODULE 1 2 3 4 SS qu NS 4 9147 15 EYELETS MALE B2 B3 B6 B7 p Er L 19147 11 EYELETS FEMALE S p E MAKE PER E1911 523006 POWER TERMINAL B1 B4 B5 B8 i E ga POT PER E1911 E 43042527 EPOXY ENCAPSULATING RESIN cs 4 QOL 10 TEST PER E3826 SW 24869 1 PC BOARD SHIELD 52486 2 PC BOARD SHIELD n pt LL MANUFACTURED AS Be PC BOARD SHIELD i i H C6 4 DIS c18 4 b ss G3501 1 FO 1 8 M tya
61. 9 1 9 lt 7 d S3 WATER CB2 AUX2 1 5 10 lt 1 8 TRANSFORMER Waite 1 5 i D M3 1 he A COOLER 2 lt i INPUT BOARD TO SWITCH TO SWITCH RECEPTACLE 511 000 220 BD 2 BDH mim m ES mE 2 oe NEG POS AUX 2 4 NE 6 lt lt 13 224 VIE 2 61 CB2 lt 5 7 14 5 THERM CURRENT J10A 2 x3 AUX FAN men me ER BD 5 M TRANSFORMER Lemm 1 3 gt 238 L6 lt 7 W 2 54 gt s Bos th 5 HARMONIC DEVICENET 1 c D2A RED Wire THIS AREA VIEWED FROM RIGHT SIDE OF MACHINE FILTER CONNECTOR 202A c CHOKE N E 1 2 12 D 7 1 R TO 3 m SECONDARY PRIMARY SWITCH BOARD 2 RIGHT gt 8 gt 231 JJ 24V 21 804 TO 500 WORK J712 4 BOTTOM BOTTOM savann 3 893 A u75 ELECTRODE zo RIGHT RIGHT i i NEG P s m O O Can eot 9 206 amp 4 bm 2 6 1 gt 17 753 503 oro RECTIFIER gt 8 N O O A ANER Se m 3i x lt 4 ROBOTIC 24 222 5 NEG lt gt 6 0 506 NEG POS WIREDRIVE E NES gt x 7 5 INTERFACE 10A eom 4 506 m 8 POS 5 5 S 8 gt HD AC3 2 5 302 2 1 POS 9 gt D RECEPTAC
62. 912 Return to Section Return to Master TOC Return to Master TOC 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 4 Locate the input contactor Label and carefully remove the leads from the input contactor ter minals Note placement for reassembly See Figure F 15 5 With a 5 16 nut driver or socket remove the three mounting screws See Figure F 15 6 Carefully remove the input contactor indi TROUBLESHOOTING amp REPAIR dits INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 15 INPUT CONTACTOR REMOVAL AND REPLACEMENT INPUT CONTACTOR 601 S S Lili T REPLACEMENT PROCEDURE 1 Mount the contactor and tighten the mounting Screws NY T2 2 Connectthe leads to the correct terminals See Figure F 15 3 Replace the case top sides and input access panel POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section T
63. ASBLY oni REVISION cIE i TS SUN RETE 501 B jJ 5 STRP LL DEM a cR Ix ELM I A a Ec E NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp machine ELECTRIC Return to Section TOC Return to Section TOC Return to Master TOC O o Fle 9 gt olg 4 5 oO Return to Section Return to Master TOC Return to Master TOC G 25 ELECTRICAL DIAGRAMS SCHEMATIC VOLTAGE SENSE PC BOARD LINCOLN 8 31 50 m 2 gt TO HEAD P CB lt 143 JLN 3 N BRASS Di 1A 400V Rz 67 LEAD NETWORK lt _ _ TO 40V BUS COM 100v GENERA
64. DRIVES CONTACTOR AND PRECHARGE CONTROL SIGNALS ARC LINK 45V RS232 THERMOSTATS CONTROL BOARD 5 V ARC LINK POWER 45V SPI BOARD S2 WORK SENSE S3 RS232 LEFT S B CAP V F RIGHT S B CAP V F 4 15V SPI 45V 415V 15V tH j LEFTCT RIGHT O CURRENT CURRENT FB FB STATUS THERMAL LIGHT LIGHT In addition the Control Board monitors the ther mostats the main transformer primary currents and input filter capacitor voltages Depending on the fault condition the Control Board will activate the thermal and or the status light and will either disable or reduce the machine output In some conditions the input con tactor will be de energized NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Qo Fie x 9 gt 0912 f c yo Return to Section TOC Return to Master TOC E 8 THEORY OF OPERATION FIGURE E 7 OUTPUT RECTIFIER OUTPUT CHOKE AND STT CHOPPER BOARD MAIN TRANSFORMER IGBT DRIVE FROM CONTROL BOARD POWER WAVE 655 R CURRENT OUTPUT DIODES TRANSDUCER D1 D4 CAP V F FEEDBACK CR INPUT RECTIFIER me HARMONIC FILTER IGBT DRIVE FR OM BoaRD TOCONTROL BOARD IL CAP V F FEEDBACK INPUT s A BOARD 67B VOLT CONTA
65. LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 Return to Section Return to Master TOC diis TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST PROCEDURE CONTINUED FIGURE F 3 RIGHT SIDE AND TEST POINTS 1 AAT AY AT AY WY 1 NS AT YS LEFT 11 NEG POS 13 12 NEG RIGHT 16 NEG POS 18 15 NEG POS TABLE F 1 SWITCH BOARD RESISTANCE TEST POINTS POSITIVE NEGATIVE DIGITAL ANALOG METER METER METER METER X1000 PROBE PROBE
66. O o Fie CiS gt 912 d Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR INPUT BOARD TEST PROCEDURE CONTINUED TABLE F 5 INPUT BOARD VOLTAGE CHECKS LEAD EXPECTED TEST POINTS NUMBERS VOLTAGE READINGS PLUG J 61 PIN 8 H1D SAME AS TO INPUT PLUG J 61 PIN 6 612 VOLTAGE PLUG J 61 PIN 10 T3 A LITTLE LESS TO THAN INPUT PLUG J 61 PIN 2 T1 VOLTAGE PLUG J 60 PIN 3 238 13 15 VDC TO PLUG J 60 PIN 4 604 PLUG 60 PIN 3 238 13 15 VDC TO PLUG J 60 PIN 5 232 POWER WAVE 655 R LINCOLN COMMENTS Present when Input Switch SW1 is closed This is Pre Charge Voltage and will normally be present 6 sec onds after activating Input S witch SW1 The Pre Charge Voltage should remain for approximately 6 seconds and then be removed This is the Coil Voltage for the Pre Charge Relay Normally this DC Voltage will be present 6 sec onds after Input Switch SW1 is activated This 13 15 VDC will remain for approximately 6 sec onds and then be removed The Relay is controlled by the Control Board See the Wiring Diagram This is the DC Coil Voltage for the Control Relay Normally this DC Voltage will be present approxi mately 12 seconds after Input Switch SW1 is activated The Relay is controlled by the Control PC Board See the Wiring Diagram NOTES Poe POWER WAVE 655 R LINCOLN amp F 32 NOL 491Se A uunjeH NOL
67. Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC ais THEORY OF OPERATION ES INPUT VOLTAGE AND PRECHARGE The Power Wave 655 R can be connected for a varie of three phase input voltages Refer to The initial input power is applied through a line switch located on the front of the machine Two phases of the three phase input power are applied simultaneously to the Input Board and both auxiliary transformers The various secondary voltages developed by trans former T1 are applied to the Input Board the fan motor via a control relay and the Bus Board rectifier The 65VDC produced from the Bus Board rectifier is used by the Bus Board to provide various DC voltages for the Power Board the Feed Head Board the Ethernet Gateway Board and the wire feeder recepta cle The 115 230VAC developed on the secondary of auxil iary transformer T2 is applied to the 115VAC receptacle and to the water cooler receptacle The 230VAC supply is also used to operate an auxil iary cooling fan in the upper section of the machine This fan runs whenever the power switch is ON The large fan in the lower section only runs when the machine is producing output It is activated through a solid state relay that responds to a signal from the Control Board Two of the inputlines are connected to the Input Board by way ofthe input line switch
68. exceed the current rating of the cable 8 Using the Diagnostic Utility Software 11 If supply voltages are correct but feedback Establish Communication with the PW655R voltages are incorrect the Current Transducer or Selectthe Calibrate tab wiring from P91 to the Control Board may be Select the 50 amp Current Set Point defective See the Wiring Diagram Select Turn Output ON Use an external calibrated ammeter to read actual current If the actual measured current does not match the set current but the feedback voltage is correct for the actual current perform the 9 Check the feedback voltage at the Control Board plug 8 per Table F 6 Pin 1 lead 211 to pin 6 lead 216 12 Click on Turn Output Off 10 Repeat the test at several other current levels 13 Disconnect the computer 14 Remove input power and replace the control box cover and case top olo O o x Of gt 912 If the feedback voltage is correct for the actual current the Current Transducer is OK TABLE F 6 CURRENT FEEDBACK CHART OUTPUT CURRENT Actual EXPECTED FEEDBACK VOLTAGE 500 4 0 450 3 6 400 3 2 350 2 8 ple 300 2 4 sis 250 2 0 8 200 1 6 5 150 1 2 100 0 8 ele 50 0 4 5 POWER WAVE 655 R LINCOLN NOTES POWER WAVE 655 R LINCOLN amp F 36 NOL 491Se A uunjeH NOL 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH
69. gt 9 5 5 o 5 0 o c c Oo FAY HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PC board switch change The Power Feed Wire Feeders are shipped with both high speed and a low speed gears As shipped from the factory the low speed high torque gear is installed on the feeder To change Gear ratio see Power Feed 10 R Instruction Manual A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves 1 Set the High Low switch code on Wire Drive PC board as follows Turn off power to the power source at the discon nect switch Remove the front cover from the power source The wire feed head board is on the right side of the power source Locate the 8 position DIP switch and look for position 8 of the DIP switch Using a pencil or other small object slide the switch rightto the OFF position when the low speed gear is installed Conversely slide the switch left to the 52 ON position when the high speed gear is installed 12 3 4 5 6 7 8 Replace the cover and screws The PC board will read the switch at power up automatically adjusting all control parameters for the speed range selected POWER WAVE 655 R LI
70. olo O o x gt 0912 Return to Section Return to Master TOC F 63 TROUBLESHOOTING amp 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the switch board s and or filter capacitor s MATERIALS NEEDED Misc Hand Tools Penetrox A13 thermal joint compound CAUTION PC Boards can be damaged by static electricity Remove your bodys static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame f you dont have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static
71. 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 mustbe setto ON on the Wire Feed Head PC Board The default setting of the switch is OFF to represent positive electrode polarity Set the Negative Polarity switch on Wire Feed Head PC board as follows WARNING 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 1 Turn off power to the power source at the disconnect Switch 2 Remove the front cover from the power source 3 The Feed Head PC Board is on the right side of the power source Locate the 8 position DIP switch and look for switch 7 of the DIP switch 4 Using a pencil or other small object slide the switch right to the OFF position for positive electrode polarity Conversely slide the switch left to the ON position for oz lt negative electrode polarity 12 3 4 5 6 7 8 5 Replace the cover and screws The PC board will read the switch at power up and configure the work voltage sense lead appropriately VOLTAGE SENSING The best arc performance occurs when the Power Waves has accurate data abou
72. tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 655 R LINCOLN F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie x Of gt 912 Return to Section Return to Master TOC dis TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A WARNING e ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity
73. wire drive Secure fitting with flow adjuster key at top Voltage Sense Leads K490 10 25 or 50 The voltage sense leads connect at the front of the machine Cool Arc 40 K1813 1 Water Flow Sensor K1536 1 Water cooled guns can be damaged very quickly if they are used even momentarily without water flow ing Recommend practice is to install a water flow sensor such as on the water return line of the torch When fully integrated into the welding system the sensor will prevent welding if no water flow is present Dual Cylinder Undercarriage K1570 1 The Dual Cylinder Undercarriage K1570 1 is not compatible in combination with the Power Wave Water Cooler K 1767 1 Coaxial welding Cable K1796 POWER WAVE 655 R LINCOLN Return to Master TOC Return to Master TOC 4 4 c 2 4 Return to Master sii TABLE OF CONTENTS MAINTENANCE e rrrrrrrrT D 1 Sale Praec QUOS ___ ______________ D 2 Routine and Periodic MAINTENANCE uio crede dct ee doge RR o xt S D 2 Main Assembly Exploded VIG ss a uito gris keane D 3 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O o Fie x Of gt 912 c yo Return to Section TOC Return to Ma
74. 0 85mm2 600 Amps 3 0 85mm2 When using inverter type power sources like the Power Waves use the largest welding electrode and ground cables that are practical At least 2 0 copper wire even if the average output current would not nor mally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used NOTE K1796 coaxial welding cable is recommended to reduce the cable inductance in long cable lengths This is especially important when Pulse welding up to 350 amps CABLE INDUCTANCE AND ITS EFFECTS ON PULSE WELDING For Pulse Welding processes cable inductance will cause the welding performance to degrade For the total welding loop length less than 50ft 15m tradi tional welding cables may be used without any effects on welding performance For the total welding loop length greater than 50ft 15m the K1796 Coaxial Welding Cables are recommended The welding loop length is defined as the total of electrode cable length A work cable length B work length C See Figure A 3 FIGURE A 3 For long work piece lengths a sliding ground should be considered to keep the total welding loop length less than 50ft 15m See Figure A 4 FIGURE A 4 SLIDING GROUND K1796 COAXIAL CABLE MEASURE FROM END OF OUTER JACKET OF CABLE CAUTION When pulsing the pulse cur
75. 1 2 Object Instance LSB see table 3 switch 2 2 Object Instance MSB see table 3 switch 3 Equipment Group 1 Select switch 4 Equipment Group 2 Select switch 5 2 Equipment Group 3 Select switch 6 2 Equipment Group 4 Select switch 7 negative polarity switch switch 7 electrode polarit positive default switch 8 high speed gear switch 8 off low speed gear default off high speed gear DeviceNET Gateway Board DIP Switch Bank S1 switch 1 2 Object Instance LSB see table3 switch 2 Object Instance MSB see table 3 switch 3 Equipment Group 1 Select switch 4 Equipment Group 2 Select switch 5 2 Equipment Group 3 Select switch 6 2 Equipment Group 4 Select switch 7 Reserved for future use switch 8 Reserved for future use TABLE 3 Object Instance POWER WAVE 655 R LINCOLN E H ed joj mjoim io mjo m oim o 2 5 E o o ues e CC al 5 E 45 Ir S o NNA 9 i gt 5 oc o ES 6 Baa LO x ae ascia ger lt maleyo 5 ue t c E I Ds 7 T KS oe gt 3 3 ac e gt gt a 3 CO 10 TH TH Sm gt 9 SoL gE E 59 Qc 3 m Qoc Sit ois o 90 LO W olol lt
76. 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of auxiliary trans former No 2 MATERIALS NEEDED Misc Hand Tools POWER WAVE 655 R LINCOLN F 52 TROUBLESHOOTING amp REPAIR F 52 o lo AUXILIARY TRANSFORMER NO 2 REMOVAL AND ele REPLACEMENT PROCEDURE CONTINUED 5 5 FIGURE F 17 AUXILIARY TRANSFORMER 2 REMOVAL AND REPLACEMENT e gt WATER eic COOLER RECEPTACLE S8 o 9 To AUX ILIARY c TRANSFORME Sje 2 PRIMARY 2 5 50 9 lle al Ni BSS 9 2 E z E E NN id RED To S4 CB2 P 29 7 J amp AUX FAN w e 352 T BLACK REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1 Remove input power to the POWER WAVE 1 Carefully place the transformer into the O o Fie x Of gt 912 Return to Section Return to Master TOC 655 R Remove the case top sides and input access panel Perform the Capacitor Discharge procedure Remove the case back Disconnect the three Molex Connectors indi cated in Figure 17 Remove the transformer mounting scr
77. 206 GAS PURGE INPUT 8 gt 858 Ta 5 SHUTDOWN 15VDC 9 gt 859 POW E R BOAR D 67 4 9 VOLTAGE SENSE i SHUTDOWN 1 INPUT 10 gt 860 212 ROBOTIC VOLTAGE SENSE B SHUTDOWN del 678 262 12444 amp SPI COMMON 0 INPUT B 12 gt 862 X3A Lo 3R A VOLTAGE SENSE SELECT gt 511 A 151 225 4 225A 1244 4 15V a f 268 3 43 SPI 45V j gt SOLID STATE RELAY gt 103 VOLTAGE SENSE SELECT 1J1 gt 512 CONTROL BOARD COMMON gt su42 gt 222 gt 104 lt CONTROL BOARD COMMON o m 4 No 3w VOLTAGE SENSE OUTPUT gt gt 67 415V SPI 266 lt _ 15758 WIRE FEEDER VOLTAGE SENSE 142 67A SPI COMMON gt 1143 267 lt 1444 SPI COMMON AUXILIARY e c TRANSFORMER T1 POWER DOWN INTERUPT gt 4J42 227 lt 7 4 POWER DOWN INTERUPT i H6 oV x 4 _ DC BUS BD 45V 3242 221 45V 2 650 575 ad ais od H5 F F D HEA 0485 ai 15V gt 2242 223 lt 114 15V H4 a 00275 500 247 COMMON ARCLINK 45V 9 5 43 274 LX 4J11 4 45V ARCLINK 45V p 5 47 475 1441 4 40V COMMON Ha POWER BD RECT 54077 Mir HONE POWER ARCLINK COMMON 9 10J435 273 lt 1 ARCLINK COMMON H3A 220 230 xi POS
78. 575V OPERATION COMPONENT VALUES fos d 14 9 16 CAPACITORS MFD VOLTS POWER TOCRS ND PIN NEAREST THE FLAT EDGE OF LED LENS ANODE ALIGNS WITH BLACK LEAD OF LED SOCKET CAPACITORS CONNECTOR CAVITY NUMBERING SEGUENCE 6128 O O NE ON SYNCHRONIZED TANDEM MIG APPLICATIONS J77 J712 OF THE ETHERNET BOARD AND J3 J7 OF THE CONTROL BOARD ARE USED WEWBITE SEE 526621 FOR DETAILS VIEWED FROM COMPONENT SIDE OF BOARD Sa VELAND OHIO U S A THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC REFERENCE EQUIPMENT TYPE INVERTER WELDERS DRAWN BY iwimbley SUBJECT WIRING DIAGRAM MATERIAL APPROVAL PROJECT FEMA 6 16 2006 CRM37721 U OTHER D TOLERAN MANUFACTURING TOLERANCE PER E2056 ON 2 PLAC Cl S PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS DO NO A HIS DRAWIN APPROVED ENGINEER KJUSTICE EN 170 O o O 5 Biz 4 t NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of th
79. 58 AUX ILIARY TRANSFORMER 2 PRIMARY P50 To S4 CB2 amp AUX FAN PROCEDURE 1 Remove the main input power to the POWER 6 Check for 115 VAC at plug P52 pins 1 and 4 WAVE 655 R machine leads 350 to 33A Check for 230 VAC at plug P52 pins 1 and 2 leads 350 to 352 2 Remove any load that may be connected to the 7 115 VAC receptacle 7 1f 115 VAC and 230 VAC are present Auxiliary Transformer No 2 is good 3 Remove the case top and right side 8 If 115 is not present between pins 1 and 4 and 4 Locate plugs P52 and P50 at the Auxiliary 230 VAC is not present between pins 1 and 2 Transformer No 2 Referto Figure F 13 check the associated leads and plugs for 5 Carefully apply the correct input power loose or faulty connections 9 Carefully test for the correct AC input voltage A WARNING applied to the primary windings at plug P50 See the Wiring Diagram ELECTRIC SHOCK can kill 10 If the correct input voltage is applied to the High voltage is present at both primary of the Auxiliary Transformer No 2 and plugs the secondary voltage is not correct the trans former may be faulty Replace 11 Replace any cables ties and insulation removed earlier 12 Replace the case top and side POW
80. 7 CONTROL TD 225 4 540 lt 482 40VDC 3R lt 15 7 4 FAN CONTROL 11 09 222 sasas VOLTAGE SENSE 100 57 0 aay 225 SIS suero D6 262 268 au i VOLTAGE SENSE RECEPTACLE uu SELECT d 238 96 13V e O O TRIGGER 15VDC 1 gt 851 440VDC 5383 886 TRIGGER INPUT 2 gt 852 2 2 604 1246 CONTROL i 2 C 40VDC 6 83 880 y 25i Cue SINGLE PHASE DETECT 1J6 COLD INCH 15VDC 5 gt 855 LOW 1 PHASE COLD IN FORWARD 6 gt 856 a 2J6 CONTACTOR CONTROL cC COLD IN REVERSE 7 gt 857 N A _ VOLT SENSE BD 6 i GAS PURGE INPUT 8 gt 858 s A 2 SHUTDOWN 15VDC 9 gt 859 BOAR D 67 lt 4 9 VOLTAGE SENSE s SHUTDOWN 1 INPUT 10 gt 860 N 67B ROBOTIC VOLTAGE SENSE N E o SHUTDOWN 2 INPUT 11 gt 861 262 lt 12 436 SPI COMMON INPUT B 12 862 2 X3A 3R A VOLTAGE SENSE SELECT gt 41 511 A 15V 1442 5 1 225 A N 225A 1234 4 15V ES a 268A 4 4 SPI 45V i V SOLID STATE RELAY 2 VOLTAGE SENSE SELECT gt 11 512 CONTROL BOARD COMMON gt 5 42 222 7 NK 222A lt 10J4 CONTROL BOARD COMMON 444 o 3w VOLTAG
