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POWERWAVE
TM
655/R
January, 2008
For use with machines having Code Numbers: 10630, 10863, 11410
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Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
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SERVICE MANUAL
Copyright © Lincoln Global Inc.
• 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
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i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing 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 position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In 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.
___________________________________________________
1.f. 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.
___________________________________________________
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.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. 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.
2.d.2. Never coil the electrode lead around your body.
2.d.3. 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.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
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ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while 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.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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3.g. Never dip the electrode in water for cooling.
3.h. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a.
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Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I 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.
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. 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 and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is 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 products.
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.
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5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug ʻ06
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iii
WELDING SPARKS can
cause fire or explosion.
SAFETY
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.d. 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
Safe 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).
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
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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.
6.b. 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.
6.c. 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.
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CYLINDER may explode
if damaged.
iii
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the 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.
6.h. Also see item 1.c.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson 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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
Mar ʻ95
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iv
PRÉCAUTIONS DE SÛRETÉ
SAFETY
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
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6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar ʻ93
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN
TOMAIN
MAINMENU
INDEX
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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-392
POWER WAVE 655/R
I
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A-1
TABLE OF CONTENTS - INSTALLATION SECTION
A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
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Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Frequency Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Input Fuse and Supply Wire Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Input Voltage Change Over (For Multiple Input Voltage Machines Only) . . . . . . . . . . . . . . . . . . . . . . .A-4
Welding with Multiple Power Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Electrode and Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Cable Inductance and its Effect on Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
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Negative Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Work Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Electrode Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Power Wave / Power Feed Wire Feeder Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Control Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
External I/O Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
High Speed Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
Dip Switch Settings and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
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Control Board Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Feed Head Board Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Devicenet/Gateway Board Dip Switch, Bank (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Devicenet/Gateway Board Dip Switch, Bank (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11
POWER WAVE 655/R
INSTALLATION
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A-2
TECHNICAL SPECIFICATIONS - POWER WAVE 655/R (K1519-1, K1519-2)
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INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS
CODE NUMBERS
10630
OUTPUT
CONDITIONS
[email protected]%
460/575V - 60HZ. 815A@44V. 60%
10863
400V - 50HZ.
11410
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A-2
[email protected]%
675A@44V. 60%
460/575V - 60HZ. [email protected]%
815A@44V. 60%
OPEN
PULSE
CURRENT
PULSE
CIRCUIT
RANGE FREQUENCY VOLTAGE
VOLTAGE
RANGE
75 VDC
INPUT
IDLE
POWER FACTOR EFFICIENCY
CURRENT POWER
@ RATED
@ RATED
AMPS
OUPUT
OUPUT
43/34
53/42
40
51
41/33
53/42
400 Watts
Max.
OUTPUT
PULSE AND
BACKGROUND
TIME RANGE
PROCESS CURRENT RANGES (DC)
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50-815 Average Amps
40-815 Average Amps
30-600 Average Amps
15-880 Peak Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT
VOLTAGE /
FREQUENCY
TYPE 75°C
COPPER WIRE IN
CONDUIT AWG[MM2]
SIZES
TYPE 75°C
GROUND WIRE IN
CONDUIT AWG[MM2]
SIZES
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
460V - 60HZ.
575V - 60HZ.
6 (16)
6(16)
8 (10)
10 (6)
70
60
HEIGHT
26.10 in
663 mm
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40 VDC AT
10 AMPS
110 VAC AT
10 AMPS
CURRENT
MIG/MAG
FCAW
SMAW
Pulse
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AUXILIARY POWER
(CIRCUIT BREAKER
PROTECTED)
0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. 3.3 SEC.
20-880
84%
.95 MIN.
WIDTH
19.86 in
505 mm
PHYSICAL DIMENSIONS
DEPTH
32.88 in
835 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
WEIGHT
306 lbs.
139 kg.
