Instruction/ maintenance manual of the product 655/R Lincoln Electric
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PO WER W A VE 655/R SVM180-A January , 2008 For use with machines having Code Numbers: 10630, 10863, 1 1410 TM SER VICE MANUAL Return to Master TOC Return to Master TOC Return to Master TOC Return.
SAFETY i i Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.
SAFETY ii ii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume.
SAFETY iii iii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar ʻ95 FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b.
SAFETY iv iv Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions.
I I - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - POWER W A VE 655/R RETURN TO MAIN INDEX Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INST ALLA TION A-2 A-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
INST ALLA TION A-3 A-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC state fan control relay , located on the back of the Control PC board enclosure.
INST ALLA TION A-4 A-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power W ave.
INST ALLA TION A-5 A-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
INST ALLA TION A-6 A-6 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
INST ALLA TION A-7 A-7 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE SENSING The best arc performance occurs when the Power W aves has accurate data about the arc conditions.
INST ALLA TION A-8 A-8 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE / POWER FEED WIRE FEEDER INTERCONNECTIONS Connect the control cable between the power source and wire feeder .
INST ALLA TION A-9 A-9 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PC board switch change.
INST ALLA TION A-10 A-10 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DIP Switch Settings and Locations DIP switches on the P .
INST ALLA TION A-11 A-11 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES A-12 A-12 POWER W A VE.
T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERA TION B-2 B-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine.
OPERA TION B-3 B-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to M.
OPERA TION B-4 B-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECOMMENDED EQUIPMENT • Automatic Operation All welding programs and procedures are set through software for the robotic Power W aves.
OPERA TION B-5 B-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Light Condition Steady Green Blinking Green Alternating Green and Red Steady Red Blinking Red Meaning S y s t e m O K .
OPERA TION B-6 B-6 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to M.
OPERA TION B-7 B-7 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES B-8 B-8 POWER W A VE 6.
T ABLE OF CONTENTS - ACCESSORIES C-1 C-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES C-2 C-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONAL EQUIPMENT F ACTOR Y INST ALLED There are no factory installed options available for the Power W ave.
T ABLE OF CONTENTS - MAINTENANCE D-1 D-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE D-2 D-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.
MAINTENANCE D-3 D-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 1 7 7 7 7 7 7 3 3 4 4 5 5 2 2 6 6 2 2 2 2 1.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES D-4 D-4 POWER W A VE 6.
T ABLE OF CONTENTS - THEOR Y OF OPERA TION E-1 E-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEOR Y OF OPERA TION E-2 E-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC .
THEOR Y OF OPERA TION E-3 E-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT VOL T AGE AND PRECHARGE The Power W ave 655/R can be connected for a variety of three-phase input voltages.
THEOR Y OF OPERA TION E-4 E-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC .
THEOR Y OF OPERA TION E-5 E-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC .
THEOR Y OF OPERA TION E-6 E-6 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E.
THEOR Y OF OPERA TION E-7 E-7 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC .
THEOR Y OF OPERA TION E-8 E-8 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC .
THEOR Y OF OPERA TION E-9 E-9 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL PROTECTION Three normally closed (NC) thermostats protect the machine from excessive operating temperatures.
THEOR Y OF OPERA TION E-10 E-10 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INSULA TED GA TE BIPOLAR TRANSISTOR (IGBT) OPERA TION An IGBT is a type of transistor .
THEOR Y OF OPERA TION E-11 E-11 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TO.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES E-12 E-12 POWER W A VE.
T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR F-1 F-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING & REP AIR F-2 F-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions.
TROUBLESHOOTING & REP AIR F-3 F-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Sometimes machine failures appear to be due to PC board failures.
TROUBLESHOOTING & REP AIR F-4 F-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power W ave / Power Feed are best diagnosed as a system.
TROUBLESHOOTING & REP AIR F-5 F-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Mas.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not un.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not un.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not un.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not .
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not .
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 .
SWITCH BOARD CAP ACIT OR TERMINALS FIGURE F .1 – CAP ACITOR DISCHARGE PROCEDURE INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the left and right case sides. 3. Remove the two Hi gh V oltage Protection shields.