81. A c2 12 35V amp 33W A env gnd_mops 100V T 20v D 35V 50v 15Volts 250Amps TY sw _ c2 30V RAT 01 38 28 PI 1 asv sov 56 2K 5 62K 5 aw ae Overvoltage op c28 8 249 oo 8 i Shutdown 50V 1000 J43 3 121 gt 55 VDC 15 m 16A 43 200V 60V ove Hd 2 VE lt q 5 Volts Amps 4 A Ax LE LO Jalisco 5 10 m on 16V 16V 16V sv Sw saw 8 saw M SPI 024 332 y i 2 lt Ej olo din 015 x7 S 4 gt IN OUT 5 1A i 4 600V ND J43 5 T L gi 55 5Volts 100 Amp T p au K onvi7s m AM 12 2 35V 50V 35V 33W t ung iA A ud Vib2 _ o 6 600V cj 20Volts D 5 10 475K B cat 200 Amps Fel o 35V 35V 50V Z 249k Gate Drive Wa 9 amp 33W 16 46 150p p 100V c c Kl 016 R22 5 R24 J43 amp N P 5 10 0K i Di J43 t a 50V D6 X6 oO Di E tC 5 m 20Volts x i i GND TL431 9 5Volts 100 Am T2 000 09 022 RM 200 Amps 1 T2 4 9 C29 0115 p 4 47 0 1 Q 2 49 x s 35 35V 50v 33W Gate Drive ME n 1 33W Eg RS232 gt S S 1 12 NOTES
82. Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of either the Control Board the Feed Head Board the Auxiliary Driver Board or the Voltage Sense Board MATERIALS NEEDED Misc Hand Tools Anti static wrist strap CAUTION PC Boards can be damaged by static electricity Remove your bodys static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 resistive cord con nected to a grounded part of the equipment frame f you dont have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC Board must be either conductive anti static or static dissipative POWER WAVE 655 R LINCOLN F 53 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC F 54 TROUBLESHOOTING amp REPAIR 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
83. Cyce and TIME PENOU TP B 4 FION CONC Wer TALI B 5 E Welding Moge kaiia dear a ie MLD De o ce ead ad ME e B 6 Constant Voltage Welding 5 5 B 6 7 4 4 c 2 4 Return to Master POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC OPERATION in SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine A WARNING 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 Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes DA ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause 7 Tx x fire or explosion Keep flammable material away not weld on con
84. DIA MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS R47 R75 2 519400 2001 RESISTOR MF 1 4W 2 00K 1 INE BAR MUST BE FREE OF ENCAESULATION MATERIAL ON BOTH TO BE CENTERED WITHIN 0 100 DO NOT GET ON THE MATING SURFACES OPPOSITE COMPONENT R79 519400 2213 RESISTOR MF 1 4W 221K 1 SURFACES AROUND MOUNTING HOLES AND ENTIRE LENGTH OF SIDE ENCAPSULATION RESISTOR ME THW E TK 17 12 aged N N ENCAPSULATE COMPONENT SIDE OF P C BOARD TO A THICKNESS OF 30 12 00 IN AREA SHOWN RESISTOR ORICA l ENCAPSULATE OPPOSITE COMPONENT SIDE OF P C BOARD TO A THICKNESS OF 25 12 00 N G DO NOT COAT THE TOP SURFACES OR THREADS WITH ENCAPSULANT MATERIAL C15 C16 C17 C18 C19 C20 20 520500 1 CAPACITOR 0 1 1000V 10 BOX 4 TERMINALS MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS u NT C21 24 C25 C26 C27 C28 N gx C33 520500 14 CAPACITOR PPMF 022 100V BOX 5 2 J40 524020 6 CONNECTOR MOLEX MINI PCB 6 PIN TIN 4 PLACES L1 L2 L3 L4 L5 L6 L7 L8 L9 x L10 L11 L12 L13 L14 L15 L16 20 712218 15 CHOKE RF FERRITE BEAD 180 OHM N L17 L18 L19 L20 X DZ13 112702 4 ZENER DIODE 1W 20V 5 IN4747A LNs De D73 ues Hen van Des s anos ZENER DIODE 1W 15V 5 IN4744A ex gA P C BOARD COMPONENT SIDE 0210212 HoA ot 021 074 027 0210 4 112702 40 ZENER DIODE 1W
85. DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 37 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The test will help determine if any of the output rectifiers are shorted MATERIALS NEEDED Misc Hand Tools Analog Volt Ohmmeter POWER WAVE 655 R LINCOLN F 37 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 Return to Section Return to Master TOC F 38 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER TEST
86. FOR PARTS ORDERS ONLY CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING I INCLUDE 25251 INSULATION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED SOLID EDGE PLACE DECIMALS IS 002 in amp 0 05 mm UNITS MATERIAL APPROVAL PROJECT HEFERENCE DO NOT SCALE THIS DRAWING INCH N _ 8 9 2006 numsen CRM38081 141745 L11745 1 PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UNLESS OTHERWISE SPECIFIED TOLERANCE DESIGN INFORMATION EQUIPMENT TYPE INVERTER WELDERS ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the ON 2 PLACE DECIMALS IS 02 in 0 5 mm aee SUBJECT EXCITER BOARD MODULE ASSEMBLY EXCITER BOARD MODULE ASSEMBLY WITH PUBL
87. O dc DELTA 71 HrPUCHL2 pe HaT b ADDR 3 gt die SG_ON OFF lt 71 py H6 uuo a o low SIGNAL TPUEHLA p 33 DATAGI 1320 1 00 g 7 10 i MISD 69 poso 61902 DATA 5 1 01 MOSI 19 rere 5 c ogliz7 DATA AT usc SPECS 125 DATAN ADORI 24 ag 1 04 ET SPLESI 453 olia AS t 21 eposi un i ui cc POSS 01 23 aro vo DATAGLA m SPLCS2 71 posg 012 18 mE Mee Tipos pia H8 2 spam 1 08 ADDRUA 26 B DATAISI 5 NITE i RXD 014 Ins ADRISI 244 OATALION VSTDRY 15 ADORG 43 B2 DATANT MC6B3326CPY25 A15 von uar 35 OATAN2I T ADDRHBP __ 44 is 1 913 ES DATA 94 m 37 DATAILAI 50 au 17014 GND 1 mm RA Woe PS DATARS D BANKH C5 nan BAH Aor are r0 5 0 151 DATAA LAST NO USED R 164 GENERAL INFORMATION BERE a ELECTRICAL SYMBOLS PER E1537 c 165 Ec 9 6 89 10912 144 25 CAPACITORS 022 50V UNLESS OTHERWISE SPECIF
88. PAGE Op 2 Mis 2 BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR SN IPASE DECIMALS IQ 69286 DOCUMENT TOUT c CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER A Aae Eae ntet mcm 1 Yoon PC BOARD SCHEMATIC 63825 _ 0 ae Ed WITH FUBLISHED STANDARDS MATERIAL APPROVAL PROJECT 4 i OROT E ORANA Larrrover Tona doae 901520 CRM37919 8 5 5 5 x m SSS Se Em lito NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC pur o O gt 4 Return to Section Return to Master TOC Return to Master TOC 4 c 2 rm G 19 ELECTRICAL DIAGRAMS G 19 SCHEMATIC FEED HEAD PC BOARD SHEET 2 LINCOLN 8 ENGINEERING CONTROLLED MANUFACTURER No CHANGE DETAIL NEW MOTOR SOLENOID seni m as Kore d GAS SDLENBID CIRCUITRY CIE T 187 9 RLS e bw 87 10 A os ais aw 9 xd 86 10
89. SCALE THIS DRAWING INCH ur meer conss 03498 2 B MATERIAL TOLERANCE t TO AGREE Insight PRINT DIAGRAM TO 10 X 15 5 ON E3269 9 LABEL SHEET SOLID EDGE EN 170 O o O 5 Biz 4 t NOTE This diagram is for reference only It may not be accurate for machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN amp ELECTRIC G 5 COMPLETE MACHINE SCHEMATIC CODE 10630 ELECTRICAL DIAGRAMS
90. Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes MATERIALS NEEDED Analog volt ohmmeter Misc Hand Tools Wiring Diagram POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O o Fie x Of gt 0912 Return to Section Return to Master TOC Return to Master TOC F 18 TROUBLESHOOTING amp REPAIR F 18 INPUT RECTIFIER TEST PROCEDURE CONTINUED FIGURE F 4 INPUT RECTIFIER TEST INPUT RECTIFIER PROCEDURE Disconnect the input power to the POWER WAVE 655 R Remove the case top and Input Panel Perform the Capacitor Discharge P rocedure Locate the Input Rectifier and lead locations Refer to Figure F 4 Use an ohmmeter to perform the tests detailed In If the rectifier does not meet the expected read ings remove the POS and NEG leads and re test If it still fails the test it should be replaced POS NOTE Some of the RTV material will have to be removed Th
91. TRANSFORMER NO 1 REMOVAL AND REPLACEMENT INPUT CONTACTOR FAN MOTOR WINDING 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 4 Remove the case back 5 Disconnect lead X4 from the input contactor coil 6 Remove leads X1 and X2 from the power board rectifier bridge Refer to Figurel6 7 Cut X3 and X5 from the fan motor leads Leave enough length to splice in the new transformer leads 8 Cut the X3 lead that is connected to the input board Leave enough lead length to splice in the new transformer lead 9 Locate label and remove primary lead H1 from circuit breaker CB4 10 Label and remove primary leads H2 H3 H4 and H5 from the terminals on the reconnect panel Note lead placement for reassembly 11 Cut cable ties as necessary and clear the leads 12 Remove the two mounting screws holding the transformer to the fan baffle and the base 13 Carefully remove the transformer from the POWER WAVE 655 R X11 lt gt X2 POWER BOARD RECTIFIER BRIDGE FAN RELAY 3A REPLACEMENT PROCEDURE 1 19 Carefully place the transformer into the POWER WAVE 655 R Secure the transformer to the fan baffle and the base Connect the primary leads H2 H3 H4 and
92. amp ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q o O o Fle Sa 9 gt 091 29 5 Return to Section TOC Return to Master TOC G 8 ELECTRICAL DIAGRAMS SCHEMATIC DEVICENET GATEWAY PC BOARD SHEET 1 LINCOLN 8 6 45 he a le P n UNDERVOLTAGE RESET 45y aris A 0 EEPROM way 0 7 0 I 4 n un a US WO el DATA PU a EG NS 5 40K AD na DATAUS diw E 5 ADOREI 20 45 99 A 15 lo CRYSTAL hb ADORE nave MCU VOOSYN XFC EXTAL ES 159 eSB Za RESET VT D TANO mnz LRLRRRD SEPT EELS 64K X 16 SRAM 7 DATAS 100017 __ 15 DATAIOTS GENERAL INFORMATION ELECTRICAL SYMBOLS FER E1537 PROPRIETARY amp CONFIDENTIAL TU ORER ANTES UR USED POR ANT RUSSE WITHOUT THE PERESS UF GLOBAL MO DIAGRAM MAY NOT SHOW THE SUBJECT SCHEMATIC GATEWAY PCB EAR HAVING A COMMON COUE MATERIAL NA APPROVAL 9725 2006
93. amp REPAIR F 27 POWER BOARD TEST PROCEDURE CONTINUED TABLE F 4 POWER BOARD VOLTAGE CHECKS TEST CONNECTOR LEAD NO OR NORMAL DESCRIPTION PLUG PIN NO IDENTITY ACCEPTABLE VOLTAGE READING CHECK 40 VDC 471 4 38 42 VDC INPUT FROM 475 DC BUS BOARD CHECK 15 225 4 415 VDC VDC SUPPLY FROM 222 POWER BOARD CHECK 5 VDC 221 4 45 VDC SUPPLY FROM 222 POWER BOARD CHECK 15 VDC 222 4 15 VDC SUPPLY FROM 223 POWER BOARD CHECK 45 VDC 274 4 45 VDC ARCLINK SUPPLY 273 FROM POWER BOARD CHECK 45 VDC 226 4 45 VDC 85 232 SUPPLY 228 FROM POWER BOARD CHECK 15 VDC 266 15 VDC SPI SUPPLY FROM 267 POWER BOARD CHECK 440 VDC 478 4 38 42 VDC INPUT FROM 476 DC BUS BOARD CHECK 45 VDC 268A 4 45 VDC SPI SUPPLY FROM 262 POWER BOARD CHECK 420 VDC STT 345 4 420 VDC SUPPLY FROM 346 POWER BOARD POWER WAVE 655 R LINCOLN NOTES ilies POWER WAVE 655 R LINCOLN amp F 28 NOL 491Se A uunjeH NOL 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 29 TROUBLESHOOTING amp REPAIR INPUT BOARD TEST PROCEDURE A WARNING Service
94. are missing or low check to make certain the primary is configured correctly for the input voltage applied See the ELECTRIC SHOCK can Wiring Diagram ing Diagram 10 If the correct input voltage is applied to the prima High voltage is present at primary of d th d the Auxiliary Transformer ry and the secondary voltage s are not correct the T1 transformer may be faulty A WARNING Return to Section TOC Return to Master TOC 11 Replace any cables ties and insulation removed earlier 8 Check for the correct secondary voltages according 12 Replace the case sides and top to Table F 7 NOTE The secondary voltages will vary proportionally if the input line voltage varies from nominal Return to Section TOC Return to Master TOC TABLE F 7 SECONDARY VOLTAGES LEAD IDENTIFICATION NORMAL EXPECTED VOLTAGE X1 to X2 X3 to X5 X3 to X4 olo O o Fie x Of gt 0912 Return to Section Return to Master TOC POWER WAVE 655 R LINCOLN NOTES re POWER WAVE 655 R LINCOLN amp F 42 NOL 491Se A uunjeH NOL 0 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Sect
95. build up Be Sure not to touch any electrically live parts at the same time Tools which come in contact with the PC Board must be either conductive anti static or static dissipative POWER WAVE 655 R LINCOLN F 63 idi TROUBLESHOOTING amp REPAIR dii SWITCH BOARD AND FILTER CAPACITOR olo ele REMOVAL AND REPLACEMENT PROCEDURE CONTINUED 5 5 FIGURE 23 SWITCH BOARD AND FILTER CAPACITOR REMOVAL REPLACEMENT olg 9 5 5 5 5 2 2 x D a 5 2 O n 4 OTTO 2 JE olg 2 2 2 d 5 NX 2 E M NI D AW NEM cs D CAPACITOR TERMINALS REMOVAL PROCEDURE tions Board 9 Remove leads 19C D and 20C D from Lead and plug references below use a slash to the switch board capacitor connection bolts indicate machine right side left side wire number differences 10 With a slot head screwdriver remove the two nylon mounting screws at the bottom of the
96. fire extinguisher readily available Where compressed gases are to be used at the job site special precautions 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 When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper 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 S afe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the
97. in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN 9 machine G 23 ELECTRICAL DIAGRAMS G 23 SCHEMATIC SWITCH PC BOARD O10 O o c i i 5 9 BEST PONT Le Pn z wo we et BTH c 8585542 Dinky A L nen uem 28 Di coor 5 ue kar xd z if OHH m 1 qj oU co ow a p lm _ 5 n I mj I mm d E li T as Eme SF HER JE Bina ERR PHPMAAT T 1 x amas P sn F 1062 a mi PW b t miu aud E bl i og SE d L 1 j Ad FILTER fU CAPACITOR is mo Ll EET 4 x re Ld mat Wo 66 VIE me d ra c 1 O10 T 444 ii PONI ET wur 20 Fi ae a Tua rie 8 Em ER 5 8 faa 5
98. located inside the reconnect input access door for this purpose See your local and national electrical codes for proper grounding methods HIGH FREQUENCY PROTECTION Locate the Power Wave away from radio controlled machinery CAUTION The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O1O O o Fie x Of gt 912 Return to Section Return to Master TOC Return to Master TOC ns INSTALLATION at FIGURE A 1 CONNECTION DIAGRAM ON CONNECTION INPUT ACCESS DOOR WARNING Disconnect input power before inspecting or servicing machine Do not operate with covers removed ELECTRIC SHOCK CAN KILL Do not touch electrically live parts Only qualified persons should install use or service this equipment THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A _____ ____ _____ d 524190 NOTE Turn main input power to the machine OFF before performing connection procedure Failure to do so will result in damage to the machine INPUT CONNECTION A WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electrical codes and the
99. on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment l e some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 11 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running AX 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN amp 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS may be dangerous Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding Current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and
100. rectifier Left side facing machine input configuration 33 Capacitor B under voltage When accompanied by an overvoltage error on the same side it Right side facing machine indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine 34 Capacitor A over voltage Excess voltage on the main capacitors May be caused by improper Left side facing machine input configuration 35 Capacitor B over voltage When accompanied by an under voltage error on the same side it indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine Return to Section TOC Return to Master TOC Right side facing machine Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine 36 Thermal error 31 S oft start error Capacitor precharge failed Usually accompanied by codes 32 35 The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition referred to as noodle welding Secondary overcurrent error NOTE The secondary limit is 570 amps for the standard stud and 325 amps 43 Capacitor delta error The maximum voltage difference between the main capacitors has been exceeded May be accompanied by errors 32 35 49 Single
101. right side of the rectifier assembly Return to Section TOC Return to Master TOC POWER WAVE 655 R LINCOLN TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC NNI iJ Return to Section TOC Return to Master TOC RECTIFIER MODULE TESTING RECTIFIER MODULE REPLACEMENT 1 Remove the leads and copper plate from one of 1 Remove the cap screw from the center and the Diode Module pairs See Figure F 22 two hex head bolts that mount the module to NOTE Observe the placement and the mounting aNG TEMOVE WE MOQUE sequence of the leads and hardware so 2 Apply a thin even film 004 t0 01 of thermal they can be put back in exactly the same compound Penetrox A13 to the module Keep way The assemblies may be different the compound away from the mounting holes depending on the age of the machine Compound in the holes or on the threads of the 2 Using an ohmmeter check the 4 diodes 2 per screws will affect the ability to get the proper olo O o Fie x Of 9 gt 912 Return to Section Return to Master TOC module for shorts If a shorted device is detected recheck at the Output studs as
102. shield covering leads nal is lined up with the correct hole on the switch 11 12 or 15 16 Replace the cable tie board 11 Connect molex plug 40 50 to the top of the 2 All heat sink and IGBT mounting surfaces must be switch board P clean 12 Replace the high voltage protective shield 3 Apply a thin even film 004 01 of thermal P udi compound Penetrox A13 to the module Keep 13 Replace the case top and sides compound away from the mounting holes Compound in the holes or on the threads of the screws will affect the ability to get the proper torque 4 Apply a thin coat of Penetrox A13 to the capacitor terminals Be careful not to apply compound to screw threads or threaded area of terminals Return to Section TOC Return to Master TOC 5 Mount the new Switch Board and tighten the four cap head screws in the following manner Tighten all until snug Tighten all from 24 to 28 in lbs Tighten all from 40 to 48 in lbs 6 Make sure the capacitor is positioned correctly Connect leads 19C D and 20C D to the correct terminals Tighten to 55 in Ibs 7 Position and mount the two nylon screws fiber Spacers and washers Torque from 4 to 8 in lbs 8 Connect leads 11 12 or 15 16 to the correct termi nal Ko O o x Of gt 912 Return to Section Return to Master TOC POWER WAVE 655 R LINCOLN NOTES ibas POWER WAVE 655 R LIN
103. solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible installation et entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux interieur de poste la debranch er linterrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU P card gt Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Troubleshooting and Repair
104. the machine It can also be accessed from the Lincoln Service Navigator or down loaded from the web at Powerwavesoftware com POWER WAVE 655 R LINCOLN TROUBLESHOOTING REPAIR mod CURRENT TRANSDUCER TEST PROCEDURE CONTINUED c 2 FIGURE F 9 CURRENT TRANSDUCER TEST Ofa e gt 09152 CONTROL BOARD cys oye J8 olo 211 212 213 o Ec 14213 4 516 gt ele 5 6 7 8 216 5 5 mu 4 cic acc N A A NN H KA 7 ai HESS SS WS S SYS NON a m x 4 N9 N Y N a SS N NS e gt 5 CURRENT TRANSDUCER 9 ae PROCEDURE 5 2 1 Disconnect the input power to the POWER 5 Turn the POWER WAVE 655 R Check for 9 5 WAVE 655 R the correct DC supply voltage to the current 0912 transducer at plug 8 See Figure F 9 cfc 2 Remove the case top and the control box cover 5 A Pin 2 lead 212 to pin 6 lead 216 510 3 Locate the current transducer leads at Control should read approximately 15 VDC c Board plug J8 See Figure F 9 Pin 3 lead 213 to pin 6 lead 216 4
105. welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible Never coil the electrode lead around your body Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Return to Master TOC Return to Master TOC 4 gt 4 c 2 4 Return to Master 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 6 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 In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while