STORAGE TEMPERATURE RANGE
-40°C to +40°C
POWER WAVE 655/R
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A-3
SAFETY PRECAUTIONS
INSTALLATION
Read this entire installation section before you
start installation.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment. Turn off the input power
to any other equipment connected to the welding system at
the disconnect switch or fuse
box before working on the
equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door)
to a proper safety (Earth) ground.
SELECT SUITABLE 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 surfaces. Where there is a combustible surface directly
under stationary or fixed electrical equipment, that surface 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 circulate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign material 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.
A-3
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 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.
------------------------------------------------------------------------
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
POWER WAVE 655/R
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A-4
INSTALLATION
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
INPUT SUPPLY CONNECTION DIAGRAM
. Disconnect input power before
.
.
.
W / L3
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V / L2
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A-4
U / L1
XA
inspecting or servicing machine.
Do not operate with covers
removed.
Do not touch electrically live parts.
Only qualified persons should install,
use or service this equipment.
CR1
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
S24190
NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.
WARNING
INPUT CONNECTION
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 connection diagram 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 A.1 .
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
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 connection 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.
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 voltage, 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.
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
wire sizes. Fuse the input circuit with the recommended 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.
POWER WAVE 655/R
INSTALLATION
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A-5
WELDING WITH MULTIPLE POWER
WAVES
CAUTION
Special care must be taken when more than one
Power Wave is welding simultaneously on a single
part. Arc blow and arc interference may occur or
be magnified.
Each power source requires a work lead from the work
stud to the welding fixture. Do not combine all of the
work leads into one lead. Perform welding in the direction away from the work leads. 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 frequency will be the same, helping to stabilize the arcs.
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas coverage.
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
TWO POWER WAVES
POWERWAVE
POWERWAVE
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-
+
Electrode Lead
-
Travel
Direction
+
Electrode Lead
Connect All Work
Sense Leads at the End
of the Joint
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Connect All Welding
Work Leads at the
Beginning of the Joint
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A-5
POWER WAVE 655/R
INSTALLATION
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A-6
ELECTRODE AND WORK CABLE
CONNECTIONS
Connect a work lead of sufficient size and length (Per
Table 1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work and wire feeder. Avoid
excessive lengths and do not coil excess cable.
Minimum work and electrode cable sizes are as follows:
TABLE 1 (For cable length up to 100 ft, or 30 meters)
CURRENT (60% Duty Cycle)
MINIMUM COPPER
400 Amps
2/0 (67mm2)
500 Amps
3/0 (85mm2)
600 Amps
3/0 (85mm2)
When using inverter type power sources like 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 normally 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.
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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), traditional 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).
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.)
POWER
WAVE
B
A
A
B
WORK
SLIDING GROUND
K1796 COAXIAL CABLE
C
B
MEASURE FROM END
OF OUTER JACKET OF
CABLE
CAUTION
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.
-----------------------------------------------------------------------Most welding applications run with the electrode being positive (+). For those applications, connect one end of the electrode 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-tometal electrical contact. The electrode cable should be sized
according to the specifications given in the work cable connections 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 welding is planned. Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory welding performance.
A
C
FIGURE A.4
C
FIGURE A.3
POWER
WAVE
A-6
WORK
POWER WAVE 655/R
INSTALLATION
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A-7
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) stud, and work cable to the positive (+)
stud).
When operating with electrode polarity negative the
DIP switch 7 must be set to ON on the Wire Feed Head
PC Board. The default setting of the switch is OFF to
represent positive electrode polarity.
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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.
8
7
6
5
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) connects to the Power Wave at the four-pin connector
located underneath the output stud cover.
Enable the voltage sense leads as follows:
TABLE 2
Process Electrode Voltage
Work Voltage
Sensing 67 lead *
Sensing 21 lead
GMAW 67 lead required
21 lead optional**
GMAW-P 67 lead required
21 lead optional**
FCAW 67 lead required
21 lead optional**
GTAW Voltage sense at studs Voltage sense at studs
SAW
67 lead required
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.