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 .
FIGURE F .2 – LEFT SIDE SWITCH BOARD TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case sides. 3. Perform the Capacitor Discharge Procedure. 4 Using the volt-ohmmeter , perform the resistance tests detailed in T able F .
(LEFT ) 11 NEG POS 13 12 NEG POS 14 (RIGHT ) 16 NEG POS 18 15 NEG POS 17 FIGURE F .3 – RIGHT SIDE AND TEST POINTS SWITCH BOARD TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-15 F-15 POWE.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-16 F-16 POWER W A VE.
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 .
NEG (-) A B C INPUT RECTIFIER POS (+) FIGURE F .4 – INPUT RECTIFIER TEST INPUT RECTIFIER TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top and Input Panel. 3. Perform the Capacitor Discharge Procedure.
T ABLE F .2 – INPUT RECTIFIER TEST POINTS AND ACCEPT ABLE READINGS INPUT RECTIFIER TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-19 F-19 POWER W A VE 655/R Return to Section TOC Return .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-20 F-20 POWER W A VE.
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 .
INPUT CONT ACTOR 601 X4 FIGURE F .5 – INPUT CONT ACTOR COIL INPUT CONT ACTOR TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 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.
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 .
A1 C13 L1 C15 R12 R9 R10 R11 R25 D1 D2 DZ4 C6 R4 R5 R7 R8 R19 X1 X2 C2 C3 C5 C7 C8 C9 C10 C11 MOV1 LED1 R3 R13 R14 R20 R21 R22 R23 DZ5 DZ6 R15 R16 D3 J47 J46 C14 C16 C17 D4 D5 MOV2 R26 R27 R28 R29 C1 LED J47 J46 1 2 1 2 3 4 5 6 7 8 3 4 C3 Power Bd. Rectier FIGURE F .
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 .
PO WER PC BO ARD CAP ACITOR C3 P ower Bd. Rectier 6 5 4 4 3 12 11 10 9 8 7 3 2 1 2 1 6 5 4 3 2 1 FIGURE F .7 – POWER BOARD TEST POWER BOARD TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top.
T ABLE F .4 – POWER BOARD VOL T AGE CHECKS POWER BOARD TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-27 F-27 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Sec.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-28 F-28 POWER W A VE.
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 .
FIGURE F .8 – INPUT BOARD AND CONT ACTOR INPUT BOARD TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top. 3. Remove lead X4 from the coil terminal of main input contactor CR1. Insulate lead X4.
T ABLE F .5 – INPUT BOARD VOL T AGE CHECKS INPUT BOARD TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-31 F-31 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Sec.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-32 F-32 POWER W A VE.
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 .
FIGURE F .9 – CURRENT TRANSDUCER TEST CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top and the control box cover . 3. Locate the current transducer leads at Control Board plug J8.
FIGURE F .10 – RS 232 port CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-35 F-35 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-36 F-36 POWER W A VE.
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 .
NEGA TIVE (-) OUTPUT TERMINALS POSITIVE (+) OUTPUT TERMINALS R1 FIGURE F .1 1 – OUTPUT RECTIFIER TEST OUTPUT RECTIFIER TEST PROCEDURE (CONTINUED) PROCEDURE 1. Remove main input supply power to the POWER W A VE 655/R. 2. Remove the case sides and perform the Input Filter Capacitor Discharge procedure.
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 .
INPUT CONT ACTOR 601 X4 POWER BOARD RECTIFIER BRIDGE X1 X2 + - X3 X5 AUXILIAR Y TRANSFORMER #1 WHITE RED F AN MOTOR WINDING F AN RELA Y 444 X3A FIGURE F .12 – AUXILIAR Y TRANSFORMER NO. 1 TEST AUXILIAR Y TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED) PROCEDURE 1.
AUXILIAR Y TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED) TROUB L ESHOOTING & REP A IR F-41 F-41 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-42 F-42 POWER W A VE.
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 .