106. 0 015 5 m aov COMMCARCLINK 5V gt ss 274 4311 ARCLINK 5V POWER BD RECT 540 lt 4047 40VDC POWER ARCLINK COMMON gt 10J43 gt 273 ARCLINK COMMON ae POS lt 1946 40VDC POWER gt 7 47 477 2041 40V i gt 25 CB4 POS 5 lt 2046 COMMON 6447 476 4 sov common P2792 55V 4e Pu fo H 52v esve Ioro Sii m goy 98282 COMMON gt 9 2 228 lt 54 lt RS232 COMMON 51 WIRE FEEDER x2 E DS 612 24000uF 100V RECEPTACLE NEG 4246 12 J 52 lt 40VDC i 01 13 200 gt 1247 51 aan 51 0VDC AUXILIARY E 440VDC FEEDER 347 50 6 _ 52 TRANSFORMER 2 352 1 67 C ELECTRODE SENSE 10A H6A 5 S8 WATER COOLER L5 550 575 352 lt 2 612B 612A 5 56 saa RECEPTACLE i M 53 lt A AROLINK 1 H4 H4A 3 mm gt 4 gt 34 Y 54 lt 33 gt 4 gt 33 i N H3A 2 ov gt 1 S5 DEVICENET n 220 230 EU 350 lt 1 82 1 A s CONNECTOR NOTES H2A Ge 2 1 PC BOARD COMPONENTS SHOWN FOR 5A at i MEE MEME 1 198 nA 1 T 894 2 24VDC BRE NOTSHOWNE ALE COMPONENTS ELECTRICAL SYMBOLS PER E1537 S4 ot 7 cor earlier version 568 Sirens lt 3 115V MO iam 115V RECEPTACLE 2 _ R
107. 1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 Return to Section Return to Master TOC F 22 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST PROCEDURE CONTINUED FIGURE F 5 INPUT CONTACTOR COIL PROCEDURE 1 Disconnect the input power to the POWER WAVE 655 R 2 Remove the input access panel and case top 3 Locate mark and remove the two leads 601 X4 that are connected to the input contactor coil Refer to Figure F 5 4 Use an ohmmeter to check the resistance of the coil It should be approximately 6Q 5 Check the resistance across the contacts Refer to Figure F 5A 1 to T1 L2to T2 and to T3 All three readings should show open If the resistance is low the input contactor is faulty INPUT 601 FIGURE F 5A CONTACTOR TEST POINTS gt 2 S 6 Press in the test button and recheck the contacts as in Step 5 NOTE If a 24 vac supply is available it can be connec
108. 15V SPI THERMOSTATS CONTROL BOARD POWER BOARD S2 WORK SENSE 53 RS232 LEFT S B CAP V F RIGHT S B CAP V F LEFTCT RIGHT CT O CURRENT CURRENT FB STATUS THERMAL LIGHT LIGHT Each switch board feeds current to separate opposite ly wound primary coils in the Main Transformer The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT Switch boards induce an AC square wave output signal at the secondary of the main transformer Current transformers monitor the primary currents If the pri mary currents become abnormally high the Control Board will shut off the IGBTs thus disabling the machines output The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off This is needed due to the inductance of the transformer pri mary windings The firing of the two switch boards occurs during halves of a 50 microsecond interval cre ating constant 20 KHZ output See the WIDTH MODULATION discussion in this section NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 655 R LINCOLN THEORY OF OPERATION ES FIGURE E 4 DC BUS BOARD POWER BOARD FEED HEAD BOARD Return to Section TOC Return to Master TOC o 4 gt lt Return to Section Return to Master TOC
109. 200V D3 Vret e vrer vee 2 28 D19 J42 E N ae oci DC Input 2 do 4 prior _ N x our WE Hy 600V R10 R5 gt 3w 600V 5 GND cs 3 Jat 100K 100K 2 6 4 4 x AD T 0 al ZN 40A n FR 22 AN ul 210 S 121k i Tt 30V 2 475 35V 50V 35V 33W 221 Machine Control A 7 6 Shut Down C6 C7 C45 2 47 R39 R12 189 Capacitor 35V 50v 56 2K 56 olo T am x i 2 0 AK 1 2700p 100 a L 5 J4 GND xi 8 cla DC Input V 55 rast FEF si Coe P EM 15Volts 100Amp 6 AT a X x p 27 35V 50V 35V 0 3 J42 O 8 ADJ gt v T wv i 24V 14 j D 318 318 9 D8 T2 Er WV mcps di gt Undervolt A e Operation Dos c ndervoltage 8 30 55 VDC cot Detect be Z YT 2000 1 d D23 lt 30VDC 600V us pu c Lond i cnY17 3 Dio Q J42 4 6 2 J43 7 vcc our 6 R32 xa 6 i DZ2 C49 ve 8 vnEr 150 D9 6 zo 2 5 pos 4 RrCT n Rat Vibo L 5w 221K IX ADJ 58 C53 75K R29 gt e 6 C26 Els ov ch 100K 024 Ces 023 1 21K 150
110. 28 C POS C POS TO AUX 1 N C 54 4 8 J60 10 LEFT i 87 lt 9 238 292 115V 53 o 350 gt 1 e 1 aas 352 gt 2 RECEPTACLE ml aH lt 2 262 BA TA i x lt Be gt 4 dier M s T 6 ig 404 4 lt 6 CURRENT un 58 f z 31 32 TO 3 WATER Z 5 h TRANSFORMER 414 f a 32A 2 2 J87 lt 9 1 1 RED WHITE k 12 COOLER es pam pam RECEPTACLE lt 5 TO 12 lt NEG POS AUX FAN i 1412 N B 8 gt 1 601 gt 2 L1 7 2W 14 HERM CURRENT J10A gt x3 wins 2B 15 POWER BD TO p TRANSFORMER K lt gt 238 4 L6 54 S5 P E m RECTIFIER gum 80V 2 H 5 1 J60 647 04 HARMONIC 10 lt N twee 1 Sb aig 2 gt 5 232 aux DEVICENET T D2A Ware THIS AREA VIEWED FROM RIGHT SIDE OF MACHINE J6 FILTER 52 77 gt lt seco SWITCH BOARD 22 RIGHT a8 5 i 24 894 TO R 500 WORK 45 zn SSR 24V GND 3 893 J75 ELECTRODE W 4 S2 RIGHT RIGHT 91 gt 5 ITI i CANH 4 892 Q 92 gt Vee INPUT gt CANL 56 841 206A 211 17 gt 3 503 000000 19 1 0 22 ap n RECTIFIER JJ 2 212 J50 4 6 AUX DRIV
111. 3 221 J4 lt lt 8 lt 4 227 lt 2 lt 93 5 222 10 TO 18 lt 40 lt 6 AUX 2 14 lt 4 x 1 CB4 TO AUX 1 lt 15 lt 2 22 475 RECONNECT PANEL L 2 477 TO BOE ml 0 MH 3 476 ur 6 1e 14 lt 1 C lt 444 TP4 X3A 45 DI 4 lt 7 478 TO POWER BD RECTIFIER TO lt 164 24 TO FAN AUX 1 CRI 4 lt 1 lt 4 oni J60 ms lt um Tun 2 4 226 MAIN CHOKE NE 4 m 214 L1 TO SOLID STATE RELAY be WO pe 224A r X5 lt 0 3 D pu UN Mens CIL SHORE TOAUKM 1 1 143 yj TO 4 lt 754 lt 10 273 THERM TO SOLID STATE RELAY VOLTAGE 4 52 741 5 lt 5 lt 1 267 hy 291 SENSE 3 gt 4 19 t X lcu ml ee PI 262 RECEPTACLE 224 22 4 5 g 8 THIS AREA VIEWED FROM LEFT SIDE OF MACHINE 2 54 9 lt i 4 1 SWITCH BOARD 1 LEFT 3 CONDUCTOR 5 lt 10 O case 1 As em 1 X2 DC BUS THIS AREA VIEWED FROM REAR OF MACHINE lt ie 2 m si OUTPUTRECT 4 MAIN TRANSFORMER E gt 1 4 02 Zs za edla 27 m LEFT SIDE 3 Pola RECONNECT PANEL 5 2 1 892 4 lt 6 m J lt 2 POS TO o 800V ene di gt 3 403 i I RS232 6 DEO lt 2 893 712 lt 7 7 3 C3 16 s 54 5
112. 3 278 5 298 904 ROLE CR EORR d OON Are Dos Rari cR CR Roc S G 2 2 Wiring Diagram for Code 10863 3408 1 G 3 Wiring Diagram for Code 11410 53498 2 G 4 Schematic Complete Machine for Code 10630 63611 G 5 Schematic Complete Machine for Code 10863 3611 1 G 6 Schematic Complete Machine for Code 11410 G3611 2 G 7 Schematic Devicenet Gateway PC Board Sheet 1 G3821 2 G 8 Schematic Devicenet Gateway PC Board Sheet 2 63821 2 G 9 s Schematic Ethernet Gateway PC Board Sheet 1 63893 1 G 10 8 Schematic Ethernet Gateway Board Sheet 2 G3893 1 G 11 gt Schematic Ethernet Gateway PC Board Sheet 3 G3893 1 G 12 Schematic Board Sheet 140 3789 2 Pe 3C Od goce E es G 13 E Schematic Control PC Board Sheet 2 63789 2 G 14 Schermiauc Contool PC Board Sheela 63 8922 x oe Code ne Ra HR dow eed Ged ee eed G 15 Schematic Control PC Board Sneet4 63789 2 pina hi au veers wees G 16 Schematic Digital Power Supply PC Board G3631 3
113. 5 TO SUPPLY LINES TO J108 V X TO J9 TO G X 206 58 SIC HEA 215 gt EX TO A SYSTEM GROUND PER BY ND 9 2109 ASSN gg 4 NATIONAL ELECTRICAL CODE fos STATUS LED R G T 05 600 2 lt ale A J2 5 11 06 16 2006 J8 JAD TP2 lt 4 J10A J10B J41 46 72 J47 J60 461 77 28 2 4278 J7 4712 J79 J86 LY Hh I CURRENT 352A 6 J82 tes THERMAL LED T081 YYYY TRANSDUCER l4 gt 1 17 13 1 4 1 5 206A 0 54 0000 00000 AUXILIARY lesa ooo ELECTRODE m AUX FAN TRANSFORMER 2 x 2 374 ioe EROGO 85 RECONNECT PANEL TOP NOTES s P50 JUMPER J413 J1 6 7 ELECTRICAL SYMBOLS PER E1537 MAY NOT BE PRESENT 174 J10 J70 J85 TO J61 LOADLINE CONTACTOR NA PIN NEAREST THE FLAT EDGE OF LED LENS CATHODE ALIGNS WITH BLACK LEAD OF LED SOCKET PEAR COLOR CODING ON EARLIER MACHINES ES 3 443 71 T 87 HID O N B CTs MUST BE ORIENTED IN THE PROPER DIRECTION TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED RIGHT SIDE OF MACHINE B BLACK 555555 655555 1 8 56555555 SIDE OF CT TO THE SWITCH BOARD THE ARROW ON THE CT SHOULD POINT FROM THE SWITCH BOARD TO THE TRANSFORMER GGREEN 5 1 N C PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 550
114. 7 NE 83 me Ae n L1 TO SOLID STATE RELAY i 8 1 841 J43 4 R5 444 9 lt mm 2 842 224 3 843 TO mx ps TO AUX 1 1 14 7546554 56 10 273 TORECT THERM THERM TO SOLID STATE RELAY VOLTAGE 3 u lt 2 lt 5 lt lt 5 845 p 2 E DERE e amp 846 00 291 SENSE 3 Se mem Lii 7 7 m 262 e RECEPTACLE 27 4 lt 8 THIS AREA VIEWED FROM LEFT SIDE OF MACHINE 9 E 22 73 L 1 SWITCH BOARD 1 LEFT 3 CONDUCTOR 3 lt lt 10 lt olo NEPOS 1 m LG e A ep Ra THIS AREA VIEWED FROM REAR OF MACHINE 228 gt 2 OUTPUTRECT 4 MAIN TRANSFORMER ui um RECONNECT PANEL gt 121 x3 09 12 neus 27 LEFT SIDE 32 gt 5 1 4 42 6 856 2 POS TO 00 300V 5 3 403 6 lt 5 7 857 TO lt 54 gt 404 R292 7 251 6 lt 8 858 57 ms G D4A n gt 5 405 3 085 lt 4 4 D CONNECTOR 527 lt 7 9 89 1 jays E SE ND RY gt 6 2 406 lt n 2 Pg 50 74 7 wr o gt CBI 6 lt 19 lt 3 50 TO EFT EFT 52 1 11 12 4 50 CB1 s4
115. 73 CEB s TUS 51 i PCS CSS A118 AGE Ti 6 22 amp iur 5 PUS i8 CS 2 a ae Jus 28 eco ES rca ana PUCHT i s 5 FUNCEN 24 PC2 CS FCO 22 130 21 1387 DATA 2 17 16 138 DATAS 15 133 BATA 1 3 MISO 65 138 st MOST 66 07522 1t SCK 67 125 DATAS oye SRL Cae 68 124 DATAIO 58 C51 89 k n en E EE MEE S w SP C33 n 118 8 507 85252 10 _ 75 117 LT NET KR 05232 RYO 116 jogp 27 RESET 7 78 32 STROBE AD MCSB332PV oap 21 CAPB Uv 39 CAPB Ov 20 LR CAP 2 20 27 O e 23 10158 01681 20 NOTE This diagram is for reference only It may not be accurate for machines covered by this manual THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC N MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 96 sn X27 t 44 it Ss 23 1 ADOR4 27 ADDRB
116. AAAA L1 216 6J8 lt CONTROL BOARD COMMON 406 6 40 IGBT DRIVE 800 320V 1960 gt 2160 x3 845 TACH 2A DIFF INPUT Pot 7 a 8 1 4 160 211 CURRENT FEEDBACK 1 13 i 1 1 1 4 232 846 L 6 84 TACH 2B DIFF INPUT 9 x 25 5 14 lt e POS T e e 12 CELL 5 212 286 5 WORK VOLTAGE SENSE gt 6 9 21A 3 MAIN CONTACTOR CONTROL 7384 SINGLE TACH INPUT 2800uF lt 12 i i 500V 4 swt inb T fate 851 lt 185 TRIGGER 15VDC sai F 414 CT CURRENT 852 L 2385 TRIGGER INPUT S O a 418 lt 2J10A CURRENT i A 13V 853 3 85 DUAL PROC INPUT s 514 lt 08 CT CURRENT THERMAL LED gt 87 2B 4 gt 4J60 602 4 N A E i 854 lt 485 4 STEP INPUT YELLOW RELAY SWITCH BOARD 2 RIGHT GATEWAY BD sie ertum t AY eet s ii 612 gt 4J61 gt T2 855 lt 5 66 COLD INCH 15VDC 53 1473 ARCLINK T THERMAL LED gt 77 5 2W j f 1764 830 I7 i 856 6J85 COLD IN FORWARD 54 lt 2273 i 413V gt 3J60 gt 238 76 405 lt 866 VI
117. ANEL SEE ELECTRONIC FILE CAPACITORS MFD VOLTS Return to Section TOC Return to Master TOC FOR ADDITIONAL INFORMATION DUC ANGE REQD PARTNO DESCRIPTION SEE BLANK INFO P C BOARD BLANK _ NN uua SCHEMATIC REFERENCE 24779 3CO Return to Section TOC Return to Master TOC N A DO NOT COAT WITH ENCAPSULATION MATERIAL N B DO NOT COAT WITH ENCAPSULATION MATERIAL 23 MIN DIA 3 PLACES ON NON COMPONENT SIDE 20 N A 1 80 A 1 79 19540 3 1 55 69 59 u Olor O MAKE E1911 ROHS ENCAPSULATE WITH E1844 2 DIPS MANUFACTURED AS TEST PER E3689 VS 20 8 cm 4 0 5 04 0 1 00 2 00 19540 3 O o e 5 9 gt 09128 cc VOLTAGE SENSE SELECT R2 ALL COMPONENTS AND MATERIALS USED IN THIS STRP IDENTIFICANO CODE ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 B DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 9 UNLESS OTHERWISE SPECIFIED TOLERANCE REFERENCE 5 8 ON2PLACEDEGMALSISE Qo EQUIPMENT TYPE COMMON DIGI
118. BE COVERED 0109 5 D 2 09129 6 00 4 04 cic 515 9 t x MAKE PER E1911 ROHS mE Em MANUFACTURED AS SCHEMATIC REFERENCE M19528 2B0 L11396 2BO IDENTIFICATION CODE ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CON OTHER PARTIES USED FOR PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUEACTURNG TOLERANCE PER E2086 DESIGN INFORMATION EQUIPMENT TYPE INVERTER WELDERS PAGE 1 OF OF _ ON 3 PLACE DECIMALS IS 002 DRAWN BY L11396 1 1 DOCUMENT DOCUMENT Wed epic Me NEEL BORD eet Ed WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT L11 2 APPROVED 11 UF page 3 16 2007 CRM34409 396 B SOLID EDGE STRP Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
119. CEDURE 1 Disconnect the input power to the POWER 5 Turn on the POWER WAVE 655 R Carefully WAVE 655 R test for the correct voltages at the Power Board 2 Remove the case top 3 Locate the Power Board and plugs 42 and 43 Do not remove plugs or leads from the Power Board Refer to Figure F 7 4 Carefully apply input power to the POWER WAVE 655 R A WARNING e ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine according to Table F 4 6 If either of the 40 VDC voltages is low or not present at plug J 41 perform the DC Bus PC iring Diagram Also perform the T1 Auxiliary Transformer Test 7 If any of the DC voltages are low or not present at plugs J 42 and or J 43 the Power Board may be faulty 8 Replace the case top POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O1O O o Fie x Of 9 gt 912 Return to Section Return to Master TOC Return to Master TOC F 27 CHECK POINT LOCATION POWER BOARD CONNECTOR PLUG 41 POWER BOARD CONNECTOR PLUG 42 POWER BOARD CONNECTOR PLUG 42 POWER BOARD CONNECTOR PLUG J 42 POWER BOARD CONNECTOR PLUG 43 POWER BOARD CONNECTOR PLUG 43 POWER BOARD CONNECTOR PLUG 43 POWER BOARD CONNECTOR PLUG 41 POWER BOARD CONNECTOR PLUG 43 POWER BOARD CONNECTOR PLUG 43 TROUBLESHOOTING
120. COLN amp F 66 NOL 491Se A uunjeH NOL 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 67 TROUBLESHOOTING amp REPAIR CALIBRATION PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in checking and if necessary adjusting the calibra tion of the Power Wave 655R Calibration should be checked as part of the Test After Repair and or if the Control Board is replaced MATERIALS NEEDED Diagnostic Utilities Software Laptop or other Suitable Computer RS 232 Serial Modem Cab
121. CTOR AND PRECHARGE SENSE ECHAR e CONTROL SIGNALS FROM BOARD FROM CONTROL BOARD CONTROL BOARD IGBT RELAY DRIVES ARC LINK 115 VAC 5V RS232 CONNECTION se TO WIRE DRIVE POWER ARC LINK WIRE BOARD 15V SPI Ea C LEFTCT RIGHT CT O O CURRENT CURRENT FB FB STATUS THERMAL LIGHT LIGHT VOLTAGE SENSE OUTPUT DEVICE NET TO TO ETHERNET LEFT RIGHT GATEWAY BOARD VOLTAGE SENSE SELECT CONNECTION ARC LINK TO 0 ROBOT AUX RECONNECT or lt fh CONTROL BOARD 52 VAC A 65 VbC BUS BOARD DC RECTIFIER BUS BOARD sv 40 VDC OUTPUT RECTIFIER OUTPUT CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level The output choke is in series with the negative leg of the output rectifier and also in series with the welding load Due to the current smoothing Capability of the output choke a filtered DC output current is applied through the machine output termi nals to the welding arc NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE 655 R LINCOLN E 8 ELECTRODE TERMINAL OUTPUT ENRE CHOKE TO FAN RELAY CONTACTOR AND PRECHARGE CONTROL SIGNALS THERMOSTATS S2 WORK SENSE S3 RS232 LEFT S B CAP V F RIGHT S B CAP V F Return to Section TOC Return to Master TOC Return to Section TOC Re
122. Carefully apply input power to the POWER should read approximately 15 VDC WAVE 655 R NOTE Do not attempt to check the voltages at the Current Transducer connector The termi A WARNING nals are small and delicate and may be damaged if probed with meter leads ELECTRIC SHOCK can kill o If the DC supply voltages are not present the High voltage is present when input control board may be faulty If the supply volt power is applied to the machine ages are correct procede to Step 6 Return to Section TOC Return to Master TOC POWER WAVE 655 R LINCOLN amp TROUBLESHOOTING amp REPAIR did CURRENT TRANSDUCER TEST PROCEDURE CONTINUED 9 c 2 FIGURE F 10 RS 232 Ola 2 2 E amp o 5 2 ae RS 232 PORT c G f ONO 9 6 Connect a laptop computer to the PW655 R via If the feeback voltage is not present check the olg the RS232 port on the front of the machine See wiring from the Control Board to the Current ele Figure F 10 Transducer See the Wiring Diagram 2 2 7 Connect a Load Bank or 50 weld cable to the CAUTION If using a weld cable across the output Positive and Negative Output Studs of the Studs instead of a Load Bank do not PW655 R
123. D ELECTRICAL DIAGRAMS RIB 475 CED Rig 221 RIS 475 AW R17 475 tT VV Ws p 38v NOISE OND NOISE_ GND Dig 16v ae B 43 85 a 4 SCK7 1 f 5 ip 2510153 5152 CPLD RES 35 THERMOSTAT 4 elt gral t 1 0 rid Sloan mn UV 4 rer Soa Sav es 72 Cun 42 82007 MMSZ523 82007 4 B 5 2 36 10 ad n FILTER CAPACITOR VOLTAGE MONITORING 6 WALENT s 8 R2 5 R34 V E 1240138 CD Wi rapes 475 l014A MM QUT 16 016A E 02 SAH Blow 51v aaoo 019 172 MMS25231 4 R3 455 SINGLE THREE PHASE DETECT INT 1 3PH THERMOSTAT n 17 51251 e 5 59 15 SALTS MMBRI3 LTS MMBRIZOLTS FR R16 221 R161 221 T 1 2 co4 m 187 4 7uF 1 5W 15MB5938 WOE m 7486573 E uf 1 RES 1 C185 1 DATA G 15 DATA 38v 35V 2 Ear 3 M ois MMBT4403 m 1 jd 2122 10 9K RB SL 22 1k Rae es 1 3 1 ns E 35 1V
124. E x 1 S5 DEVICENET j AC 32 1 CONNECTOR NOTES CB3 3 32 31 SER CB2 1 PC BOARD COMPONENTS SHOWN FOR aU ma 1 gt UG T 894 24VDC ELECTRICAL SYMBOLS PER E1537 54 ee y 27 32A 4 earlier version 115V 7 115V 893 lt 3 24V GND RECEPTACLE 2 RECEPTACLE 892 44 CAN HH Neutral Bonded UR ERAN Neutral Floating L l 891 lt 5 CANL PROPRIETARY amp CONFIDENTIAL 5 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED 23 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC RAN MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION INFORMATION REFERENCE EQUIPMENT TYPE POWERWAVE 655 R i ON 3 PLACE DECIMALS IS 002 DRAWNBY RAS G3611 1 DOCUMENT DOCUMENT ON ALL ANGLES IS 5 OF A DEGREE SUBJECT MACHINE SCHEMATIC NUMBER REVISION MATERIAL TOLERANCE t TO AGREE ENGINEER PW SCALE WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT a DO NOT SCALE THIS DRAWING NONE Joisposition NA 03 01 2007 nummer RM38677 G3611 2 EN 170 SOLID EDGE NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 5 9 gt 8 EIS cic LINCOLN
125. E SENSE OUTPUT 232 67 15V SPI 6 3 266 aui 18 SPI 1 i SPI COMMON WIRE FEEDER VOLTAGE SENSE 132 gt 67A SPI COMMON 11y43 267 14 AUXILIARY 7 c POWER DOWN INTERUPT gt 4 42 227 74 POWER DOWN INTERUPT 1 o ig DC BUS BD 45V 9042 221 45V p H6A ede 045250 15V gt 2342 223 114 15V cc 500 247 COMMON ARCLINK 45V 9 5435 274 h 4 11 45V ARCLINK 45V 880 415 COMMON gt 5147 475 1341 4 440V COMMON POWER BD RECT 540 lt 4047 40VDC POWER ARCLINK COMMON gt 10J43 gt 273 ARCLINK COMMON i Pos 1046 40VDC POWER gt 7247 477 241 4 440V i 2 POS Eoo new common 75222 5 99 226 4 RS232 45V A FUSE 65VDC C3 ee pue ide P8292 COMMON gt 344 228 lt 54 lt 5232 COMMON 51 WIRE FEEDER 612 x2 24000uF 100V E fx NEG NEG 345 RECEPTACLE UL 612 N nm NEG 46 L2 52 D 40VDC 03 01 200 gt 147 51 WW 51 0VDC AUXILIARY 7 440VDC FEEDER 3 47 50 52 TRANSFORMER 2 352 1 67 C ELECTRODE SENSE 10A 58 WATER COOLER 550 575 352 lt 2 CB2 Dd 33A 4 RECEPTACLE Lk 53 ARCLINK ay 4 gt 88 5 Vann ARCLINK 33 gt 4 gt 33 m
126. ECEPTACLE 892 44 CANH Neutral Bonded Neutral Floating ae L l 891 65 PROPRIETARY amp CONFIDENTIAL 115 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED 22 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 7 MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION ON 2 PLACE DECIMALS IS 02 PLACE DECIMALS IS 002 DRAWN ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE ENGINEER WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING REFERENCE EQUIPMENT TYPE INVERTER WELDERS SUBJECT PW655 R MACHINE SCHEMATIC eod ENSOR MATERIAL APPROVAL PROJECT E N pare 01 13 2005 Jumper CRM 36674 G3611 1 EN 170 SOLID EDGE NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 5 9 gt 8 EIS cic LINCOLN amp ELECTRIC EY ELECTRICAL DIAGRAMS COMPLETE MACHINE SCHEMATIC CODE 11410
127. ED FROM REAR OF MACHINE mu Bu 28 8 ah OUTPUTRECT MAIN TRANSFORMER RECONNECT PANEL gt 4 3 268 Wap 5 855 2 1 POS J 022 LEFT SIDE 22 5 TO 4 342 6 856 TO fow 300V 3 403 i i 892 J46 4 2 POS J40 E RS232 6 42 2 893 TO 5 mue 7 lt 857 lt 3 NEG C3 SAL 16 734 gt J6 CONNECTOR 7 21 pixie 85 4 4 a 26 J854 lt 8 lt 858 57 4 NEG D4A 5 45 4 olo ae 8 21 aje x 1 51 PRIMARY 4 lt 2 lt 5 804 6 ees lt 2 500 6 lt lt o 0 gt 1 52 TO 5 10 2 12 862 3 T 50 EFT 11 4 540 54 10A CIRCUIT L2 2 lt 830 V 12 D m 512 MW _ 5 415 J41 9 LL 44 5t 18 J47 lt 3 N lt J82 BREAKER 50 1 TO 6 476 x 16 15 81 o 4 lt lt 2 224 16 251 477 aan J L 1 opcra 220 THEM a 8 M 4 54 TOSWI gt TO 4 lt a 5 5 5 i ELECTRODE isma zs E S cic lt 2 2 m 27 4 7022 H i pen c 63 lt 5 220N ow 2 800 H5 e 440 4601 4 J86 DC BUS 12 50 0 o za 5 504 to 756 THERM De H6 550 575V 7 lt D 6 302 40 8e 93 PRIMARY 11 13 12 14 x7 A50 2