3
4
If the voltage sensing is enabled but the sense
leads are missing or improperly connected,
extremely high welding outputs may occur.
2
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
negative electrode polarity.
CAUTION
1
3. The Feed Head PC Board is on the right
side of the power source. Locate the 8position DIP switch and look for switch 7
of the DIP switch.
The best arc performance occurs when the Power
Waves has accurate data about the arc conditions.
Depending upon the process, inductance within the
electrode and work lead cables can influence the voltage apparent at the contact tip. Voltage sense leads
improve the accuracy of the arc conditions and can
have a dramatic effect on performance.
O
N
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2. Remove the front cover from the power source.
VOLTAGE SENSING
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5. Replace the cover and screws. The PC board will
“read” the switch at power up, and configure the
work voltage sense lead appropriately.
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A-7
POWER WAVE 655/R
INSTALLATION
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A-8
Work Voltage Sensing
The Power Waves are shipped from the factory with
the work sense lead enabled.
For processes requiring work voltage sensing, connect
the (21) work voltage sense lead from the Power Wave
to the work. Attach the sense lead to the work as close
to the weld as practical. Enable the work voltage sensing in the Power Wave as follows:
WARNING
ELECTRIC SHOCK can kill.
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• 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.
8
7
6
5
4
3
2
1
4. Using a pencil or other small object,
slide the switch right to the OFF position
if the work sense lead is NOT connected. Conversely, slide the switch left to
the ON position if the work sense lead is
present.
5. Replace the cover and screws. The PC
board will “read” the switch at power up, and configure the work voltage sense lead appropriately.
O
N
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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.
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.
A-8
POWER WAVE / POWER FEED
WIRE FEEDER
INTERCONNECTIONS
Connect the control cable between the power source
and wire feeder. The wire feeder connection on the
robotic Power Waves is located under the spring
loaded output cover, near the bottom of the case front.
The control cable is keyed and polarized to prevent
improper connect.
For convenience, the electrode and control cables can
be routed behind the left or right strain reliefs (under
the spring loaded output cover), and along the channels 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 connection 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 use of non-standard cables, especially in
lengths greater than 25 ft(7.6m), can lead to communication 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
EXTERNAL I/O CONNECTOR
INSTALLATION
The Power Wave is equipped with a port for making
simple input signal connections. The port is divided into
three groups: Trigger group, Cold Inch Group and
Shutdown Group. Because the Power Wave is a ʻslaveʼ
on the DeviceNet network, the Trigger and Cold Inch
Groups are disabled when the DeviceNet / Gateway is
active.
The shutdown group is always enabled. Shutdown 2 is
used for signaling low flow in the water cooler. Unused
shutdowns must be jumpered. Machines from the factory come with the shutdowns already jumpered.(See
Figure A.5)
B
• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
G
1. Set the High/Low switch code on Wire Drive PC
board as follows:
• Turn off power to the power source at the disconnect switch.
7
6
5
4
• Using a pencil or other small object,
slide the switch right to the OFF position,
when the low speed gear is installed.
Conversely, slide the switch left to the
ON position when the high speed gear is
installed.
3
• The wire feed head board is on the right
side of the power source. Locate the 8position DIP switch and look for position
8 of the DIP switch.
8
• Remove the front cover from the power source.
2
9 10 11 12
H
F
ELECTRIC SHOCK can kill.
1
8
Reserved for future use
7
E
C
Shutdown2 input (Water Fault)
6
Shutdown1 input
5
D
WARNING
O
N
A
+15 for shutdown group
4
Gas Purge Input
3
Cold Inch Reverse
4 Step Input
2
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.
HIGH SPEED GEAR BOX
-----------------------------------------------------------
Cold Inch Forward
Dual Procedure Input
1
A-9
• Always wear dry insulating gloves.