1 2 5 3 4 3 2 1 5 2 6 3 6 4 4 1 35 0 (W HITE ) 35 2 (BL ACK ) 3 3 (R ED ) 32 (W HITE ) 3 52A (BL AC K) H6 33 A (RE D) H1 T o W A TER COOLER RECEPT ACLE (S8) T o S4, CB2 & A UX. F AN T o AUX.ILIAR Y TRANSFORMER #2 PRIMARY (P50) FIGURE F .13 – AUXILIAR Y TRANSFORMER NO.
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 .
NEG (-) A B C INPUT RECTIFIER POS (+) FIGURE F .14 – INPUT RECTIFIER REMOV AL AND REPLACEMENT INPUT RECTIFIER REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R. 2. Remove the case top, sides, and input access panel.
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 .
INPUT CONT ACTOR 601 X4 FIGURE F .15 – INPUT CONT ACTOR REMOV AL AND REPLACEMENT INPUT CONT ACTOR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R. 2. Remove the case top, sides and input access panel.
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 .
INPUT CONT ACTOR 601 X4 POWER BOARD RECTIFIER BRIDGE X1 X2 + - X3 X5 AUXILIARY TRANSFORMER #1 WHITE RED F AN MOTOR WINDING F AN RELA Y 444 X3A FIGURE F .16 – AUXILIAR Y TRANSFORMER NO. 1 REMOV AL AND REPLACEMENT AUXILIAR Y TRANSFORMER NO. 1 REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1.
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 .
1 2 5 3 4 3 2 1 5 2 6 3 6 4 4 1 35 0 (W HIT E) 35 2 (BL AC K) 3 3 (R ED ) 32 (W HITE ) 3 52A (BL AC K) H6 33 A (RE D) H1 T o W A TER COOLER RECEPT ACLE (S8) T o S4, CB2 & A UX. F AN T o AUX.ILIAR Y TRANSFORMER #2 PRIMARY (P50) FIGURE F .17 – AUXILIAR Y TRANSFORMER NO.
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 .
C ONTROL BOARD FEED HEAD BO ARD A UXILIARY DRIVER BD . VOL T AGE SENSE BD . Step 6 Removal Step 6 Removal FIGURE F .18 – CONTROL OR FEED HEAD BOARD REMOV AL AND REPLACEMENT CONTROL, FEED HEAD, VOL T AGE SENSE OR AUXILIAR Y DRIVER BOARD REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1.
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 .
Suppor t the P anel Ethernet/ Gateway PC Board FIGURE F .19 – GA TEW A Y BOARD REMOV AL AND REPLACEMENT ETHERNET/GA TEW A Y PC BOARD REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R. 2.
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 .
CURRENT TRANSDUCER + THIS SIDE F ACES REAR FIGURE F .20 – POWER W A VE CURRENT TRANSDUCER REMOV AL AND REPLACEMENT PROCEDURE CURRENT TRANSDUCER REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R.
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 .
J 60 J48 J40/50 Output Choke Connection F an Relay Fr ont Horizontal Divider Panel Rear Horizontal Divider Panel F ront P anel Screws P ower Switch FIGURE F .21 – ACCESSING THE RECTIFIER MODULE OUTPUT RECTIFIER MODULE REPLACEMENT PROCEDURE (CONTINUED) ACCESSING THE RECTIFIER MODULE 1.
FIGURE F .22 – RECTIFIER MODULE REPLACEMENT OUTPUT RECTIFIER AND RECTIFIER MODULE REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) RECTIFIER MODULE TESTING 1.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-62 F-62 POWER W A VE.
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 .
SWITCH BOARD CAP ACIT OR TERMINALS FIGURE F .23 – SWITCH BOARD AND FIL TER CAP ACITOR REMOV AL AND REPLACEMENT SWITCH BOARD AND FIL TER CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE Observe all static electricity precau- tions .
SWITCH BOARD AND FIL TER CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-65 F-65 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Sec.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-66 F-66 POWER W A VE.
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 .
CALIBRA TION PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-68 F-68 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .
CALIBRA TION PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-69 F-69 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CALIBRA TION PROCEDURE 1.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-70 F-70 POWER W A VE.
RETEST AFTER REP AIR TROUBLESHOOTING & REP AIR F-71 F-71 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T EST PROCEDURE 1.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-72 F-72 POWER W A VE.
T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL DIAGRAMS G-2 WIRING DIAGRAM - CODE 10630 EN-170 G3498 INVERTER WELDERS WIRING DIAGRAM NO NE G3792 lw imb ley K.J U STI CE EAE UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± .
ELECTRICAL DIAGRAMS G-3 WIRING DIAGRAM - CODE 10863 EN-170 G349 8- 1 INVERTER WELDERS WIRING DIAGRAM NO NE G3498 lw imb ley K.J U STI CE - UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± .
ELECTRICAL DIAGRAMS G-4 WIRING DIAGRAM - CODE 1 1410 EN-170 S O L ID E D G E G349 8- 2 PO WE R W AVE 65 5/R W IRI N G DIA GRAM NONE G3498- 1 DO NO T SC AL E T HIS DR A WING EQ UIP M ENT TYPE: SUBJECT:.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 COMP.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 COMP.
ELECTRICAL DIAGRAMS G-7 COMPLETE MACHINE SCHEMA TIC - CODE 1 1410 EN-170 S O L ID ED G E G361 1- 2 POWERWAVE 65 5/R MACHI NE SCHEMATI C NO NE G3611-1 RAS PW - UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± .
ELECTRICAL DIAGRAMS G-8 SCHEMA TIC - DEVICENET/GA TEW A Y PC BOARD (SHEET 1) G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-9 SCHEMA TIC - DEVICENET/GA TEW A Y PC BOARD (SHEET 2) G-9 NOTE: This diagram is for reference only .
ELECTRICAL DIAGRAMS G-10 SCHEMA TIC - ETHERNET/GA TEW A Y PC BOARD (SHEET 1) G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-11 SCHEMA TIC - ETHERENET/GA TEW A Y PC BOARD (SHEET 2) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-12 SCHEMA TIC ETHERNET/GA TEW A Y PC BOARD (SHEET 3) G-12 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-13 SCHEMA TIC - CONTROL PC BOARD (SHEET 1) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI .
ELECTRICAL DIAGRAMS G-14 SCHEMA TIC - CONTROL PC BOARD (SHEET 2) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI . UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-15 SCHEMA TIC - CONTROL PC BOARD (SHEET 3) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI .
ELECTRICAL DIAGRAMS G-16 SCHEMA TIC - CONTROL PC BOARD (SHEET 4) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI . UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-17 SCHEMA TIC - DIGIT AL POWER SUPPL Y PC BOARD .1 C 53 Vfb2 Vref 1 100K R29 CNY17-3 OCI2 4 2 1 6 5 .
ELECTRICAL DIAGRAMS G-18 SCHEMA TIC - FEED HEAD PC BOARD (SHEET 1) G-18 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-19 SCHEMA TIC - FEED HEAD PC BOARD (SHEET 2) G-19 NOTE: This diagram is for reference only .
ELECTRICAL DIAGRAMS G-20 SCHEMA TIC - FEED HEAD PC BOARD (SHEET 3) G-20 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-21 SCHEMA TIC - INPUT PC BOARD G-21 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
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.
ELECTRICAL DIAGRAMS G-23 SCHEMA TIC - SWITCH PC BOARD G-23 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
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.
ELECTRICAL DIAGRAMS G-25 SCHEMA TIC - VOL T AGE SENSE PC BOARD G-25 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
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.
ELECTRICAL DIAGRAMS G-27 SCHEMA TIC - 40VDC BUS PC BOARD G-27 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
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.
ELECTRICAL DIAGRAMS G-29 SCHEMA TIC - AUXILIAR Y DRIVER PC BOARD G-29 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
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.
An important point after buying a device Lincoln Electric 655/R (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric 655/R yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric 655/R - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric 655/R you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric 655/R will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric 655/R, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric 655/R.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric 655/R. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric 655/R along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