128. ENT PROCEDURE CONTINUED FIGURE F 14 INPUT RECTIFIER REMOVAL AND REPLACEMENT INPUT RECTIFIER REMOVAL PROCEDURE Remove input power to the POWER WAVE 655 R Remove the case top sides and input access panel Perform the Capacitor Discharge procedure Remove the RTV sealant from the input rectifi er connection terminals See Figure F 14 Label and carefully remove the five leads from the input rectifier terminals Note placement for reassembly See Figure F 14 Using a 3 16 allen wrench remove the two mounting screws and washers from the rectifier module Carefully remove the input rectifier module HEPLACEMENT PROCEDURE NOTE Any instructions that are shipped with the replacement part will supersede these instructions Clean heat sink surfaces Apply a thin even film 004 t0 01 of thermal compound Penetrox A13 to the module Keep the compound away from the mounting holes Compound in the holes or on the threads of the screws will affect the ability to get the proper torque Mount the module to the heat sink and evenly torque the mounting screws with washers to 44 in lbs Assemble the
129. ER BOARD X3 9 58 v 6 7 E S6 p14 ae 5 Ne pos O ROBOTIC 52 i gt enn Sw c WIREDRIVE CB2 gt 3 503 TO 816 1 1 INTERFACE gt 4 gt f 508 8 82 Pos gt 4 10A CIRCUIT gt 5 302 J6 2 4 4 206 POS O gt 9 gt 4 o RECEPTACLE BREAKER 6 205 n TO J1 VOLTAGE SENSE 4 73 o gt 7 225A J42 3 202 ELECTRODE 1 o 9 A 31 8 403 050 29 E bep es i TO J61 I gt 406 5 12 POWER BD RECT SECONDARY PRIMARY D 843 7 1 emits IGHT IGHT TO J60 T3 T2 n m olo ECT 55 VOLTAGE SENSE 5 5 G 87 SELECT BOARD C iem TO CT 2 2 13 6 colo c c lt 8 1 154 io 1 2 co TO lt 1 512 2 4 38 o 16 18 15 17 lt J83 2 82 C 1 NEG NEG C o k 51 J84 lt 3 67 To TO AUX 1 L3 L2 515 41 I 32A c RIGHT SIDE E iu lt 522 2 lt sza 110 2 678 Re 56 V U GND A 2 s 14 TO SUPPLY LINES 2 J10B 1 lt i TO 9 TO 50 G A Num 206 5 HEA TO SYSTEM GROUND PER i 3 4 gt 350 21 6
130. ER WAVE 655 R LINCOLN amp TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the input rectifi er module MATERIALS NEEDED Misc Hand Tools Torque Wrench Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 Return to Section Return to Master TOC F 46 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEM
131. ES 18 400 UNLESS OTHERWISE SPECIFIED SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE 8088D THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER PROPRIETARY amp CONFIDENTIAL THIS DOCUMENT REFERENCE CONTAINS PROPRIETARY INFORMATION OWNED THE LINCOLN ELECTRIC CO BY LINCOLN ELECTRIC GLOBAL INC MAY CLEVELAND U S A NOT BE DUPLICATED COMMUNICAREO TO OTHER MLO NONE PARTIES OR USED FOR ANY PURPOSE WITHOUT DO NOT ENGR MEO scate _ MATERIAL THE EXPRESS WRITTEN PERMISSION OF SCALE THIS EN sw 1 Ca Dn Tur OR BY MAB APPD DISPOSITION GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 G 21 2 gt J69 3 CONTACTOR rms LKI LUIL LUNISCL 4 gt J60 CAMNTAC TOD COUTO 5 LUA EHU TUI LON gt 131 FROM CONTROL BOARD 4 PRE CHARGE CONTROL F J60 H3v 02 o tA 1500 8 SINGLE PHASE LAST USED 8 25 SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION 7777 FRAME CONNECTION TE EARTH GROUND CONNECTION TIRE INVERTER WELDERS SUBJECT SCHEMATIC INPUT PCB DOCUMENT REVISION APPROVAL PROJECT 4 DOC pate 8 3 2006 MER 38146 a M19528 280 NO
132. F C M i AUX RECONNECT 857 7385 COLD IN REVERSE 505 m tL 5 ee 2726 ARCLINK H SINGLE PHASE DETECT 281 2800uF 504 lt 5 6 VIF STATUS LED HI FOR RED 37 1w dp gt LOW 1 PHASE 858 l 4 885 GAS PURGE INPUT 500V T L__ 172 ARCLINK L i M i 18 4 505 lt 10064 REDIGREEN gt Se 440 460 859 SHUTDOWN 15VDC 1 lt 3 72 lt COMMON QO STATUS 2 eso S 154 lt 1311 ARC LINK H v 503 3J50 IGBT DRIVE 4172 40VDC c 860 lt X 10088 SHUTDOWN 1 INPUT um 222 is T ARC LINKL STATUS LED HI FOR GREEN gt 47 gt 1B 5 861 11985 SHUTDOWN 2 INPUT 504 lt 450 V F 894 5 754 424VDC e S6 ROBOTIC _ 505 5350 893 lt 20754 424V GND N 301 14J6 IGBT DRIVE INTERFACE 862 lt 1285 INPUT B RECEPTACLE 506 6 50 IGBT DRIVE Reb Wire 8 2 lt 5 lt 302 lt 666 lt IGBT DRIVE AUX DRIVER BD 154 208 ARCLINKH ae ee Wo 891 TX 4754 1 TACH 15VDC A gt 841 153 1 82 ARCLINKL m TACH COMMON gt 844 gt BJIAD 403 TACH 1A DIFF SIGNAL gt 842 TACH 1B DIFF SIGNAL D gt 843 406 741 lt 2081 ARCLINKH V POS oe
133. 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 CAUTION Excessive voltage drops at the work piece connec tion often result in unsatisfactory pulse welding performance 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 CAUTION The
134. G 522 83 SOLENOID INPUT 11 Pm 270 D1 D8 RS232 COMMON 1J2 gt 251 7 206A i 539 MOTOR 28000 pu n L 20 8 13 F o o i 541 lt 23383 MOTOR Ri TP3 5 3 500 150V CURRENT 80J x4 Wo 841 lt 184 H5VDC TACH Pm 270 TRANSDUCER 403 lt 340 IGBT DRIVE ii 202A 202 1 lt 339 ELECTRODE VOLTAGE SENSE TACH 1A DIFF INPUT aie ELECTRODE 404 490 inm CO lt 3 4 TACH 18 DIFF INPUT e 2 52 VOLTAGE SENSE t INPUT BOARD 4858 CHOKE RECEPTACLE ae 844 4184 TACH COMMON 270 11 216 lt CONTROL BOARD COMMON 406 6 40 IGBT DRIVE 55 55 ei 320V lt 160 gt 260 gt L 845 5984 TACH2ADIFF INPUT 160 211 1 X 18 lt CURRENT FEEDBACK lt 1 413V 11 PIA faa 4 CH so gt 232 _ 846 lt 884 TACH 2B DIFF INPUT 5 A S SUE ae 213 lt lt 15V L4 SS 0 n s ii Se NN 1 WORK VOLTAGE SENSE gt 69 3 21 MAIN CONTACTOR CONTROL 847 7384 SINGLE TACH INPUT cs i m 495 418 i 2800uF 12 ajo 500V I 4 rower En SES A Poe a d 414 1104
135. G 15 017 MMAT 4403 HCPL 8601 2181 2194 18 BK 475 016 MMBT4483 5 HCPL 8601 w GCAN THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION EQUIPMENT TYPE INVERTER WELDER PAGE 2 oF 4 DRAWNBY FEI ON ALL ANGLES S SOFA Dean SUBJECT SCHEMATIC DIGITAL CONTROL NUMBER Revision E MATERIAL TOLERANCE t TO AGREE ENGINEER SCALE a WITH PUBLISHED STANDARDS MATERIAL yp APPROVAL PROJECT CRMI0115 GA G3789 2FO B DO NOT SCALE THIS DRAWING APPROVED 2 NONE _ DISPOSITION DATE 10 26 2006 NUMBER 9 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 14 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle Sa 9 gt 912 E 5 oO cc Return to Section TOC Return to Master TOC G 15 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BOARD SHEET 3 LINCOLN amp ELECTRIC 03C 68 5 ENGINEERING CONTROLLED CHANGE DETAIL PAGE 3 R65 REVISED VALUE MANUFACTURER
136. H5 to the proper terminals on the reconnect panel Connect primary lead H1 to circuit breaker Splice the X3 lead of the new transformer with the X3 lead connected to the input board Splice X3 and X5 leads of the new trans former to the fan motor leads X3 and X5 Connect lead X4 to the main contactor coil terminal Connect leads X1 and X2 to the power board rectifier bridge Reposition any wire leads and install cable ties aS necessary Replace the case back sides and top POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 51 TROUBLESHOOTING amp REPAIR F 51 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call
137. HEORY OF OPERATION FIGURE E 2 INPUT VOLTAGE AND PRECHARGE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fie x gt oje f Return to Section TOC Return to Master TOC IGBT DRIVE POWER WAVE 655 R BOARD CAP V F FEEDBACK CRI INPUT RECTIFIER HARMONIC FILTER IGBT DRIVE FROM BOARD ARD CAP V F FEEDBACK 67 FE VOLT SENSE CONTACTOR AND PRECHARGE BOARD CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD OA RELAY gt 115 52 50 65 gt BUS BOARD DC 11 RECTIFIER BUS Auxiliary Fan AUX RECONNECT Or lt FfN BOARD 40 VDC 40 VDC ARC LINK WIRE ui FEEDER RECP GENERAL DESCRIPTION The Power Wave 655 R power source is designed to be a part of a modular multi process welding system It is a high performance digitally controlled inverter welding power source capable of complex high speed waveform control The Power Wave 655 R is designed to be used with the family of Power Feed wire feeders operating as a system Each component in the system has special cir cuitry to talk with the other system components so each component power source wire feeder electrical accessories knows whatthe other is doing at all times The components communicate with Arc Link TO CONTROL BO
138. IED 07 98 oe 51 88 m 11 19 37 4751 72 8 109121 135 RESISTORS Ohms i 1 4W UNLESS OTHERWISE SPECIFIED LABELS 10 397 590 50 5 sv ies jp CDM T EDT E Pc SYMBOL INDICATES WHEPE TEST POINT PADS SHOULD ac cb dc CMM ee fj SUPPLY VOLTAGE MET Lr T Tm TES 2 107120178 1342 x LE GNO ADDED ON SECONDARY SIDE OF ARTWORK POWER SUPPLY SOURCE POINT 5 7 COMMON CONNECTION FRAME CONNECTION mia EARTH GROUND CONNECTION Hi Vo THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC SINCE COMPONENTS OR CIRCUITRY ONA ESIGN INFORMATION PRINTED CIRCUIT BOARD MAY CHange 0510 INFORMA REFERENCE EQUIPMENT TYPE COMMON DIGITAL CONTROLS PAGE 91 03 01 OF 03 WITHOUT AFFECTING THE INTERCHANGE pRAWN MJH N MATT s ABILITY OF COMPLETE BOARD THIS BILITY OF A COMPLETE EOAR SUBJECT SCHEMATIC ETHERNET GATEWAY PCB humeen REVISION COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual SCALE THIS MATERIAL NA APPROVAL APPROVED DRAWING nisPnarrinw DATE 1 25 02
139. IN lt 11 dp ou 52 V Ab i 5 058 2 50 7B AreVOLTS 035 1 1 gat t 939 7462 BAV9S 815 51v iV A 1 2 r YAN a 1 29 GU 1 28 3 E E MMSZ5231 t m 525231 9 E MMSZ5231 8 MMSZ523 s 5 e 4 R74 R76 1 1 568k 1 506 1 80 150k TURM OFF N zi 2 2 2 2 amp 4 MMS28231 MMSZ5231 A MMSZ52 51 Meza 3 4 afa Hite 2119 742 25 AL 1 2N 172W T 1 4 MN 475 SH Ys Bd 1 1 1 al er MERECE PN VOLTAGE FEEDBACK ey AGHA THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUFACTURING TOLERANCE PER E2056 REFERENCE EQUIPMENT TYPE INVERTER WELDER ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 DRAWNBY FEI G3789 1E2 DOCUMENT DOCUMENT MM ME onsen 8807 GE CEN RS on APPROVAL WITH PUBLISHED STANDARDS MATERIAL PROJECT DO NOT SCALE THIS DRAWING NONE par 10 26 2006 numper CRM22115 GA G3789 2FO EN 170 SOLID EDGE NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 15 SS ELECTRICAL DIAGRAMS G 16 SCHEMATIC CONTROL PC BOARD SHEET 4 128 _05 ATS 3
140. IOPES e es orc FWHD CPB IOPB1 182 1 MF IOPC2 PB CuPT I0PB0 l c 5 ay faloionc3 100 STON te 1 a 67 1 1 5 20 D n 0 RIA Ba CAP2 0zP2 10PC5 58 gt 5 1 26 2 gt 55 94 _ o T 0 O 44 4 45 1 92 ae 1 5 e e 5N XILINX gt o DATAS Pm 4 m B 49 s GAIA 3704 520 5 0208 8 BE 458Pb fA 1550 E AS OJIS ANY Ripa 01 m 2 gt 9 ES V R223 180 R282 332 42 015 at 18 J3 3 T4HC245 R224 10b 1 2 i 2 a 1 E eee t creed IR TTA SOS QUA ANa ale te E 1 R226 199 8 OI eH 18 tc 5 48 j 8227 100 29 d 7 E i 2 5 8028 100 532 5 2 1 1 Y 12 Bae HEE A SES ang 45V 2 AT2 128 ASV 5 se amp 2182 5 4 75K i i 54 5 i 74ACiA Biv TM 1 20 525231 22pF THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRE
141. ISHED STANDARDS LINCOLN machine Return to Section TOC Return to Master TOC G 29 ELECTRICAL DIAGRAMS G 29 SCHEMATIC AUXILIARY DRIVER PC BOARD OJO ge 5 5 IT D S 15V FROM POWER BD D2 mm 6 5 0 9 Vin Vc our 40 7 5 CONTROL BD 5 Ld Xi GND e INV IN 01 8 gt 50V Um TO PULSE TRANSFORMER 221K LEFT SIDE Vin Vc OUT 9 TO CONTROL BOARD X DRIVER OUTPUT INV EN 50V 41 Rm 2 21K c 4 o 2 4 Return to Master TOC TO PULSE TRANSFORMER Ly T a5V RIGHT SIDE lo J1 o o gt 51 6 5 2 1 NOISE GROUND z 2 FROM POWER BD Im NOISE GROUND c E gt TO CONTROL BD elo cc THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC NOTES file name 24530 1AB GENERAL INFORMATION LABELS HA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED A CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER 21537 SUPPLY VOLTAGE NET 7 7 CONNECTION THE INTERCHANGEABILITY OF A COMPLETE BOARD CAPACHORS MFO 022 50V UNLESS OTHERWISE SPECIFIED PO
142. ITRY OF CONTROLS HAVING A CUMMUN CULE NUMBLH _ APPROVED ORAWING preeosrmow 12 26 02 CRM34209 3893 140 A D NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 o O gt Return to Section 4 c 2 rm Return to Master G 13 SCHEMATIC CONTROL PC BOARD SHEET 1 LINCOLN amp ELECTRIC EN 170 O3c 68 9 ENGINEERING CONTROLLED CHANGE DETAIL 3 R65 REVISED VALUE MANUFACTURER Yes R268 221k AAA i R88 221 Has R269 2 216 R14 221 NOISE ONG RAT T P HERMAL LED AAA 4 75 MMBTA481 NOISE GNO ay CONTROL s nias 18485931 081 ARES 1 3 3 R36 475 e Ix R11 475 475 LEVEL IN gt E 5 025 51y R187 26 7K MMS25231 V NORMAR FAULT R38 RSS NOISE_ A 22 1k R136 1 80k Dv DAVIS R135 1 004 3 2 05 1 R85 RAV 1 24 C78 MMSZ5231 Been 2 2 NOISE OND R37 OV HORMAR 5v FAULT R168 1 48 23 tk 22 1 NOISE ON
143. ITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER ON ALL ANGLES S S OFA DEGREE MATERIAL IBLIBHED STI SOLID EDGE NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 20 SCHEMATIC FEED HEAD PC BOARD SHEET 3 ELECTRICAL DIAGRAMS G 20 olo O O FE 0352950 ENGINEERING CONTROLLED CHANGE DETAIL NEW 01 9 MANUFACTURER 4 2 2 TR CNCHINTIR cdd m 5 P TT c J85 1 LZ is dae c ee ARE TK Rus 515 TRIGGER TEER gt oy BATAEO 113 a 28518 wae A T 30 du m mui om M DUAL mds PROCEDURE Y POWER MONITOR mds e m mia ps ja mms 285 3 STEP r J85 4 WA O iiy 30 che O O o 9 O m TPI E 48515 re GAS PURGE E 218 FUTE 38516 eta iw L h ve LAM pit Im Uk 1 KAK 3 SATEASLTI im m Fit 26517 vv Tih M ida 0 ohn PR ruse
144. L INFORMATION LAST NO USED g 3 ELECTRICAL SYMBOLS PER E1537 c 1 CAPACITORS MFO 022 50 UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A400V UNLESS OTHERWISE SPECIFIED SUPPLY POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION T NT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL 10 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC rererence EQUIPMENT TYPE WIRE FEEDERS DRAWN BY JPZ YY Y SUBJECT SCHEMATIC V SENSE SELECT 20907 DOCUMEN S24779 3C0 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER G 25 2520 ELECTRICAL DIAGRAMS G 26 PC BOARD ASSEMBLY VOLTAGE SENSE PC BOARD OVS6LIN ENGINEERING CONTROLLED CHANGE DETAIL REVISED MAKE SPECIFICATION MANUFACTURER No R 3 BOARD BLANK INFORMATION 113640 18 BUY COMPLETE AS 19540 2 LAYER BOARD PER E3281 e 54 BOARDS PER P
145. L SIGNALS FROM CONTROL BOARD VOLT SENSE BOARD FROM CONTROL BOARD RELAY 3 115 VAC 52 50 65 VDC AUX RECONNECT 4 DC T BUS ge BOARD 40 VDC ARC LINK WIRE 5 FEEDER RECP SWITCH BOARDS AND MAIN TRANSFORMER There are two switch boards in the Power Wave 655 R machine Each contains two input capacitors and insu lated gate bipolar transistor IGBT switching circuitry Refer to Figure E 3 The input capacitors on each board are connected in parallel The two paralleled pairs are then connected in series to accomodate the high DC voltage from the rectifier When the input capacitors are fully charged they act as power supplies for the IGBT insulated gate bipolar transistors switching circuits The IGBT s switch the DC power from the input capacitors on and off thus Supplying pulsed DC current to the main transformer primary windings See SION AND DIAGRAMS this section FROM CONTROL CT CURRENT TO CONTROL BO VOLTAGE SENSE OUTPUT VOLTAGE SENSE SELECT ARC LINK CONNECTION IGBT OPERATION DISCUS MAIN TRANSFORMER CURRENT TRANSDUCER e ELECTRODE TERMINAL OUTPUT DIODES D4 WORK OUTPUT TERMINAL CHOKE U R R DEVICE NET ed ME GATEWAY CONNECTION SB 58 T BOARD ROBOT F IGBT TO FAN RELAY DRIVES CONTACTOR AND PRECHARGE CONTROL SIGNALS ARC LINK 5V RS232 5 V ARC LINK 5V SPI
146. LE BREAKER J1AD 8 205 m TO Jt VOLTAGE SENSE T 7 225A lt 3 i B e 4 8 403 d TO J61 I TP 406 5 POWER BD RECT PRIMARY Z C o AUX2 SECONDARY D 10 0 301 x 1 ial GT _ TOJ60 u 13 Un val m E 2 6 2 TOCT 2 o O 601 js DG B H n m 1 TO 40VDC 1 512 2 5 LENS 83 lt 2 lt 3 x 2 K J84 lt 3 678 4 h TO AUX 1 L3 L2 L1 J2VS 4 511 M 5 32A SW TOSW1 C Kyse j 2 L3A LIA p lant PR RIGHT SIDE i 2A 67 5 352A W V U 5 E TO SUPPLY LINES 1 G y J10B TO J9 iM H6 Ne 206 58 550575 56 TO A SYSTEM GROUND PER cO NATIONAL ELECTRICAL CODE i 1W 57 1B ND d c 1 STATUS LED RIG T 05 600V me Nu TP2 33 4 2B ow Ge ae COMPONENT VALUE UNITS THERMAL LED Y TORI Frat YYYY TRANSDUCER CAPACITOR MFD VOLTS 191 o IOTP3 ul RESISTOR OHMS WATTS FRONT FAN CB2 AUXIL ARY 1eHIA REAR RECONNECT RECONNECT i TO ELECTRODE 7 AUX FAN TRANSFORMER 2 RET MERE SHROUD SHELL BRACKET 485 TO RECONNECT PANEL TOP 55 CONNECTOR PIN NUMBERS 9 NOTES ELECTRICAL SYMBOLS PER E1537 EX 12 PIN CONNECTOR 9 9 TO J61 LOAD LINE CONTACTOR NA PIN NEAREST THE FLAT EDGE OF LED LENS CATHODE ALIGNS WITH BLACK LEAD OF LED SOCKET LEAD COLOR CODI
147. NCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC A 10 DIP Switch Settings and Locations DIP switches on the P C Boards allow for custom con figuration 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 Loosen but do not completely remove the bottom two screws holding the access panel Open the access panel allowing the weight of the panel to be carried by the bottom two screws Make sure to prevent the weight of the access panel from hanging on the harness e Adjust the DIP switches as necessary Replace the panel and screws and restore power Feed Head Board Control Board Right DeviceNET G ateway Board Control Board DIP Switch switch 1 Object Instance LSB see table 3 switch 2 Object Instance MSB see table 3 switch 3 Equipment Group 1 Select switch 4 Equipment Group 2 Select switch 5 2 Equipment Group 3 Select switch 6 2 Equipment Group 4 Select switch 7 reserved for future use switch 8 2 work sense lead 1 LEASE SIGNIFICANT BIT 2 MOST SIGNIFICANT BIT aa work sense lead work sense lead not connected E Sense lead connected INSTALLATION Feed Head Board DIP Switch switch
148. NG HID O CTs MUST BE ORIENTED IN THE PROPER DIRECTION TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED RIGHT SIDE OF MACHINE 12 6 SIDE OF TO THE SWITCH BOARD THE ARROW ON THE CT SHOULD POINT FROM THE SWITCH BOARD TO THE TRANSFORMER G CREEN Ped um E a AU SW1 N C PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 550 575V OPERATION N BROWN 000000 FRONT UPPER UPPER 2 1 POWER TOCB3 A N D PIN NEAREST THE FLAT EDGE OF LED LENS ANODE ALIGNS WITH BLACK LEAD OF LED SOCKET jen ON 12 BASE BASE 6128 O O ON SYNCHRONIZED TANDEM MIG APPLICATIONS J77 J712 OF THE ETHERNET BOARD AND J3 J7 OF THE CONTROL BOARD ARE USED WEWHITE Ss LATCH PROTECTIVE BONDING 5 SEE 526631 FOR DETAILS RESISTORSZOHMSIWATTS VIEW OF CONNECTOR ON PC BOARD CLEVELAND OHIO U S A THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL 70 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC wmemme POWERWAVE 655 R pace d ON 3 PLACE DECIMALS IS 002 in 0 05 mm DOCUMENT DOCUMENT ANGLES IS 5 OF A DEGREE Days SUBJECT WIRING DIAGRAM NUMBER REVISION ENGINEER WITH PUBLISHED STANDARDS UNITS MATERIAL REFERENCE 8 DO NOT
149. OC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 49 TROUBLESHOOTING amp REPAIR F 49 AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of auxiliary trans former No 1 MATERIALS NEEDED Misc Hand Tools Wire splicing or soldering equipment POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC F 50 TROUBLESHOOTING amp REPAIR F 50 AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 16 AUXILIARY
150. OL O O 2 C 40VDC 6 83 880 y Cue SINGLE PHASE DETECT 231 1J6 COLD INCH 15VDC 5 gt 855 LOW 1 PHASE COLD IN FORWARD 6 gt 659 B 2J6 4 MAIN CONTACTOR CONTROL cC COLD IN REVERSE 7 gt 857 NA _ VOLT SENSE BD 6 GAS PURGE INPUT 8 gt 858 A 2 SHUTDOWN 15VDC 9 gt 859 BOAR D 67 lt 4 9 VOLTAGE SENSE SHUTDOWN 1 INPUT 10 gt 860 N 67B 31 ROBOTIC VOLTAGE SENSE IN E o SHUTDOWN 2 INPUT 11 gt 861 262 lt 12 436 SPI COMMON INPUT B 12 862 2 X3A 3R A VOLTAGE SENSE SELECT gt 41 511 A 15V 1442 5 1 225 A N 225A 1234 4 15V gt fe a N_ 268a _ 3443 4 SPI 45V JL i V SOLID STATE RELAY VOLTAGE SENSE SELECT 1J1 512 CONTROL BOARD COMMON 5442 3 222 222A lt 1044 CONTROL BOARD COMMON O Q 444 o 3w VOLTAGE SENSE OUTPUT 232 67 15V SPI 6 3 266 aui 18 SPI 9 i SPI COMMON WIRE FEEDER VOLTAGE SENSE gt 1 2 gt 67A SPI COMMON O311443 267 14 c AUXILIARY TRANSFORMER T1 POWER DOWN INTERUPT gt 4J42 227 7J4 POWER DOWN INTERUPT o 5 NA DC BUS BD rn a H6A RET C 5 T 049260 15V gt 2342 223 114 15V i 500 2 47 COMMON SM 274 ae 58