+15 VDC for Cold Inch Group
Trigger Input
FIGURE A.5
+15 VDC for Trigger Group
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A-9
I
• 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
INSTALLATION
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A-10
DIP Switch Settings and Locations
DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP
switches:
WARNING
• Turn off power at the disconnect switch.
-----------------------------------------------------------------------• Remove the top four screws securing the front
access panel.
• 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.
• Adjust the DIP switches as necessary.
• Replace the panel and screws, and restore power.
Control Board
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Right
Control Board DIP Switch:
switch 1 = Object Instance LSB1 (see table 3)
switch 2 = Object Instance MSB2 (see table 3)
=
=
=
=
=
=
1
2
3
4
5
6
7
=
=
=
=
=
=
=
switch 7
off
on
electrode polarity
positive (default)
negative
switch 8 = high speed gear
switch 8
off
on
wire drive gear
low speed gear (default)
high speed gear
DeviceNET/Gateway Board DIP Switch:
switch
switch
switch
switch
switch
switch
switch
switch
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
off
off
on
on
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
reserved for future use
work sense lead
1 LEASE SIGNIFICANT BIT
2 MOST SIGNIFICANT BIT
switch 8 work sense lead
off
on
Object Instance LSB (see table 3)
Object Instance MSB (see table 3)
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
negative polarity switch
Object Instance LSB (see table3)
Object Instance MSB (see table 3)
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
Reserved for future use
Reserved for future use
TABLE 3
Object Instance
switch 2 switch 1
DeviceNET/Gateway Board
3
4
5
6
7
8
switch
switch
switch
switch
switch
switch
switch
Bank (S1):
Feed Head Board
Left
switch
switch
switch
switch
switch
switch
Feed Head Board DIP Switch:
work sense lead not connected
work sense lead connected
POWER WAVE 655/R
off
on
off
on
Instance
0 (default)
1
2
3
A-10
INSTALLATION
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A-11
Bank (S2):
switch
1
2
Description
Devicenet Baud Rate
(see table 4)
S24958-6 and later
switch 1 switch 2
off
off
off
on
on
off
on
on
software
baud rate
125K
250K
500K
Programmable value
TABLE 4
Prior to S24958-6 software
switch 1 switch 2 baud rate
off
off
Programmable value
on
off
125K
off
on
250K
on
on
500K
Bank (S2):
switch
3
thru
8
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description
Devicenet Mac ID
(see table 5)
TABLE 5
SWITCH 8 SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
A-11
SWITCH 8 SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3
18
0
1
0
0
19
0
1
0
0
20
0
1
0
1
21
0
1
0
1
22
0
1
0
1
23
0
1
0
1
24
0
1
1
0
25
0
1
1
0
26
0
1
1
0
27
0
1
1
0
28
0
1
1
1
29
0
1
1
1
30
0
1
1
1
31
0
1
1
1
32
1
0
0
0
33
1
0
0
0
34
1
0
0
0
35
1
0
0
0
36
1
0
0
1
37
1
0
0
1
38
1
0
0
1
39
1
0
0
1
40
1
0
1
0
41
1
0
1
0
42
1
0
1
0
43
1
0
1
0
44
1
0
1
1
45
1
0
1
1
46
1
0
1
1
* 47
1
0
1
1
48
1
1
0
0
49
1
1
0
0
50
1
1
0
0
51
1
1
0
0
52
1
1
0
1
53
1
1
0
1
54
1
1
0
1
55
1
1
0
1
56
1
1
1
0
57
1
1
1
0
58
1
1
1
0
59
1
1
1
0
60
1
1
1
1
61
1
1
1
1
62
1
1
1
1
*Software Selectable (Line 0)
**Default Setting (Line 62)
POWER WAVE 655/R
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
**
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A-12
NOTES
POWER WAVE 655/R
A-12
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B-1
TABLE OF CONTENTS - OPERATION SECTION
B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Recommended Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
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Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Duty Cycle and Time Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Welding Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Constant Voltage Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
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Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
POWER WAVE 655/R
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B-2
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
WARNING
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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.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Use ventilation or exhaust to remove
fumes from breathing zone.