151. PECIFICATIONS POWER WAVE 655 R K1519 1 K1519 2 INPUT AT RATED OUTPUT THREE PHASE ONLY CODE NUMBERS INPUT VOLTS OUTPUT INPUT IDLE POWER EFFICIENCY CONDITIONS CURRENT power RATED RATED AMPS OUPUT OUPUT 600A 44V 100 460 575V 60HZ 400 Watts 95 MIN 84 815A 44V 60 400V 50uz 5504 44V 100 675A 44V 60 gt lt 460 5 75 60HZ 600A 44V 100 815A 44V 60 OUTPUT OPEN CURRENT PULSE AND AUXILIARY POWER CIRCUIT RANGE FREQUENCY VOLTAGE BACKGROUND CIRCUIT BREAKER VOLTAGE PROTECTED 40 VDC AT TIME RANGE 10 AMPS 110 VAC AT 75 VDC 20 880 0 15 1000 2 5 55 VDC 100 MICRO SEC 10 AMPS PROCESS CURRENT RANGES DC CURRENT MIG MAG 50 815 Average Amps FCAW 40 815 Average Amps SMAW 30 600 Average Amps Pulse 15 880 Peak Amps RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT TYPE 75 C TYPE 75 C TYPE 75 C VOLTAGE COPPER WIRE IN GROUND WIRE IN SUPER LAG FREQUENCY CONDUIT AWG MM CONDUIT AWG MM OR BREAKER SIZES SIZES SIZE AMPS 460V 60HZ 8 10 575V 60HZ 10 6 PHYSICAL DIMENSIONS HEIGHT WEIGHT 26 10 in 306 Ibs 663 mm 139 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 C 40 C to 40 C POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O o Fie x Of gt 912 Retur
152. PONENTS OF CIRCUITRY OF CONTROLS APPROVED GRAWING Disposition NA gate 9 19 2006 CRM38151 A 19330 2 0 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 27 G 28 ELECTRICAL DIAGRAMS G 28 PC BOARD ASSEMBLY 40VDC BUS PC BOARD L SGDZL L1 ENGINEERING CONTROLLED CHANGE DETAIL NEW ITEM PART NO DESCRIPTION QTY MANUFACTURER 1 m9559 ears 1 1110782 40V DC BUS BD ASSEMBLY 525930 1 TORZ BUTTON HEAD SCREW 2 2 5926223 2 00 JOINTCOMPOUND 0002 RETAINING COMPOUND LOCTITE 242 T 2 lt 71325912 ermos 0111 4 54050 SELF TAPINGSCREW f gt E2529 ELECTRICAL JOINT COMPOUND 0107 THESE ITEMS NOT SHOWN Return to Section TOC Return to Master TOC NOTES N A ASSEMBLE ITEM 2 WITH HEADERS LOCATED AS SHOWN N B MOUNT THE DC BUS amp TIGHTEN THE MODULES PER E3875 N C APPLY A SMALL DROP OF ITEM 3 TO THE FIRST 2 3 THREADS OF THE SOCKET HEAD CAP SCREW N E APPLY FILM OF COMPOUND TO MOUNTING SURFACE OF ITEM 4 THERMOSTAT MOUNT WITH TERMINALS POSITIONED AS SHOWN N E Return to Section TOC Return to Master TOC S N A N B PLAIN WASHER 1 4 20HN O o e Cc 5 9 gt 0912 oO
153. PROCEDURE CONTINUED FIGURE F 11 OUTPUT RECTIFIER TEST Ss 2 NEGATIVE OUTPUT OUTPUT i TERMINALS TERMINALS PROCEDURE 1 Remove main input supply power to the POWER WAVE 655 R 2 Remove the case sides and perform the Filter Capacitor Discharge procedure 3 Remove any output cables that may be con nected to the POWER WAVE 655 R 4 Disconnect one end of lead 206A that connects R1to the Positive Output Terminal 5 With an ohmmeter measure the resistance between the positive and negative output termi nals Refer to Figure F 11 IMPORTANT The positive meter probe must 6 7 8 be attached to the positive output terminal and the negative meter probe must be attached to the nega tive output terminal If the reading is more than 200 ohms the out put rectifier modules are not shorted If the reading is less than 200 ohms one or more
154. Return to Master TOC Return to Master TOC c 2 Return to Master View Safety Info View Safety Info q 2 q Qn gt gt View Safety Info Lid vara J anuary 2008 POWERWAVE 655 R For use with machines having Code Numbers 10630 10863 11410 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT most importantly think before you act and be careful SERVICE MANUAL LINCOLN Copyright Lincoln Global Inc e World s Leader in Welding and Cutting Products 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 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Gasoline Engines
155. S BE CENTERED WITHIN 0 100 N K INSPECT POWER TERMINAL PER E1880 MAKES 2 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION C30 516668 5 CAPACITOR 022 50V 20 c DO NOT GET ON MATING SURFACES PANEL SIZE PER E1911 C1 C2 C3 C4 C31 516668 6 CAPACITOR CEMO 4700p 50V 10 5 5 N L ELECTRONIC MODULES ON A COMMON P C BOARD ASSEMBLY C32 lt 16668 11 CAPACITOR CEMO 0 1 50V 10 N C MOLEX CAVITIES AND AREA AROUND LOCKING TAB TO BE FREE OF ENCAPSULANT HAVE VGE TH AND VCE SAT IN SAME SORT CODE 0 1 VSPAN AND THE SAME R1 R6 R7 R8 R9 R10 R11 R16 MATERIAL MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS VENDOR CODE R17 R18 R19 R20 R21 R26 e g M16100 46 X XX XXX mor ROB R31 25 519400 1060 RESISTOR MF 1 4W 10 0 1 c N D FEMALE EYELET TO BE AGAINST THE OPPOSITE COMPONENT 837 R38R39R40R69 SIDE AS SHOWN EYELET MUST NOT SPIN AFTER CLINCHING VENDOR CODE MM R78 19400 1000 _ RESISTOR MF 1 4W 100 1 SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND VCE SAT R2 R12 R22 R32 519400 1001 RESISTOR 1 4W 1 00 1 ALL AROUND EYELET ON OPPOSITE COMPONENT SIDE ONLY NO VGE R46 R74 19400 1002 RESISTOR MF 1 4W 10 0K 1 ICICLES OR SOLDER BLOBS PERMITTED N M DO NOT COAT WITH ENCAPSULATION MATERIAL TOP AND BOTTOM FOR 0 80 MIN DIA AND R70 R71 R72 519400 1003 RESISTOR MF 1 4W 100K 1 0 85 MAX
156. SS WRITTEN PERMISSION OF LINCOLN GLOBAL INC DESIGN INFORMATION INFORMATION REFERENCE EQUIPMENT TYPE INVERTER WELDER 4 of 4 4 OF 4 ON 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE DRAWN BY DOCUMENT ENGINEER SCHEMATIC DIGITAL CONTROL NUMBER WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING pisposiion UF pare 10262006 Numer CRM22115 GA G3789 2FO U D TOLERAN MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 PLACE DECIMALS IS 002 ALL ES IS EN 170 SOLID EDGE O E 21 g gt cig cic sis 42 x NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ELECTRIC Return to Section TOC Return to Master TOC G 17 SCHEMATIC DIGITAL POWER SUPPLY PC BOARD ELECTRICAL DIAGRAMS
157. SW1 They are then con nected to the input rectifier through the precharge relay on the Input Board During the precharge or soft start sequence these two phases are current limited by resistord on the Input Board The AC input voltage is rectified and the resultant DC voltage is applied through a harmonic filter to the input capacitors located on the right and left switch boards A Voltage to Frequency circuit on the Switch Boards sends a signal to the Control Board When the capaci tors have charged to an acceptable level the Control Board signals the Input Board to energize the main input contactor CR 1 At this point the Power Wave 655 R is in the Run Mode of operation If the capaci tors become undervoltaged overvoltaged or unbal anced the Control Board will signal the Input Board to de energize the main input contactor and the Power Wave 655 R will be disabled See POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fie x 9 gt 0912 c yo Return to Section TOC Return to Master TOC E THEORY OF OPERATION ET FIGURE E 3 SWITCH BOARDS AND MAIN TRANSFORMER IGBT DRIVE OM POWER WAVE 655 R CONTROL CAP V F FEEDBACK CR1 INPUT RECTIFIER HARMONIC FILTER IGBT DRIVE BOARD CAP V F FEEDBACK s 67A 67B CONTACTOR AND PRECHARGE Se CONTRO
158. T Chi C37 VP SYMBOL INDICATES WHERE TEST POINT PADS SHOULD POWER SUPPLY SOURCE POINT D xib ADDED QN SECONDARY SIUE OF ARTWORK 57 COMMON CONNECTION 2040 1 4 Xy AS82527 171 7 FRAME CONNECTION 7 2e ai 17 EARTH GROUND CONNECTION 3 172 THES DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT DUPLICATED COMMUNICATED 9 PROPRIETARY amp CONFIDENTIAL orden PARTIES CR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 3 LI D SINCE COMPONENTS DR CIRCUITRY ON A DNE ale lt 2x b gt PRINTED CIRCUIT BOARD PAY Ce REFERENCE EQUIPMENT TYPE COMMON DIGITAL CONTROLS PAGE 02 OF 03 DRAWN BY un i COMMON ABILITY OF A COMPLETE BOARD THIS DOCUMENT DOCUMENT E c DIAGRAM MAY NOT SHOW THE EXACT MIDER REVISION COMPONENTS OR CIRCUITRY OF CONTROLS ari APPROVAL PROJECT E 5 HAVING A COMMON CONF NLIMRER DATE 11 26 02 CRM34209 3893 1409 510 ac NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 G 12 ELECTRICAL DIAGRAMS G 12 SCHEMATIC ETHERNET GATEWAY PC BOARD SHEET 3
159. TACH COMMON B gt lt 84 gt 8J1AD gt 403 ubl m 1A DIFF SIGNAL C 5 842 1B DIFF SIGNAL D gt 843 N gt gt 406 N ARGUINKH 5 45 2A DIFF SIGNAL E gt 845 cz 224A TACH 2B DIFF SIGNAL F gt 846 gt gt 503 N ARCUINKL 2800uF THERMOSTAT SINGLE TACH INPUT G gt 847 4 500V 291 224 25 4 THERMOSTAT VOLTAGE SENSE gt 67B sa gt 506 7 F o NORMALLY CLOSED MOTOR J gt 539 COMMON fM 292 220A 220 35 THERMOSTAT i SK gt Bd N 301 J 5 PIS STO SOLENOID 40VDC N gt 521 4 840 4181 40VDC OUTPUT RECTIFIER DCBUS i SOLENOID INPUT gt 522 NE SEEN a THERMOSTAT THERMOSTAT T gt GND A coli a frr oa ORE lt 16 7 lt FAN CONTROL gt 2254 4 540 lt 482 40VDC 3R lt 157 4 FAN CONTROL 11 09 222 tues VOLTAGE SENSE 100 57 0 205 5 X18 SELECT D6 262 268 8444 45V SPI VOLTAGE SENSE RECEPTACLE s12 RI 26 238 13V O O TRIGGER 15VDC 1 gt 851 440VDC 5383 886 TRIGGER INPUT 2 gt 852 2 J 604 1236 PRECHARGE CONTR
160. TAL CONTROLS PAGE 1 oF 1 5 0 M19540 2 DOCUMENT DOCUMENT DEMOS N sue SURE VOLTAGE SENSE PCBRDASBLY us Sie WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED 1 1 Disposition UF 3 16 2007 NUMBER CRM34409 M19540 3 C eic NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN 9 machine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC pur o O gt 4 Return to Section Return to Master TOC 4 c 2 rm G 27 ELECTRICAL DIAGRAMS SCHEMATIC 40VDC BUS PC BOARD LINCOLN 8 40 VOC J47 16 A AE pos 100uH 10 pT lt z 1000 D IS i Work Lead Sen E 20 gt ees eee Disconnect 500 2 C45 rorec
161. TE This diagram is for reference only It may not accurate for all machines covered by this manual de ELECTRICAL DIAGRAMS G 22 PC BOARD ASSEMBLY INPUT PC BOARD O O O O Eu EI 2 962 1171 ENGINEERING CONTROLLED CHANGE DETAIL REVISED MAKE SPECIFICATION MANUFACTURER No 9 5 2 8 10010W e 519400 2673 267K 1 4W eee on R11 R12 R13 R14 R15 R16 15 512400501 SOT BUY COMPLETE AS L11396 B R17 R18 R19 R20 R21 R22 2 LAYER BOARD PER E3281 R23 R24 R25 MAKES 8 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION 4 50 04 ITEM REQ D PART NO IDENTIFICATION SEE BLANK INFO P C BD BLANK 1 0 OZ E2861 SEALANT 5 O o 4 Return to Master TOC CAPACITORS MFD VOLTS RESISTORS OHMS WATTS 3 k X N A THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH ITEM 2 PRIOR TO X X ENCAPSULATION MATERIAL MUST BE APPLIED THRU SLOTS FROM BOTTOM X X SIDE TO COMPLETELY FILL TO UNDERSIDE OF DEVICE ON COMPONENT SIDE X N B P C BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL X N C DO NOT COAT WITH ENCAPSULATION MATERIAL X K N D APPLY ITEM 2 AS SHOWN ALL EXPOSED LEADS MUST BE COVERED MATERIAL e E MUST BE APPLIED PRIOR TO ENCAPSULATION NB LT APPLY ITEM 2 ON NON COMPONENT SIDE OF BOARD PRIOR c ENCAPSULATION ALL EXPOSED PINS MUST
162. TION Sit MANUFACTURER No ny 2 Paa BORRE BEANIE REFERENDE INEORMATION FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS 3 8 O c 2 NA 3 2 2 2 1 212 c N B m 4 PLACES olo oe UNLESS OTHERWISE SPECIFIED c 5 30 CAPACITANCE MFD VOLTS INDUCTANCE HENRIES 3 RESISTANCE OHMS 111067 1 X AUX DRIVER C1 e c 5 o D MANUFACTURED AS 2 L11067 1C0 PART NUMBER IDENTIFICATION CODE pr Lond 20 6 1911 ENCAPSULATE WITH E1844 3 TIMES TEST PER E3826 AD 20 E 0 2 50 04 NOTES N A DO NOT COAT WITH ENCAPSULATION MATERIAL N B AFTER ENCAPSULATION DRILL HOLES BOTH SIDES THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UNLESS OMMERWISE SPECIEDTOLERANCE pricy INFORMATION REFERENCE MANUFACTURING
163. TOLERANCE PER E2066 E EQUIPMENT TYPE INVERTER WELDERS PAGE 1 of 1 DOCUMENT DOCUMENT SUBJECT AUXILIARY DRIVER P C BD ASSEMBLY A MATERIAL TOLERANCE t TO AGREE TK SCALE WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT DONOTSCALETHISDRAWING APPROVED 11 DATE 12 3 02 __ Nuwper CRM34209 L11067 1 EN 168 SOLID EDGE STRP O o O FEE 5 g gt 9129 4 t NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN 9 machine
164. TYPICAL TYPICAL 11 16 13 18 POS 19 12 15 14 17 POS 21 NEG 20 11 16 13 18 NEG 22 12 15 14 17 NOTE suspect board should re checked after removal from the machine The actual readings may be different at that time but all similar test points should be comparable If not the board is probably defective POWER WAVE 655 R LINCOLN NOTES POWER WAVE 655 R LINCOLN amp F 16 NOL 491Se A uunjeH NOL 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 17 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric
165. WER SUPPLY SOURCE POINT L THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms TAW UNLESS OTHERWISE SPECIFIED EARTH GROUND CONNECTION OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES FA 40 UNLESS OTHERWISE SPECIFIED COMMON CONNECTION EQUIP THE LINCOLN ELECTRIC CO Wee POO __ CLEVELAND OHIO U S A supsect 508 SCHEMATIC o ScALE NONE REV 77 SHT Zi MI 7A SUP S D G c NO 524530 A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER 2056 ON 2 PLACE DECIMALS 15 O2 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES 15 5 OF A DEGREE MATERIAL TOLERANCE AGREE WITH PUBLISHED STANDARDS Return to Section TOC Return to Master TOC LINCOLN 8 G 30 ELECTRICAL DIAGRAMS G 30 MAKE FROM 519399 MAKES 14 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION BLANK PART NUMBER L11067 C serene caracrron cav0 0 2 Sim _ D1 D2 D3 D4 D5 D6 D7 D8 12705 37 DIODE AXLDS 40V SCHOTTKY T12218 15 CHOKE RF FERRITE BEAD 180 OHM 01 03 05 07 4 T12704 41 TRANSISTOR N T220 8A 150V MJE15030 02 04 06 08 T12704 49 TRANSISTOR P T220 8A 150V MJE15031 l PC BOARD ASSEMBLY AUXILIARY DRIVER PC BOARD O o 5 L 290LL 1 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROM X A 03 REQ D PART No DESCRIP
166. Wwimbley WELDERS ac 2r ON ALL ANGLES IS 5 OF DEGREE SUBJECT PW575 STT 208 575 MACHINE SCHEMATIC wuusen REVISION ENGINEER TK MATERIAL TOLERANCE n TO AGREE WITH PUBLISHED STANDARDS DO NO A HIS DRAWING APPROVED TK MATERIAL N APPROVAL DISPOSITION DATE EN 170 PROJECT 63611 12 5 02 FEE 5 9 gt 8 EIS LINCOLN amp ELECTRIC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 6 ELECTRICAL DIAGRAMS COMPLETE MACHINE SCHEMATIC CODE 10863
167. Yes MURSS2813 EL 1 Rita 5 1 UE i 4 ese 1uF MURS320T3 12 MC33874AD BL 024 1N5358B 1N53336 aie 021 40_ 3 012 RESET gt ESET 4 75k ta AD DATAG AD DATAS DATAZ BAD DATAZ 15 DATAA AD DATAS DATAG Ag AD 4 Ab DATAS AD DATATG A D CONVERSION DATATZ B DATAIS MC33874AD 1 533368 R238 47 5 GENERATOR EVA ADB4OSARUTO C129 10 089 5 1 1 20 53 MMSZ5231 X32 B 22 18 RIS 18 2151 18 148 19 RISI 18 2158 2185 ig 2152 1 5149 ADBABIARL MURS326T3 MURS328T3 Ries 2186 MNA oA 1 Wy xi PRIMARY CURRENT SENSE AD DATA 15 10k MURS326T5 AD DATA 26 AD DATA ip AD DATAS 1 12 0 b a oN AD DATAS n 2 22 1 FLOW SIT m 47 5K ALAS dx 2 MC330744D R218 ZRES 1 fn gt AD DATA a 2 gt AD DATAS AD DATAS RE AD DATATG AD DefAit Ra R662 2 1k X PEL OC DA CS 7 e ANAS AWA gt 09 ii 121k E de R207 j 109k ANA X6 125 V 4 PRIMARY CURRENT SHUTDOWN 9 3 0 2 ANN AAVV d Ri R58 1 006 2 1
168. a 1 28 i MMSZ5231 SUBS iS p iia rod R256 ANUS i punc on i 3 2 ux m 1 096 y 44 7 PN Va 9 13 R255 5 s i2eur RB7 ANUS ats 31 Bay 18 0 D44 e DAT 41 55 77 iid p 2 MMSZ52 H ae a SATA 2 MMBT4481 42 OATAG TUE 4 44777 35v 46 22 30 77 PWRON INT 32 DATAS Y ADOS a5 38 30 2 Zn UE t ADDRTD 16 A amp E lt k amp e 43 2238 28 25 DATAIS E EZ d 57 11 a S Flag Slade lad 28 PS x S 2 477 J Lai C 8 1 14 Secsh _ 7081 BOACH ZEB 13 _ 7052 ee 27 AIPIPE ES PE un ZEKPT 79 ABPO fPGA RESET mes ee DSACKO PE lt DONE ____ DONE TIS sess ___ MEM LEVEL IN 112 ayer RNC Se CAVEC PE2 Se fe e 105 d Ir He 3 fe OUTPUT OM OUTPUT ON 102 5 a S RESET SYS RESET igi e 23 oss BWRDN INT A FAULT INF 98 Mud aa FPOA INT 05 d O D RT RW CAN gt 2 um 97 FPCA FPGA_ 96 mH 108 93 prz a Y i 5 4 57 20 67 c
169. acti cal and instead the arc length is setby adjusting trim Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length Most pulse welding programs are syngeric As the wire feed speed is adjusted the Power Wave will automati cally recalculate the waveform parameters to maintain similar arc properties 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 tacttip to the work piece The Power Wave waveforms are optimized for a 0 75 19mm stick out The adap tive behavior supports a range of stickouts from 0 50 13mm to 1 25 32mm At very low or high wire feed speeds the adaptive range may be less due to reach ing physical limitations of the welding process Wave control in pulse programs usually adjusts the focus or shape of the arc Wave control values greater than 0 increase the pulse frequency while decreasing the background current resulting in a tight stiff arc best for high speed sheet metal welding Wave control values less than 0 decrease the pulse frequency while increasing the background current for a soft arc good for out of position welding See Figure B 3 FIGURE B 3 PULSE WAVE CONTROL CHARACTERISTICS Current itive Canine 10 0 Winer Denm
170. and procedures are set through software for the robotic Power Waves FANUC robots equipped with RJ 3 controllers may communicate directly to the Power Wave Other pieces of equip ment such as PLC s or computers can communicate to the Power Wave using DeviceNET All wire welding processes require a robotic Power Feed wire feeder Semi Automatic Operation Operating the Power Wave 655 R in the semi auto matic mode requires an Arc Link compatible wire feeder and user interface REQUIRED EQUIPMENT Control Cables 22 pin to 22 pin K1795 10ft 25ft 50ft 100ft Control Cables for use on FANUC robot arm 22 pin to 14 pin 10ft 3m K1804 1 Control Cables for use on FANUC robot arm 22 pin to 14 pin 18in 457mm K1805 1 Control Cables for use on FANUC robot arm 22 pin to 14 pin 18in 457mm K1804 2 LIMITATIONS e Power Waves are not to be used in outdoor environ ments Only Arc Link Power Feed wire feeders and user interfaces may be used Other Lincoln wire feeders or non Lincoln wire feeders cannot be used DUTY CYCLE AND TIME PERIOD The Power Feed wire feeders are capable of welding ata 10096 duty cycle continuous welding The power source will be the limiting factor in determining system duty cycle capability Note that the duty cycle is based upon a ten minute period A 6096 duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period POWER WAVE 655 R LINCOLN
171. 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Input Board is sending the correct voltages and also if the Input Board is regulating and producing the correct DC voltages MATERIALS NEEDED Misc Hand Tools Volt ohmmeter Wiring Diagram POWER WAVE 655 R LINCOLN F 29 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC Return to Master TOC ae TROUBLESHOOTING amp REPAIR didis INPUT BOARD TEST PROCEDURE CONTINUED FIGURE F 8 INPUT BOARD AND CONTACTOR INPUT PC BOARD N J6o
172. are at the factory The preprogrammed voltage is the best average voltage for a given wire feed speed With synergic programs when the wire feed speed changes the Power Wave will automatically adjust the corre sponding voltage Wave control adjusts the inductance of the waveshape This adjustment is often referred to as pinch In ductance is inversely proportional to pinch Increasing wave control greater than 0 results in a harsher colder arc while decreasing the wave control to less than 0 provides a softer hotter arc See Figure B 2 FIGURE B 2 CV WAVE CONTROL CHARACTERISTICS em 7 gt _ gt Current Time of P m POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Olo O o Fie Cc gg x gt 0912 Return to Section Return to Master TOC oe OPERATION E PULSE WELDING Pulse welding procedures are set by controlling an overall arc length variable When pulse welding the arc voltage is highly dependent upon the waveform The peak current back ground current rise time fall time and pulse frequency all affect the voltage The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known Using a preset voltage becomes impr