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• Keep your head out of fumes.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
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• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the beginning
of this manual.
POWER WAVE 655/R
B-2
OPERATION
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B-3
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
INPUT POWER
SMAW
ON
GMAW
OFF
FCAW
HIGH TEMPERATURE
GTAW
U0
MACHINE STATUS
CIRCUIT BREAKER
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U1
U2
WIRE FEEDER
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B-3
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 PHASE INVERTER
I1
I2
OPEN CIRCUIT
VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVE
GROUND
INPUT POWER
WARNING OR
CAUTION
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THREE PHASE
DIRECT CURRENT
POWER WAVE 655/R
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B-4
OPERATION
The Power Wave power source is designed to be a
part of a modular, multi-process welding system.
Depending on configuration, it can support constant
current, constant voltage, and pulse welding modes.
GENERAL DESCRIPTION
The Power Wave power source is designed to be used
with the family of Power Feed wire feeders, operating
as a system. Each component in the system has special circuitry to "talk with" the other system components, so each component (power source, wire feeder,
electrical accessories) knows what the other is doing at
all times. The components communicate with Arc-Link.
Robotic systems can communicate with other industrial machines via DeviceNET. The result is highly intrigated and flexible welding cell.
The Power Wave 655/R is a high performance, digitally 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 output rating of either 650 amps, 44 volts (at 100% duty
cycle) and 800 amps, 44 volts (at 60% 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
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 preprogrammed 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.
RECOMMENDED PROCESSES
• Automatic Operation
All welding programs 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 equipment such as PLCʼs or computers can communicate
to the Power Wave using DeviceNET.
All wire welding processes require a robotic Power
Feed wire feeder.
RECOMMENDED EQUIPMENT
• Semi-Automatic Operation
Operating the Power Wave 655/R in the semi-automatic 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
• Power Waves are not to be used in outdoor environments.
• 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.
LIMITATIONS
The Power Feed wire feeders are capable of welding
at a 100% 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 60% duty cycle represents
6 minutes of welding and 4 minutes of idling in a ten
minute period.
DUTY CYCLE AND TIME PERIOD
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The Power Wave 655/R can be configured for either
robotic or semi-automatic use.
B-4
POWER WAVE 655/R
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1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green
light. Error conditions are indicated per table 4.
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NOTE: The robotic Power Waveʼs status light will flash
green, and sometimes red and green, for up to one
minute when the machine is first turned on. This is a
normal situation as the machine goes through a self
test at power up.
Meaning
Light
Condition
Steady Green System OK. Power source communicating normally with wire feeder and its components.
Blinking
Green
Alternating
Green and
Red
5
LINK
STUD
Blinking Red
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Occurs during a reset, and indicates the PW655/R is mapping (identifying) each component
in the system. Normal for first 1-10 seconds
after power is turned on, or if the system configuration is changed during operation.
Non-recoverable system fault. If the PS
Status light is flashing any combination of red
and green, errors are present in the PW655/R. Read the error code 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.
5
B-5
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature situation occurs. Output is disabled until the
machine cools down. When cool, the light goes out
and output is enabled.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER:
Protects 110 volt AC case front receptacle auxiliary
supply.
6. LEAD CONNECTOR S2 (SENSE LEAD)
7. 5-PIN ARC LINK S1
8. 5-PIN DEVICENET CONNECTOR S5
9. I / O CONNECTOR
TABLE 6
Steady Red
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OPERATION
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
CASE FRONT CONTROLS
SENSE
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B-5
To clear the error, turn power source off, and
back on to reset. See Troubleshooting
Section.
10. NEGATIVE STUD
11. INTERFACE CONNECTOR S6
12. POSITIVE STUD
13. AUXILIARY OUTPUT
FIGURE B.1
3
2
POWERWAVE
1
6
7
8
11
9
10
12
-
+
Not applicable.