173. ateway NC PC Board 5 5 Support the Panel REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1 Remove input power to the POWER WAVE 1 Install the new Ethernet Gateway Board to the 655 R case front cover with the self locking nuts 2 Using a phillips head screw driver remove the 2 Reconnect the molex plugs and the network six screws from the case front cover Tilt the cable cover down and support it from below to avoid stressing the electrical connections See Figure F 19 olo O o Fie x Of gt 912 3 Re attach the cover to the case front being careful not to stress or pinch the wires Observe all static electricity precau tions 3 Disconnect the four molex plugs and the net work cable from the Ethernet Gateway Board 4 Remove the self locking mounting nuts and carefully remove the board Refer to Figure F19 Return to Section TOC Return to Master TOC POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 57 TROUBLESHOOTING amp 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
174. before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be separated by a green light To clear the error turn power source off and back on to reset Not Applicable Not applicable POWER WAVE 655 R LINCOLN TROUBLESHOOTING amp REPAIR ERROR CODES FOR THE POWER WAVE The following is a list of possible error codes that the Power Wave 655 can output via the status light If connect ed to a PF 10 11 these error codes will generally be accompanied by an Err 006 or Err 100 on the user inter face display Error Code Indication CAN communication bus off Probably due to excessive number of communication errors 12 User Interface time out error is no longer responding to the Power Source The most likely cause is a fault bad connection in the communication leads or con trol cable Return to Section TOC Return to Master TOC 21 Unprogrammed Weld Mode Contact the Service Department or powerwavesoftware com for instructions on reloading the Welding Software 22 Empty Weld Table Contact the Service Department or powerwavesoftware com for instructions on reloading the Welding Software the Service Department or powerwavesoftware com for instructions on reloading the Welding Software main transformer or outout
175. building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c LINCOLN CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders
176. cer Removal and F 57 s Output Rectifier Module Removal and Replacement F 59 E S witch Board and Filter Capacitor Removal and Replacement F 63 E Bru F 67 E Fil oc POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Olo O o Cc gg x gt 0912 Return to Section Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grou
177. connection dia gram located on the inside of the reconnect input access door of the machine Failure to do so may result 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 on the upper left case back next to the input access door Connect L1 L2 L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure 1 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire 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 to local or national electrical codes Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if the machine is not being used at high currents INPUT VOLTAGE CHANGE OVER FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY Welders are shipped connected for the highest input voltage listed on the rating plate To move this con nection to a different input voltage see the diagram located on the inside of the input access door If the main reconnect switch or link position is placed in the wrong position the welder will not produce output power
178. cunk STATUS LED HI FOR GREEN 5 1B t mua SHUTDOWN 2 INPUT 047 0 VIF AAV i i 505 5J50 V F 893 lt 2J75 24V GND 301 14 6 IGBT DRIVE e SERE pee RECEPTACLE 506 M IGBT DRIVE Reb 892 4 1 75 amp CAN 302 lt 66 lt IGBT DRIVE N A AUX DRIVER BD 154 282 ARCLINK H ica 891 lt 4756 CAN TACH 15VDC A gt 841 _ J82 ARCLINKL mE TACH COMMON B gt lt 84 gt 8J1AD gt 403 ubl m 1A DIFF SIGNAL C 5 842 1B DIFF SIGNAL D gt 843 N gt gt 406 N ARGUINKH 5 45 2A DIFF SIGNAL E gt 845 cz 224A TACH 2B DIFF SIGNAL F gt 846 gt gt 503 N 743 181 AROLINKL 2800uF THERMOSTAT SINGLE TACH INPUT G gt 847 f4 500V 291 224 235 4 THERMOSTAT VOLTAGE SENSE gt 67B H1AD gt 506 F o NORMALLY CLOSED MOTOR gt 59 8 LN COMMON 2 17 292 220A 220 305 lt THERMOSTAT i i Sablon eins N am 840 4181 40VDC s 3 NE E gt DCBUS SOLENOID INPUT _ gt 522 9910 SEEN C THERMOSTAT THERMOSTAT T gt GND A EN COMMON 5 2D 5 222A 500 lt 3 82 lt 18
179. d the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Gateway PC Board MATERIALS NEEDED Misc Hand Tools Anti static wrist strap CAUTION PC Boards can be damaged by static electricity Remove your bodys static charge before opening the static shielding bag Wear an anti static wrist strap For safety use 1 resistive cord con nected to a grounded part of the equipment frame f you dont have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC Board must be either conductive anti static or static dissipative POWER WAVE 655 R LINCOLN F 55 didis TROUBLESHOOTING amp REPAIR dibus ETHERNET GATEWAY PC BOARD REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 19 GATEWAY BOARD REMOVAL AND REPLACEMENT Q Return to Section TOC Return to Master TOC amp 2 TS 2 EX 5 SG Ethernet Ss G
180. des Perform the Capacitor Discharge procedure Remove the 1 2 bolt that holds the 4 0 cable to the back of the lower right Output Stud Cut the tie wrap that holds the harness to the transducer and disconnect P 91 Using a phillips head screw driver remove the screws and lock washers that hold the trans ducer to the machine base Side the current transducer off of the 4 0 cable noting the direction of the current flow indicator arrow Slide the new Transducer over the 4 0 cable Be certain that the current flow indictor arrow points towards the back of the machine See Figure F 20 Mountthe Transducer to the machine base with the two Phillips head screws Re connect the 4 0 cable to the Output Stud Carefully re connect the 4 pin connector P 91 to the Transducer and secure the harness with a tie wrap Replace the case sides POWER WAVE 655 R LINCOLN TROUBLESHOOTING amp REPAIR didi OUTPUT RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE A 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 Mas
181. directed in the Output Rectifier test If the short is cleared there no more defective modules If there is still a short or if none of the disconnected devices is shorted repeat steps 1 and 2 for the other module pairs untill all defective devices are located 3 Replace any defective module and the other module of the same pair even if only one mod ule is defective NOTE Any instructions packaged with the replacement modules will supersede the following instructions torque Press module against the heat sink aligning it with the mounting holes and start all three screws by hand Tighten the two outer screws to between 5 and 10 in Ibs Tighten the center screw to between 12 and 18 in Ibs Tighten the outer screws again to between 30 and 40 in Ibs Re install the copper plate snubber lead or M O V lead and transformer leads as they were originally and tighten to between 30 and 40 in Ibs Re assemble the machine by performing steps 2 through 13 of Accessing the Rectifier procedure in reverse order POWER WAVE 655 R LINCOLN NOTES d POWER WAVE 655 R LINCOLN amp F 62 NOL 491Se A uunjeH NOL 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
182. e enclosure panels of your machine LINCOLN amp ELECTRIC SOLID EDGE G 4 ELECTRICAL DIAGRAMS WIRING DIAGRAM CODE 11410 c 86v 5 ENGINEERING CONTROLLED CHANGE DETAIL ADDED LABEL SHEET TO PRINT NOTE MANUFACTURER No POWER WAVE 655 R WIRING DIAGRAM Return to Master TOC Return to Section TOC 202 EM Y TO ETHERNET CB3 CB1 lt x 2 pe i BOARD LEFT SIDE OF MACHINE d c FEED HEAD DIGITAL POWER SOLID 2 32 BREAKER 5 lt 2 lt B RD 811 3 TO AUX 2 6 lt 3 SUPPLY BOARD STATE 816 gt AUXILIARY TRANSFORMER 1 UA eT RELAY c1 lt 8 5 lt 1 225 TO INPUT SWITCH N L 05 600V J704 1 612B n 9 lt 6 lt 2 223 12 10 7 lt 475
183. e terminals should be re sealed with RTV when testing or replace ment is complete 9 See the Input Rectifier Removal and Replacement procedure for proper torque set tings when re connecting the leads to the recti fier 10 Before installing a new rectifier perform the Switch Board test and the Input Contactor test 11 Replace the case top and input panel POWER WAVE 655 R LINCOLN TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST PROCEDURE CONTINUED TABLE F 2 INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS TEST POINT TERMINALS ANALOG METER X100 RANGE Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Return to Section TOC Return to Master TOC Approx 500 ohms Approx 500 ohms Approx 500 ohms Approx 500 ohms Approx 500 ohms Approx 500 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Return to Section TOC Return to Master TOC NOTE Digital meters may not provide enough current in the ohms mode to achieve the read ings indicated They will however indicate whether the device is shorted typical failure mode or open A shorted device will usually read a low resistance lt 100Q in both polarities An open device will read as if the meter leads were not connected to any thing typically OL in both polarities O o Fie Cc gg x Of gt 0912 Return to Section
184. ee Bae on e 9 Insulated Gate Bipolar Transistor IGBT Operation E 10 2 AU CREDE rm E 11 FIGURE BLOCK LOGIC DIAGRAM IGBT DRIVE MAIN P CONTROL TRANSFORMER OWER WAVE 655 R BORD en CURRENT OUTPUT DIODES TRANSDUCER ELECTRODE D1 D4 TERMINAL CAP V F FEEDBACK LEFT INPUT SWITCH RECTIFIER HARMONIC FILTER IGBT DRIVE FROM CONTROL CT CURRENT BoARD TO CONTROL BOARD CAP V F FEEDBACK S VOLT 678 SENSE CONTACTOR AND PRECHARGE BOARD CONTROL SIGNALS FROM CONTROL BOARD OUTPUT ENIN CHOKE O O 4 p 2 4 2 VOLTAGE SENSE OUTPUT DEVICE NET ETHERNET GATEWAY CONNECTION ARC LINK BOARD TO TO TO LEFT RIGHT B S B VOLTAGE SENSE SELECT omn eic FROM CONTROL ROBOT RD BOA IGBT TO FAN RELAY 5 a ium 115 VAC CONTROL SIGNALS 5V RS232 52 VAC 20 65 VDC AUX RECONNECT THERMOSTATS ARC LINK WIRE 51 LEFT RIGHT FEEDER CURRENT CURRENT Q RECP FB FB STATUS THERMAL LIGHT LIGHT ARC LINK CONTROL Ti RECTIFIER BUS BOARD Bui BOARD 40 VDC S3 o 40 VDC LEFT S B 2 CAP V F Auxiliary 40 VDC RIGHT S B CAP V F i gt cc POWER WAVE 655 R LINCOLN amp EV T
185. est procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The Auxiliary Receptacle is dead 1 Check the 10 amp circuit break 1 Check the receptacle and asso The 120VAC is not present at the er CB2 located on the case ciated wiring for loose or faulty receptacle front Reset if necessary connections See the Wiring Check the 6 amp circuit breaker 4 located in the reconnect 2 Perform the T2 Auxiliary area Reset if necessary Transformer Test Make sure all three phases of input power are being applied to the machine The Power Wave 655 R is trig 1 Make sure that the triggering Use the Diagnostic Software to gered for output but there is no method and device is correct locate the problem The latest soft welding output and operating properly ware and the Diagnostic Utilities software is available at power wavesoftware c
186. eter Meter Reading Probe Probe vdc N e ELECTRIC SHOCK can kill 38 to 42 to Power PC Bd High voltage is present when input power is applied to the machine 38 042 to Power PC Bd 38 to 42 to Feed Head Bd to 1 Wire Feeder Pin 3 Pin 1 38 to 42 5 Turn on the POWER WAVE 655 R The LED on the ers pow Receptacle DC Bus Board should light If any of the readings is incorrect replace the If the LED does not light check the input voltage to board the board at the terminals of the capacitor C 3 It 9 Disconnect the input power and replace the case should read 65 75vdc top POWER WAVE 655 R LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 25 TROUBLESHOOTING amp REPAIR POWER BOARD TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department f
187. ews from the Fan Baffle and the base Carefully remove the transformer from the POWER WAVE 655 R POWER WAVE 655 R Install the two mounting screws that hold the transformer to the machine base using the 3 8 nut driver Connect leads 33 and 32 to circuit breaker CB4 and the 115 V receptacle Connect plugs P50 and P52 5 Reposition any leads and install cable ties as necessary Replace the case back Replace the case top sides and input access panel POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 53 TROUBLESHOOTING amp 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed
188. ful not to touch the capacitor terminals that are located at the bottom of the left and right side switch boards With a voltmeter carefully check for a DC volt age at the capacitor terminals of both boards Note the polarity as marked on the PC board If any voltage is present proceed to Step 6 If no voltage is present the capacitors are dis charged NOTE Normally the capacitors discharge with in about two minutes after input power is removed Using the high wattage resistor 25 1000 ohms 9 25 watts with electrically insulated gloves and pliers touch the resistor across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Repeat procedure for the other capacitors Recheck the voltage across the capacitor termi nals The voltage should be zero If any voltage remains repeat the discharge procedure NOTE If the capacitor voltage is present after the discharge has been performed this may indicate a faulty switch board POWER WAVE 655 R LINCOLN F 12 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 13 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST PROCEDURE A WARNING Service and repair sho
189. he rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 4 FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure a
190. he rear louvers and out through the case sides and bottom Dirt dust or any foreign mate rial that can be drawn into the welder should be kept at a minimum Do not use air filters on the air intake because the air flow will be restricted Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns Machines above code 10500 are equipped with F A N fan as needed circuitry The fan runs whenever the output is enabled whether under loaded or open circuit 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 If desired the F A N feature can be disabled causing the fan to run whenever the power source is on To disable F A N connect leads 444 and X3A together at the output of the solid state fan control relay located on the back of the Control PC board enclosure LIFTING Lift the machine by the lift bail only The lift bail is designed to lift the power source only Do not attempt to lift the Power Wave with accessories attached to it STACKING Power Wave machines can be stacked to a maximum of 3 high CAUTION The bottom machine must always be placed on a firm secure level surface There is a danger of machines toppling over if this precaution is not taken MACHINE GROUNDING The frame of the welder must be grounded A ground terminal marked with the symbol is
191. herefore prior to cycling power to the system check the power source status light for error sequences as noted below This is especially LIGHT CONDITION Status LED is solid green no blinking Status LED is blinking green Status LED is blinking red and green Status LED is solid red no blinking Status LED is blinking red important if the user interface displays Err 006 or Err 100 Included in this section is information about the power source Status LED and some basic troubleshooting charts for both machine and weld performance The STATUS LIGHT is a two color light that indicates system errors Normal operation is a steady green light Error conditions are indicated in the following chart NOTE The Power Wave 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 MEANING 1 System OK Power source communicating normally with wire feeder and its components Occurs during a reset and indicates the Power Wave 455M CE is mapping identifying each com ponent in the system Normal for first 1 10 seconds after power is turned on or if the system configura tion is changed during operation Non recoverable system fault If the PS Status light is flashing any combination of red and green errors are present in the Power Wave 455M CE Read the error code
192. i TACH 2A DIFF SIGNAL E gt 845 CHOKE 224A TACH 2B DIFF SIGNAL F gt 846 2 900 503 N 743 lt 1981 ARCLINKL Seni ae 4 THERMOSTAT SINGLE TACH INPUT gt 847 d 5ov T 294 224 lt 215 4 THERMOSTAT gt i NORMALLY CLOSED j 800 COGOMMON e 292 220 220 3 5 lt THERMOSTAT 1 ae 10J1AD gt 301 D 9 D Gita N TE i 840 4J81 40VDC ls 3 OUTPUT RECTIFIER DCBUS SOLENOID INPUT 2 gt 522 902 THERMOSTAT THERMOSTAT gt GND A 5 xi L 378 COMMON 6 as EA 200 3w 167 lt FAN CONTROL 5 7J1AD gt 225A C 540 lt 4282 40VDC 3R 4 157 FAN CONTROL 0 SHAB 222 agg VOLTAGE SENSE 100 S7 VO ae m lt SELECT D6 262 268 lt 94 4 5 SPI VOLTAGE SENSE RECEPTACLE 512 SELECT 9 268A 5 238 13V TRIGGER 15VDC 1 gt 851 440VDC gt 5383 886 O O TRIGGER INPUT 2 gt 852 604 1236 PRECHARGE CONTROL DUAL PROC INPUT 440VDC gt 6383 880 SINGLE PHASE DETECT 4 STEP INPUT 231 lt W6 Low 1 PHASE COLD INCH 15VDC 5 gt 855 V Pu COLD IN FORWARD 6 gt 856 232 lt 216 MAIN CONTACTOR CONTROL 1 COLD IN REVERSE 7 gt 857 M 2 _ VOLT SENSE BD m
193. ie Of gt 912 c yo Return to Section TOC Return to Master TOC F 71 TROUBLESHOOTING amp REPAIR 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 TEST PROCEDURE 1 2 oF Be certain that the machine is properly connected for the input voltage being applied Turn the Power Switch ON and see that it goes through the Start up routine and the Status Light is Steady Green Turn the Power Switch OFF connect a resistive load across the Output Studs and a computer to the 5 232 port Perform thelCalibration Procedurelto be sure that the machine will produce proper weld output NOTE Welding and or wire feed problems may still exist but may only be evident after the machine is reconnected into the weld cell POWER WAVE 655 R LINCOLN NOTES POWER WAVE 655 R LINCOLN amp F 72 NOL 491Se A uunjeH NOL 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg e TABLE OF CONTENTS DIAGRAM SECTION di Electrical Diagrams 4154 sacer a gag ee G 1 5 Wining Diagram Tor Code 10630 63498 u 2
194. ill allow the IGBT to conduct and supply current to circuit components cou pled to the source Current will flow through the con ducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O1O O o Fie x Of gt 912 Return to Section Return to Master TOC 25 sec lusec 4 24sec THEORY OF OPERATION E 11 FIGURE E 10 TYPICAL IGBT OUTPUTS a 50 usec 3 lusec MINIMUM OUTPUT 14sec gt 24sec 1 5 50 5 _________ MAXIMUM OUTPUT PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION PWM is used to describe how much time is devoted to conduc tion in the positive and negative portions of the cycle Changing the pulse width is known as MODULATION Pulse Width Modulation is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing shows the minimum output sig nal possible over a 50 microsecond time period An IGBT group c