Not applicable.
13
5
4
Case Front Layout
Power Wave 655/R (Domestic/Canadian Version)
POWER WAVE 655/R
OPERATION
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B-6
WELDING MODE DESCRIPTIONS
CONSTANT VOLTAGE WELDING
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special software at the factory. The preprogrammed voltage is the
best average voltage for a given wire feed speed. With
synergic programs, when the wire feed speed changes,
the Power Wave will automatically adjust the corresponding voltage.
Wave control adjusts the inductance of the waveshape.
(This adjustment is often referred to as "pinch". Inductance 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
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
Current
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Time
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B-6
POWER WAVE 655/R
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B-7
PULSE WELDING
OPERATION
Pulse welding procedures are set by controlling an
overall "arc length" variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impractical, and instead the arc length is set by adjusting "trim".
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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 automatically recalculate the waveform parameters to maintain
similar arc properties.
The Power Wave utilizes "adaptive control" to compensate for changes in electrical stick-out while welding. (Electrical stick-out is the distance from the contact tip to the work piece.) The Power Wave waveforms
are optimized for a 0.75" (19mm) stick-out. The adaptive 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 reaching 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
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Time
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B-7
POWER WAVE 655/R
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B-8
NOTES
POWER WAVE 655/R
B-8
TABLE OF CONTENTS - ACCESSORIES
C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Factory Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Field Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
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C-1
POWER WAVE 655/R
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C-2
OPTIONAL EQUIPMENT
ACCESSORIES
FACTORY INSTALLED
There are no factory installed options available for the
Power Wave.
FIELD INSTALLED
Gas Guard Regulator (K659-1)
The Gas Guard regulator is available as an optional
accessory for Power Feed Robotic wire drive unit.
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
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.
C-2
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 flowing. 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 K1767-1.
• Coaxial welding Cable, K1796
POWER WAVE 655/R
TABLE OF CONTENTS - MAINTENANCE
D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Main Assembly (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
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D-1
POWER WAVE 655/R
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D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
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•
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 punctures in the cable jacket, or any condition that would
affect the proper operation of the machine.
CALIBRATION SPECIFICATION
Calibration of the PW-655/R is critical to its operation. The output Voltage and Current are calibrated
at the factory and generally speaking the calibration will not need adjustment. However, neglected
or improperly 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
DVDʼs
or
on
Powerwavesoftware.com. If the system does not
calibrate properly see the troubleshooting section of
this manual.
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PERIODIC MAINTENANCE
PERFORM PERIODICALLY:
Clean the inside of the machine with a low pressure air
stream. Clean the following parts. Refer to Figure D.1.
• 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.
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NOTE: The fan motor has sealed bearings which
require no maintenance.
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D-2
POWER WAVE 655/R
MAINTENANCE
D-3
FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW)
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D-3
7
7
1
7
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3
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4
2
2
6
5
1. CASE FRONT ASSEMBLY
2. TRANSFORMER AND OUTPUT
RECTIFIER ASSEMBLY
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3. INPUT ASSEMBLY
4. CONTROL BOX AND VERTICAL DIVIDER
ASSEMBLY
2
5. BASE, LIFT BAIL AND FAN
ASSEMBLY
6. SWITCH BOARD HEATSINK
ASSEMBLY
7. CASE PARTS
POWER WAVE 655/R
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D-4
NOTES
POWER WAVE 655/R
D-4
TABLE OF CONTENTS - THEORY OF OPERATION
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E-1
E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Voltage and Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Switch Boards and Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
DC Bus Board, Power Board, Feed Head Board, Gateway Board
and Voltage Sense Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
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Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Output Rectifier, and Output Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
Thermal Protection, Protective Circuits, Over Current Protection
and Under/Over Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-11
FIGURE E.1 — BLOCK LOGIC DIAGRAM.