195. ine choose 300A 650A machine choose 300A 1000A machine choose 500A Current Weld Mode Will always be mode 200 c c activated from Turn Output button Turn Output ON Enables output for calibration Light will flash Red when output is ON CALIBRATION ADJUSTMENT System will automaticaly adjust output levels as changes are made 4 Energize the PW655 R 5 Launch the Diagnostic Utility and establish commu nication with the PW655 R Refer to the Software Documentation to determine proper connection 6 Click on the Calibration tab A screen similar to Figure F 24 should appear and you are ready to begin the Calibration check NOTE The Calibration Screen may look slightly dif ferent depending on the software version FIGURE F 24 CALIBRATION SCREEN t Lincoln Electric Diagnostic Utility Communication Diagnostics System Inf Calibration Mable Tests Feed Head DeviceNet Lookup Error Feedback W A R N I N G Connect welding cables to load bank before testing Do not make changes on this screen while welding Output Current Output Voltage Current Set Point Mode Selection Cap 4 Voltage 327 E O50 Amps Voltage 319 100 Amps DC not for calibration Voltage Sense S XQ Amps Location O 500 Amps Current Weld Mode Adjustments Dutput is OFF Turn Output On Current din st Voltage
196. ion Return to Master TOC F 43 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 2 TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No 2 and also if the correct voltages are being induced on the secondary windings of the transformer MATERIALS NEEDED Voltohmmeter Misc HAnd Tools Wiring Diagram POWER WAVE 655 R LINCOLN F 43 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC Return to Master TOC id TROUBLESHOOTING amp REPAIR p AUXILIARY TRANSFORMER NO 2 TEST PROCEDURE CONTINUED FIGURE F 13 AUXILIARY TRANSFORMER NO 2 TEST To WATER COOLER RECEPTACLE
197. is would be due to improper input voltage connec tions 4 nternal component damage POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie x Of gt 0912 Return to Section Return to Master TOC THEORY OF OPERATION FIGURE E 9 IGBT OPERATION BODY REGION DRAIN DRIFT REGION BUFFER LAYER lt INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semicon ductors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned off like a light switch in the OFF position POSITIVE VOLTAGE GATE BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER lt INJECTING LAYER B ACTIVE Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source IS applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply connected to the drain terminal w
198. l Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be separated by a green light To clear the error turn power source off and back on to reset See Troubleshooting Section Not applicable Not applicable Steady Red Blinking Red OPERATION 3 10 LL 12 13 B 5 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over temper ature situation occurs Output is disabled until the machine cools down When cool the light goes out and output is enabled 10 AMP WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply 10 AMP AUXILIARY POWER CIRCUIT BREAKER Protects 110 volt AC case front receptacle auxiliary supply LEAD CONNECTOR 52 SENSE LEAD 5 PIN ARC LINK S1 5 PIN DEVICENET CONNECTOR S5 I O CONNECTOR NEGATIVE STUD INTERFACE CONNECTOR S6 POSITIVE STUD AUXILIARY OUTPUT FIGURE B 1 Case Front Layout Power Wave 655 R Domestic Canadian Version POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie CiS Of 912 912 c yo Return to Section TOC Return to Master TOC adi OPERATION WELDING MODE DESCRIPTIONS CONSTANT VOLTAGE WELDING For each wire feed speed a corresponding voltage is preprogrammed into the machine through special soft w
199. le or Ethernet Cable Resistive Load Bank Two 2 Welding Cables 20ft 4 0 Calibrated Ammeter and Voltmeter Calibration inaccuracies due to external metering can and will effect weld perfor mance Use good quality digital meters that are calibrated and traceable to National Standards POWER WAVE 655 R LINCOLN F 67 Return to Section TOC Return to Master TOC Return to Section TOC O o x Of gt 912 Return to Section Return to Master TOC Return to Master TOC F 68 TROUBLESHOOTING amp REPAIR F 68 CALIBRATION PROCEDURE CONTINUED CALIBRATION SET UP 1 Load the Diagnostic Utility Software into the com puter 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 3 Connect a resistive load bank to the output studs Calibration Tab A WARNING Machine output can be turned on with this screen Feedback Information Output Current Value of Current Sensor Device transducer Output Voltage Value of Voltage Sensing point Capacitor Group A and B Voltage values Voltage Sense Location should be sensing at studs for calibration use Cable Test tab to change Current Set Point 350A machine choose 300A 450A mach
200. leads to the correct module ter minals and torque to 31 in lbs See Figure F 14 Apply RTV sealant to the rectifier connection terminals Replace the case top sides and input access panel POWER WAVE 655 R LINCOLN F 46 did TROUBLESHOOTING amp REPAIR db INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the input con tactor MATERIALS NEEDED Misc Hand Tools Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fie x Of gt
201. lt 18 WEB ER Rox ig 2 15 gt 4 L 604 CR1 HARMONIC 55 bl o3 lt 3807 gt 5 gt 232 auxit DEVICENET px 1 lt i 2 CHOKE ED WHITE THIS AREA VIEWED FROM RIGHT SIDE OF MACHINE gt 6 gt J6 FILTER CONNECTOR amp 02A 2 lt 12 THERM ee lt 1 3 lt 13 lt I SWITCH BOARD 2 RIGHT X 29 5 QN 26 TO R 500 WORK cape E 89119 I 24V GND 3 893 J75 ELECTRODE 5 lt lt 15 RIGHT 39 xe i m CANH 4 892 5 6 16 i 5 2 1 NEG INPUT POS gt 5 ea Ser ac em i 0 423 RECTIFIER D O AUX DRIVER BOARD 3 270 2 ca 56 xi 5 gt 5 2 55 n e ROBOTIC x5 2 NEG 736 2 506 8 CRI m i WIREDRIVE m NEG x en 7 i gt 7 gt 2 T 5 INTERFACE 10A POs 5 CO ctun lt am m 1 POS 9 gt 4 D RECEPTACLE BREAKER 2 TO yt VOLTAGE SENSE 102 1 OIG E ELECTRODE TO i il am B J46 J 2 C s Ne POWER BD RECT PRIMARY 18 Z D i TO J60 m VOLTAGE SENSE o 601 d 1 r SELECT BOARD 2 TO CT 2 5 CRI c H n E p i 5 5 K J84 lt 4 g TO AUX 1 2 1 i L J2VS HM _ TOSW E L3A LIA cc RIGHT SIDE V U 352A 2
202. ly It may not be accurate for all machines covered by this manual 0 27 2000 ENGINEER Schematic Digital Power Supply APPROVED NONE DATE 11 30 98 DRAWINGNo G 3631 G 18 SCHEMATIC FEED HEAD PC BOARD SHEET 1 ELECTRICAL DIAGRAMS G 18 i i S OJ c8 D ENGINEERING CONTROLLED CHANGE DETAIL NEW 24 MANUFACTURER No o aay Avy p gt o E d T z 11 Rig ala 8 TACH COM 65 13 ig cie J85 14 CONTROL N 5 R a 8 2 Eck 0 ot 5 s a 9 a m eons I SNR m Ec p fees O LL __ ras d ___ 4 E ii gt ADORI 4 FON Ae m D lt a gt cr amn Se D M DATAS _ 4 uer v Ul y olg 5 qv wo gt wp ss und I E d ne i SSOTAEAM MA X 9 9 c 5 ARCLINK CONFIGURATION E 11 2 LAG E 18713 J87 14 Aviv AG 4 i p 2 TACHA gee 5 e on 2 14 es MONITOR pi Dr 5 8 0 giS 12 LL AME _______ Aww a GS 2
203. n to Section Return to Master TOC Return to Master TOC ae INSTALLATION as SAFETY PRECAUTIONS Read this entire installation section before you start installation WARNING ELECTRIC SHOCK kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equip ment Turn off the input power to any other equipment con nected to the welding system at the disconnect switch or fuse box before working on the equipment 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 LOCATION Do not use Power Waves in outdoor environments The Power Wave power source should not be subjected to falling water nor should any parts of it be submerged in water Doing so may cause improper operation as well as pose a safety hazard The best practice is to keep the machine in a dry sheltered area Do not mount the PowerWave over combustible sur faces Where there is a combustible surface directly under stationary or fixed electrical equipment that sur face shall be covered with a steel plate at least 060 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides Place the welder where clean cooling air can freely cir culate in through t
204. nd application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain itis within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and Cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employers safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 f Also see item 1 b Aug 06 Return to Master TOC Return to Master TOC 4 gt 4 c 2 4 Return to Master SAFETY EL WELDING SPARKS can gt cause fire or explosion 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
205. nfigured correctly for 2 Perform the Input Board Test ing the applied input voltage If the Thermal light is lit the unit Sama ui Transformer Test may be overheated Let the machine cool and adjust weld 4 Perform the Input Rectifier ing load and or duty cycle to 4 the output limits of 5 psum dre Beard 6 Perform the Power Board Test 7 The Control Board may be faulty The thermal light is litt The 1 The welding application may be 1 One of the thermostats may be machine regularly overheats exceeding the recommended faulty Also check associated duty cycle and or current limits wiring for loose or faulty con of the machine nections See the Wiring Diagram Dirt and dust may have clogged the cooling channels inside the machine Refer to the enance Section of this manual Air intake and exhaust louvers may be blocked due to inade quate clearance around the machine Make sure the fan is functioning correctly Machines above code 10500 are equipped with F A N fan as needed circuitry The fan runs whenever the output is enabled whether under load or open circuit conditions The fan also runs for a period of time approximately 5 minutes after the output is disabled CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooti
206. ng assistance before you proceed Call 1 888 935 3877 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC diii TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The machine often noodle welds 1 The machine may be trying to 1 Perform the Current when running a particular process deliver too much power When The output is limited to approxi the average output current mately 100 amps exceeds 570 amps the machine will phase back to protect itself Adjust the procedure or reduce the load to lower the current draw from the Power Wave 655 R machine 2 The Control Board may be faulty The Power Wave 655 R will not 1 The input voltage may be too 1 Perform the produce full output low limiting the output capability of the machine Make certain the input voltage is correct for the machine and the reconnect panel configuration Make sure all three phases of 2 Perform the input power are being applied to ducer Test the machine Perform the Power Board Test The Control Board may be faulty CAUTION If for any reason you do not understand the t
207. ng input power This procedure is used to check that the capac itors have properly discharged MATERIALS NEEDED Misc hand tools Volt ohmmeter 25 1000 ohms 25 watts minimum resistor Electrically insulated gloves and pliers POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ko O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC F 12 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE CONTINUED FIGURE F 1 CAPACITOR DISCHARGE PROCEDURE lt Q 3 D VN 0 D N p O ean SOS WX Ses NX 5 9 m a 9 0 SWITCH e BOARD CAPACITOR TERMINALS PROCEDURE Disconnect the input power to the POWER WAVE 655 R Remove the left and right case sides Remove the two High Voltage Protection shields Be care
208. ng to stabilize the arcs Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover age Do not attempt to supply shielding gas for two or more guns from only one regulator If an anti spatter system is in use then each gun must have its own anti spatter system See Figure A 2 FIGURE A 2 Travel Electrode Lead TWO POWER WAVES Direction Connect All Welding Electrode Lead Connect All Work Sense Leads at the End ofthe Joint Work Leads at the Beginning of the Joint POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie x Of gt 912 Return to Section Return to Master TOC e INSTALLATION me 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 Avoid excessive lengths and do not coil excess cable Minimum work and electrode cable sizes are as follows ABLE 1 For cable lenath up to 100 ft or 30 meters URRENT 60 Duty Cycle MINIMUM COPPER 400 Amps 2 0 67mm2 500 Amps 3
209. of the rectifier modules is shorted Refer to the Output Rectifier Module Replacement proce dure Reconnect lead 206A Replace the case sides POWER WAVE 655 R LINCOLN amp F 38 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No 1 and also if the correct voltages are being induced on the secondary windings of the transformer MATERIALS NEEDED Voltohmmeter Misc Hand Tools Wiring Diagram POWER WAVE 655 R LINCOLN F 39 Return to Sec
210. olex plugs to the Control Board and the Feed Head Board Be sure the lead harnesses are securely and properly posi tioned Use a Phillips screwdriver to replace the Auxiliary Driver Board Press the Voltage Sense Board onto its stand offs Make sure the board snaps into place on all three standoffs Secure the rear of the control box in place using two screws Be careful not to pinch any wires between the control box sheeet metal pieces Replace any cable ties that might have been removed Replace the PC board compartment cover Replace the case top and sides NOTE If the Control Board is replaced it will be necessar to do the Calibration POWER WAVE 655 R LINCOLN F 54 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie Cc gg x Of gt 0912 Return to Section Return to Master TOC F 55 TROUBLESHOOTING amp 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understan
211. om Check circuit breaker CB4 Reset if tripped CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC TROUBLESHOOTING amp 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This safety procedure should be performed before any internal maintenance or repair procedures are attempted on the POWER WAVE 655 R Capacitors normally discharge within 2 minutes of removi
212. on TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC THEORY OF OPERATION E 6 FIGURE E 5 POWER WAVE 655 R COMMUNICATIONS BOA Weld Controller Sequencer PW 655R mm um iNet Robot Controller POWER WAVE 655 R LINCOLN EM THEORY OF OPERATION E FIGURE E 6 CONTROL BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Olo Fie x gt 0912 f Return to Section Return to Master TOC IGBT DRIVE FROM POWER WAVE 655 R BOARD CAP V F FEEDBACK
213. onger pro vided O 4 o 4 c 2 POWER WAVE 655 R LINCOLN G 2 WIRING DIAGRAM CODE 10630 ELECTRICAL DIAGRAMS c e6r 5 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROM X A 02 clo MANUFACTURER NO gt V 9 TO p lt 1 CBI lt 2 812 1 2 CPNTROL BOARD LEFT SIDE OF MACHINE TORI 4 lt E DE Hr 3 NOT USED 612B CB3 5 Drom Rak FEED HEAD DIGITAL POWER SOLID 816 gt 4 10A CIRCUIT ie 3 SUPPLY BOARD STATE AUXILIARY TRANSFORMER 1 TO BREAKER Ct om m roms E 73 00 1 225 RELAY 2 05 600V 705 g 6 lt 2 an 2 23 1 ii 10 7 lt 3 3 221 51V mi
214. onsists of the sets of IGBT modules grouped onto one switch board The shaded portion of the signal represents one IGBT group conducting for 1 microsecond The negative por tion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only 2 microseconds of the 50 microsecond time period are devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 24 microseconds each and allowing only 2 microseconds of dwell or off time one microsecond during each half cycle during the 50 microsecond cycle the output is maximized The dark ened area under the minimum output curve can be com pared to the area under the maximum output curve The more darkened area the more power is present POWER WAVE 655 R LINCOLN E 12 NOTES POWER WAVE 655 R LINCOLN amp E 12 NOL 491Se A uunjeH NOL 01 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg _ TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR Troubleshooting and Pee wa 1 How to USE Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 T TroubleshooBng Gude
215. or electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Power Board is receiving the correct voltages and also if the Power Board is regulating and producing the correct DC voltages MATERIALS NEEDED Misc Hand Tools Volt ohmmeter Wiring Diagram POWER WAVE 655 R LINCOLN F 25 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ko O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC ins TROUBLESHOOTING amp REPAIR F 26 POWER BOARD TEST PROCEDURE CONTINUED FIGURE F 7 POWER BOARD TEST 73 __ lt gt 6 POWER gt PCBOARD B 1211 Power Bd CAPACITOR Rectifier C3 3 2 1 2 1 6 5 4 3 2 1 PRO
216. ped into the following categories output problems function prob lems wire feeding problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJ USTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the
217. phase error Indicates machine is running on single phase input power Usually caused by the loss of the middle leg L2 Other 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 try reloading the latest version operating system available at powerwavesoftware com If this fails contact the Service Department at 1 888 935 3877 POWER WAVE 655 R LINCOLN O o Fie Cc gg x Of gt 0912 Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage Contact your local authorized Contactthe Lincoln Electric Service is evident when the sheet metal Lincoln Electric Field Service Department at 1 888 935 3877 covers are removed Facility for technical assistance Return to Section TOC Return to Master TOC The input fuses repeatedly fail or 1 Make certain the fuses or break 1 Check the reconnect switches the input circuit breakers keep trip ers are properly sized and associated wiring See the ping Wiring Diagram 2 Make certain the reconnect 2 Perform the Input Rectifier panel is configu
218. r Horizontal ai ee Divider Panel E gt gt EM 7 J40 50 Pm 4 SIG de 2 59 olo Output Choke le Connection 5 5 JE Front Panel Screws ACCESSING THE RECTIFIER MODULE 1 Remove input power to the POWER WAVE 9 Remove the two phillips head screws that hold olo 655 R the Power Switch to the front panel Cut the ae E 2 Remove the case top and sides wire ties as necessary and pull the switch out to cls the right side of the machine 5 9 eee 10 Remove the 1 2 bolt that holds the Output 2 2 4 Disconnect the 60 Molex connector from the choke to the Negative Output Stud 912 Input Board See Fig 21 clc 11 Loosen do not remove the three screws atthe 5 E 5 Disconnect 40 and J 50 Molex connectors from bottom of the front panel e c ec ped 12 Remove the four screws tha hold the Front 6 Cut wire ties as necessary and pull the 40 50 Horizontal Divider panel to the Rear Horizontal amp J60 harnesses and grommets through the panel panels 13 Tilt the front panel forward far enough to 7 Disconnect the output leads 444 amp X3A from expose all four pairs of diode modules the bottom terminals of the Fan Relay CAUTION Be careful not to stress or damage 8 Disconnect the 48 Molex connector from the the Current Transformer leads that DC Bus Board lower connector 4 pin are routed pastthe
219. r les yeux du rayon nement de larc et des projections quand on soude ou quand on regarde arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger lautre personnel travaillant proximit au soudage laide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de larc de soudage Se prot ger avec des v tements de protection libres de Ihuile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o lon pique le laitier masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou autres circuits Cela peut provoquer des risques dincendie ou dechauffement des chaines et des cables jusqu ce qu ils se rompent 9 Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant dop rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du