POWER WAVE 655/R
INPUT
RECTIFIER
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HARMONIC
FILTER
NEG
SW1
WORK
TERMINAL
S1
67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
S6
VOLT
SENSE
BOARD
VOLTAGE SENSE
OUTPUT
VOLTAGE SENSE SELECT
ARC LINK
2
4
V
A
C
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
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OUTPUT
CHOKE
67A
INPUT
BOARD
A
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
380415
440460
550575
+
IGBT DRIVE
FROM
CT CURRENT
CONTROL
TO CONTROL
BOARD
BOARD
C
AUX
RECONNECT
ELECTRODE
TERMINAL
LEFT
SWITCH
BOARD
POS
A
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
MAIN
TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
ETHERNET/
GATEWAY
BOARD
DEVICE NET
S5
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
T1
230 VAC
115 VAC
115 VAC
RECP.
+5 V ARC LINK
POWER
BOARD
40 VDC
WATER
COOLER
40 VDC
+5V SPI
THERMOSTATS
CONTROL
BOARD
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
-15 V
Auxiliary
Fan
T2
S6
CONNECTION
TO WIRE
DRIVE
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
S1
ARC LINK
WIRE
FEEDER
RECP.
POWER WAVE 655/R
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
THEORY OF OPERATION
POWER WAVE 655/R
INPUT
RECTIFIER
HARMONIC
FILTER
SW1
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67B
S6
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
VOLTAGE SENSE
OUTPUT
VOLTAGE SENSE SELECT
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
ETHERNET/
GATEWAY
BOARD
DEVICE NET
S5
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
WATER
COOLER
T2
115 VAC
115 VAC
RECP.
S6
CONNECTION
TO WIRE
DRIVE
+5 V ARC LINK
POWER
BOARD
40 VDC
+5V SPI
THERMOSTATS
CONTROL
BOARD
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
Auxiliary
Fan
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VOLT
SENSE
BOARD
ARC LINK
2
4
V
A
C
230 VAC
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WORK
TERMINAL
S1
T1
Return to Section TOC
OUTPUT
CHOKE
67A
INPUT
BOARD
A
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
380415
440460
550575
+
IGBT DRIVE
FROM
CT CURRENT
CONTROL
TO CONTROL
BOARD
BOARD
NEG
AUX
RECONNECT
ELECTRODE
TERMINAL
LEFT
SWITCH
BOARD
POS
A
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
MAIN
TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
C
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E-2
FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE
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E-2
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
S1
ARC LINK
WIRE
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 circuitry to "talk with" the other system components, so
each component (power source, wire feeder, electrical
accessories) knows what the other is doing at all times.
The components communicate with Arc-Link.
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
Robotic systems can communicate with other industrial 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
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E-3
INPUT VOLTAGE AND
PRECHARGE
THEORY OF OPERATION
The Power Wave 655/R can be connected for a variety
of three-phase input voltages. Refer to Figure E.2.
The initial input power is applied through a line switch
located on the front of the machine. 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 transformer 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 receptacle.
The 115/230VAC developed on the secondary of auxiliary transformer T2 is applied to the 115VAC receptacle
and
to
the
water
cooler
receptacle.
The 230VAC supply is also used to operate an auxiliary cooling fan in the upper section of the machine.
This fan runs whenever the power switch is ON.
E-3
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 input lines are connected to the Input Board,
by way of the input line switch SW1. They are then connected 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 capacitors 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 capacitors become undervoltaged, overvoltaged, or unbalanced, 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 Figure E.2.
POWER WAVE 655/R
THEORY OF OPERATION
INPUT
RECTIFIER
HARMONIC
FILTER
SW1
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67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
VOLT
SENSE
BOARD
VOLTAGE SENSE
OUTPUT
VOLTAGE SENSE SELECT
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
ETHERNET/
GATEWAY
BOARD
DEVICE NET
S5
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
DC
BUS
BOARD
BUS BOARD
RECTIFIER
WATER
COOLER
T2
115 VAC
115 VAC
RECP.