220. red properly for the applied voltage 3 The welding procedure may be 3 Perform the Switch Board drawing too much input current or the duty cycle may be too high Reduce the welding cur rent and or reduce the duty 4 Perform the Input Contactor cycle Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR t Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The machine is dead no lights 1 Make certain the input power 1 Check the input power switch no output the machine appears to switch SW1 is in the ON posi SW1 for proper operation Also be off tion check the associated leads for loose or faulty connections See the Wiring Diagram Check the main inpu
221. rent can reach very high 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 power source located beneath the spring loaded output cover near the bottom of the case front Connect the other end of the electrode 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 Be Sure the connection to the feed plate makes tight metal to metal electrical contact The electrode cable should be sized according 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 piece connection must be firm and secure especially if pulse weld ing is planned Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding per formance POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC add INSTALLATION iid NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required
222. rion 5 Circuitry SOV 70 ew C13 gm 02 Soy 0 47uF 0V2 1A 630V AEM 400V i J47 6 2 kaa EN __ 37 CLE A gt 03 2702 35V 600 lt 3 J46 P lt a 246 2842A 13 dd Vcc x2 AUF e 2110 at 2110 50V 35V 0 004 TUTI vss 2 50V SOV GENERAL INFORMATION LAST NO USED CLUSTER 1 ee 8 9 MOV 2 X 2 ELECTRICAL SYMBOLS PER 1537 aa di CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS gt 5 02 6 1 DIODES 1A 400V UNLESS OTHERWISE SPECIFIED s Vea ee C POWER SUPPLY SOURCE POINT V comvos conection L11832 2 17 7 FRAME CONNECTION etue EARTH GROUND CONNECTION ASSEMBLY NO CLUSTER NO PROPRIETARY amp CONFIDENTIAL THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC PRINTED CIRCUIT BOARD MAY Cue DESIGN INORMATION ReFeRENCE EQUIPMENT TYPE MULTI SYSTEMS 40 VOC 8055 PAGE 01 OF 01 ITHOUT AFFE NTERCHANGE DRAWN BY TEKfM ABILITY OF A COMPLETE BOARD THIS SUBJECT SCHEMATIC POWER SUPPLY PCB REVISION DIAGRAM MAY NOT SHOW THE EXACT DO NOT NUMBER REVISION COMPONENTS OR CIRCUITRY OF CONTROLS SCALE THIS MATERIAL APPROVAL PROJECT
223. roperly calibrated machines may not yield satisfactory weld performance To ensure optimal performance the calibration of output Voltage and Current should be checked yearly The calibration procedure itself requires the use of a grid Resistive Load Bank and certified actual meters for voltage and current The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use The Diagnostics Utility includes detailed instructions and is available on the Power Wave Submerged Arc Utilities disc that comes with the machine on the Service Navigator DVDs on Powerwavesoftware com f the system does not calibrate properly see the troubleshooting section of this manual POWER WAVE 655 R LINCOLN D 3 40 Mi Lf 5 _______ WI if 9 4 2 SA 527 DN POWER WAVE 655 R LINCOLN MAINTENANCE FIGURE D 1 MAIN ASSEMBLY EXPLODED VIEW 55 lt gt SS NN 55 LSS SSS SS 5555 555 55 555 555 WY ac WY gt lt gt gt oc lt L a lt gt a Ww gt lt Ww ec i lt a lt PA a lt E O lt tc m O nz Ez a c Jm x He nt Gm Um w zr 5 pu LO uu u uo lt tn Sum lt Q lt lt Q Q
224. s Effect on Pulse Welding A 6 Negative Electrode uar d toa cR menti e RR cat OR RU od a A 7 VOTOS SENSI oe ene PER X TS eas hones RU A 7 Wok _ Dee ee A 8 Electrode Voltage SENSING succus aat aca a andere A 8 Power Wave Power Feed Wire Feeder Interconnections A 8 Contool R 8 OMMCCION d PC ee oe A 9 Homo ov eee eae 9 With and LotauOTiS s 3 edad dhe ode 10 Conuol Board A 10 reed Head Board Dip SWIC REOR tees ers A 10 Devicenet Gateway Board Dip Switch Bank 51 A 10 Devicenet G ateway Board Dip Switch Bank 52 A 11 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie Cc gg x Of gt 0912 Return to Section Return to Master TOC ik INSTALLATION ne TECHNICAL S
225. s 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 A WARNING ELECTRIC SHOCK can kill e 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 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 E 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 OZ 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 POWER WAVE POWER FEED WIRE
226. screen will flash RED indicating that the weld output is turned ON See Figure F 25 5 Adjust the load bank to 300 Amps at approximately 32 Volts as read on the external calibrated meters 6 Using the Calibration Adjustment buttons Adjust the current so that the external ammeter reads 300Amps 2A Adjust the voltage so that the Output Voltage display window reads the same as the external voltmeter 25volts 7 Click on the Turn Output Off button Calibration is complete FIGURE F 25 CALIBRATION SCREEN Lincoln Electric Diagnostic Utility Communication Diagnostics System Info Calibration Cable Tests Feed Head eedback Output Current 299 5 Output Voltage 23 6 Voltage B Voltage 375 Voltage Sense Location studs Calibration Adjustment Voltage Current 4 Adjust Adjust Connected to 10 23 8 52 ArcLink urrent Set Paint C SO Amps C 100 Amps 300 Amps 500 Amps FLASHES RED Current Weld Mode 200 when output IS ON POWER WAVE 655 R LINCOLN NOTES POWER WAVE 655 R LINCOLN amp F 70 NOL 491Se A uunjeH NOL 0 uunjeH NOL 491Se AN 01 uunjeH NOL 491Se A 0 uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL uonoes DOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o F
227. ster TOC Return to Master TOC D 2 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill e e Only Qualified personnel should perform this maintenance e Turn the input power OFF at the disconnect switch or fuse box before working on this equipment e 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 Remove any debris dust dirt or materials that could block the air flow to the machine for cooling 3 Inspect the electrode cables for any slits or punc tures in the cable jacket or any condition that would affect the proper operation of the machine PERIODIC MAINTENANCE PERFORM PERIODICALLY Clean the inside of the machine with a low pressure air stream Clean the following parts Refer tolFigure D L Transformer and output rectifier assembly Electrode and work cable connections PC board connections Intake and outlet louvers on the machine case Any obvious accumulations of dirt within the machine Fan Assembly NOTE The fan motor has sealed bearings which require no maintenance MAINTENANCE D 2 CALIBRATION SPECIFICATION Calibration of the P W 655 R is critical to its opera tion The output Voltage and Current are calibrated at the factory and generally speaking the calibra tion will not need adjustment However neglected or imp
228. t fuses or 2 Check circuit breaker for breakers If open replace or proper operation reset Check the 6 amp CB4 breaker 3 Perform the 1 Auxiliary located in the reconnect area Transformer Test Reset if tripped Make certain the reconnect 4 The power board rectifier may panel is configured correctly for be faulty Check rectifier and the applied input voltage associated wiring See the Wiring Diagram Perform the DC Buss Board Perform the Board Test The Control Board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Cc gg x Of gt 0912 Return to Section Return to Master TOC diis TROUBLESHOOTING amp REPAIR PS Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The Power Wave 655 R does not 1 Turn the input power off and 1 Perform the Input Contactor have welding output The main make certain the reconnect Input contactor 1 is not activat panel is co
229. t the arc conditions Depending upon the process inductance within the electrode and work lead cables can influence the volt age apparent at the contact tip Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance CAUTION If the voltage sensing is enabled but the sense leads are missing or improperly connected extremely high welding outputs may occur Do not tightly bundle the work sense lead to the work lead The ELECTRODE sense lead 67 is built into the K1795 control cable The WORK sense lead 21 con nects to the Power Wave at the four pin connector located underneath the output stud cover Enable the voltage sense leads as follows TABLE 2 Electrode Voltage Sensing 67 lead 67 lead required 67 lead required 67 lead required Voltage sense at studs 67 lead required Work Voltage Sensing 21 lead 21 lead optional 21 lead optional 21 lead optional Voltage sense at studs 21 lead optional The electrode voltage 67 sense lead is part of the control cable to the wire feeder For consistent weld quality work voltage sensing is recommended POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC i INSTALLATION 8 Work Voltage Sensing The Power Wave
230. tainers that have held combustibles Wear eye ear and body protection 2 ARC RAYS can burn N Observe additional guidelines detailed in the beginning of this manual POWER WAVE 655 R LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC B 3 OPERATION Bs GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER AL SMAW ON 6 GMAW Q OFF 4 FCAW E HIGH TEMPERATURE GTAW MACHINE STATUS 00 673 CIRCUIT BREAKER U4 INPUT VOLTAGE WIRE FEEDER OUTPUT VOLTAGE POSITIVE OUTPUT 4 INPUT CURRENT NEGATIVE OUTPUT lo OUTPUT CURRENT 3 PHASE INVERTER Sune D INPUT POWER 3 THREE PHASE AN Sauron OR DIRECT CURRENT POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ko O o x Of gt 912 Return to Section Return to Master TOC OPERATION ii GENERAL DESCRIPTION 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 The Power Wave power source is designed to be used with the family of Power Feed wire feeders operating as a s
231. ted to the coil terminals to activate the contactor instead of using the Test Button All readings should be very close to 00 If the resistance is high the input contactor is faulty Reconnect the two leads 601 X4 to the input contactor coil Replace the input access door and case top POWER WAVE 655 R LINCOLN F 22 CONTACTOR T3 T2 T1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC F 23 TROUBLESHOOTING amp REPAIR DC BUS BOARD TEST PROCEDURE A 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the DC Bus PC Board is receiving and processing the proper voltages MATERIALS NEEDED Misc Hand Tools Volt ohmmeter Wiring Diagram
232. ter TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the output recti fier modules MATERIALS NEEDED Misc Hand tools Penetrox A13 Thermal J oint Compound Wiring Diagram Return to Section TOC Return to Master TOC olo O o Fie x Of gt 0912 Return to Section Return to Master TOC POWER WAVE 655 R LINCOLN TROUBLESHOOTING amp REPAIR ee OUTPUT RECTIFIER MODULE REPLACEMENT Fie PROCEDURE CONTINUED 5 5 FIGURE F 21 ACCESSING THE RECTIFIER MODULE gt 2 315 cc J48 160 ia ONU oe a Fan Relay Front Horizontal Power eee 5 Divider Panel 418 Switch Rea
233. tion TOC Return to Section TOC Return to Master TOC G Q per o O 4 2 4 Return to Section Return to Master TOC Return to Master TOC 4 4 c 2 4 TROUBLESHOOTING amp REPAIR diis AUXILIARY TRANSFORMER NO 1 TEST PROCEDURE CONTINUED FIGURE F 12 AUXILIARY TRANSFORMER NO 1 TEST EX POWER BOARD ul 7 RECTIFIER BRIDGE 1 INPUT CONTACTOR NS 2 FAN RELAY WHITE RED X3 X5 3A 444 FAN MOTOR WINDING AUXILIARY TRANSFORMER 1 PROCEDURE mE 4 Locate secondary leads X1 and X2 at power 1 Remove the main input power to the POWER board rectifier bridge Refer to Figure F 12 WAVE 655 R machine 5 Locate secondary leads X3 and X5 fan motor 2 Remove the case top and sides leads 3 Perform Capacitor Discharge procedure 6 Locate secondary lead X4 at main contactor POWER WAVE 655 R LINCOLN TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 TEST PROCEDURE CONTINUED 7 Carefully apply the correct input voltage to the 9 If the correct secondary voltages are present the POWER WAVE 655 R T1 auxiliary transformer is functioning properly If any of the secondary voltages
234. 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Current Transducer MATERIALS NEEDED Misc Hand Tools Wiring Diagram POWER WAVE 655 R LINCOLN F 57 css TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER ple REMOVAL AND REPLACEMENT PROCEDURE CONTINUED 5 9 FIGURE F 20 POWER WAVE CURRENT TRANSDUCER REMOVAL 5 AND REPLACEMENT PROCEDURE ele els 512 c THIS SIDE FACES REAR olo c 09129 gt 019 5 2 eic CURRENT TRANSDUCER REMOVAL PROCEDURE REPLACEMENT PROCEDURE olo O o Fie Cc gg Of gt 912 c yo Return to Section TOC Return to Master TOC Remove input power to the POWER WAVE 655 R Remove the case si
235. ts are designed into the Power Wave 655 R to sense trouble and shut down the machine before damage occurs to the machine s internal com ponents Error Codes will be flashed out by the Red Green Status LED on the front panel and LED s on the Control Board to help identify the reason for the shutdown See the Troubleshooting Section for more information regarding Error Codes Fault codes can also be seen by using the Diagnostic Software OVER CURRENT PROTECTION If the average weld current exceeds 880 amps the peak current will be limited to 100 amps until the aver age current decreases to under 50 amps or the system is re triggered UNDER OVER VOLTAGE PROTECTION A protective circuit is included on the Control Board to monitor the voltage across the input capacitors In the event that a capacitor voltage is too high too low or becomes unbalanced side to side the protection cir cuit will de energize the input contactor Machine out put will be disabled and the soft start mode will be repeated The protection circuit will prevent output if any of the following circumstances occur 1 Capacitor conditioning is required This may be required if the machine has been off for a long peri od of time and is connected for high input voltage operation 2 Voltage across a capacitor exceeds 467 volts This could result from high line surges or improper input voltage connections 3 Voltage across a capacitor is under 70 volts Th
236. turn to Master TOC O o Fie x Of gt 912 c yo Return to Section TOC Return to Master TOC ES THEORY OF OPERATION ES THERMAL PROTECTION Three normally closed NC thermostats protect the machine from excessive operating temperatures These thermostats are wired in series and are con nected 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 Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond its duty cycle or out putrating If excessive operating temperatures should occur the thermostats will prevent output from the machine The yellow thermal light located on the front of the machine will be illuminated The thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turn ing or the intake air louvers are obstructed the power must be removed from the machine and the fan condi tion or air obstruction corrected On later production machines above code 10500 the cooling fan runs only when necessary The F A N fan as needed sys tem is controlled by the Control Board via a solid state relay PROTECTIVE CIRCUITS Protective circui
237. uld 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the power section of the switch boards are functioning cor rectly This test will NOT indicate if the entire PC board is functional This resistance test is preferable to a voltage test with the machine energized because these boards can be damaged easily In addition it is dangerous to work on these boards with the machine energized MATERIALS NEEDED Misc Hand Tools Torque Wrench Volt ohmmeter Wiring Diagram POWER WAVE 655 R LINCOLN F 13 TROUBLESHOOTING amp REPAIR mA SWITCH BOARD TEST PROCEDURE CONTINUED FIGURE F 2 LEFT SIDE Return to Section TOC Return to Master TOC Nk Yy N 9 7 c 9 per
238. 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 Lincoln control cables are copper 22 conductor cable in a SO type rubber jacket POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fie CiS gt 912 d Return to Section Return to Master TOC iis INSTALLATION 8 EXTERNAL I O CONNECTOR The Power Wave is equipped with a port for making Simple input signal connections The portis divided into three groups Trigger group Cold Inch Group and Shutdown Group Because the Power Wave is a Slave 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 Machines from the fac tory come with the shutdowns already jumpered See Figure A 5 A 3 5 2 o o 5 E a e p og s 5 55 8 o Lm O 5 o c 5 J 2 IL 5 A 9 o o c o D og UU O o S E A 2 gt ot zo 5 5 gt Ow
239. ut BREEN 15MB5931 T 1 is SMB5926 15W 6 2v D46 34 8 A 850 44 2 15W 194985936 J4 1 STATUS LED CIRCUITRY Zk 072 108 014 JUS STATUS 15W 15485029 GROUND TE POINT ELECTRICAL DIAGRAMS 85252 gt ay RS232 TXD m Y NV iaa 2202 5000 1 2 5 014 R132 IM 5 iw 200 HePL esas 4405 des 1 1 28 MMSZE24BBT aus MMSZ524BBT1 158pF MMS252488T1 MMSZ5248BT1 1 28 oto c 052 085232 ces 2 1 GVRS2352 Hd 5VA5232 42 2 44 6 GRS232 Ren ee FULL DUPLEX RS232 COMMUNICATION LINK 03232 4 Ae 5CAN S C117 2195 R195 amp tuF 1 80k 475 2 G 7 B 2198 nd RX1 RX CAN 625 1 lt P24 DSACKBe 22 3 E a 28 peser P22 8 ics P2 1 WRH P PA V CLKOUT 5 ROY MIS 1 18 J73 Sani EU ane P145 ADB 5 403 Pi 1 A08 AD4 MOSI PLAADI ADS FLS ADA ADG SCLK PLAZA PESADI 2 YTALt 26 XTAL2 P17 ADi 157 15859 551 ENS y DATA
240. ute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was notthe problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims POWER WAVE 655 R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o gx Of gt 0912 Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR USING THE STATUS LED TROUBLESHOOT SYSTEM PROBLEMS The Power Wave Power Feed are best diagnosed as a system Each component power source user inter face and feed head has a status light and when a problem occurs it is important to note the condition of each In addition errors displayed on the user interface in most cases indicate only that a problem exists in the power source not what the problem may be T
241. wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and t
242. ystem Each component in the system has spe cial circuitry to talk with the other system compo nents so each component power source wire feeder electrical accessories knows whatthe other is doing at all times The components communicate with Arc Link Robotic systems can communicate with other industri al machines via DeviceNET The result is highly intri gated and flexible welding cell The Power Wave 655 R is a high performance digital ly controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW and CAC A processes It carries an out put rating of either 650 amps 44 volts at 100 duty cycle and 800 amps 44 volts at 6096 duty cycle If the duty cycle is exceeded a thermostat will shut off the output until the machine cools to a reasonable operating temperature RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Wave 655 R can be set up in a number of configurations some requiring optional equipment or welding programs Each machine is factory prepro grammed with multiple welding procedures typically including GMAW GMAW P FCAW GTAW CAC A and SMAW for a variety of materials including mild steel stainless steel cored wires and aluminum The Power Wave 655 R can be configured for either robotic or semi automatic use RECOMMENDED EQUIPMENT Automatic Operation All welding programs

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