S6
CONNECTION
TO WIRE
DRIVE
+5 V ARC LINK
POWER
BOARD
40 VDC
+5V SPI
THERMOSTATS
CONTROL
BOARD
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
Auxiliary
Fan
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S6
ARC LINK
2
4
V
A
C
230 VAC
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WORK
TERMINAL
S1
T1
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OUTPUT
CHOKE
67A
INPUT
BOARD
A
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
380415
440460
550575
+
IGBT DRIVE
FROM
CT CURRENT
CONTROL
TO CONTROL
BOARD
BOARD
NEG
AUX
RECONNECT
ELECTRODE
TERMINAL
LEFT
SWITCH
BOARD
C
A
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
MAIN
TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 655/R
POS
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E-4
FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER
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E-4
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
S1
ARC LINK
WIRE
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 insulated 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 IGBTʼs switch the
DC power from the input capacitors "on and off," thus
supplying pulsed DC current to the main transformer
primary windings. See IGBT OPERATION DISCUSSION AND DIAGRAMS in this section.
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
Each switch board feeds current to separate, oppositely 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 primary currents become abnormally high, the Control
Board will shut off the IGBTs, thus disabling the
machineʼs 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 primary windings. The firing of the two switch boards
occurs during halves of a 50-microsecond interval, creating a constant 20 KHZ output. See the PULSE
WIDTH MODULATION discussion in this section.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
THEORY OF OPERATION
INPUT
RECTIFIER
HARMONIC
FILTER
SW1
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67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
VOLT
SENSE
BOARD
VOLTAGE SENSE
OUTPUT
VOLTAGE SENSE SELECT
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
ETHERNET/
GATEWAY
BOARD
DEVICE NET
S5
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
T2
115 VAC
S6
DC
BUS
BOARD
BUS BOARD
RECTIFIER
115 VAC
RECP.
CONNECTION
TO WIRE
DRIVE
+5 V ARC LINK
POWER
BOARD
40 VDC
WATER
COOLER
+5V SPI
THERMOSTATS
CONTROL
BOARD
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
Auxiliary
Fan
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S6
ARC LINK
2
4
V
A
C
230 VAC
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WORK
TERMINAL
S1
T1
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OUTPUT
CHOKE
67A
INPUT
BOARD
A
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
380415
440460
550575
+
IGBT DRIVE
FROM
CT CURRENT
CONTROL
TO CONTROL
BOARD
BOARD
NEG
AUX
RECONNECT
ELECTRODE
TERMINAL
LEFT
SWITCH
BOARD
C
A
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
MAIN
TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 655/R
POS
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E-5
FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
GATEWAY BOARD AND VOLTAGE SENSE BOARD
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E-5
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
S1
ARC LINK
WIRE
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 regulates that 65VDC to a +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 supply a variety of regulated DC voltages to the Control
Board. The Control Board uses these regulated voltages to power the many circuits and communication
functions incorporated within the Control Board.
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
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 voltage 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 communicates 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 communication information.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
THEORY OF OPERATION
A
rc L
i nk
Arc
Link
Control
Board
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Weld Controller /
Sequencer
Ether net/
Gate way
Board
Translator
Feed
H ead
Board
PW-655R
D
e v ic e N
et
Device
Net
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Robot
Controller
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E-6
FIGURE E.5 – POWER WAVE 655/R COMMUNICATIONS
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E-6
POWER WAVE 655/R
PF-10R
THEORY OF OPERATION
INPUT
RECTIFIER
HARMONIC
FILTER
SW1
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67B
S6
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
VOLTAGE SENSE
OUTPUT
VOLTAGE SENSE SELECT
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
ETHERNET/
GATEWAY
BOARD
DEVICE NET
S5
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
T2
115 VAC
S6
DC
BUS
BOARD
BUS BOARD
RECTIFIER
115 VAC
RECP.
CONTROL BOARD
CONNECTION
TO WIRE
DRIVE
+5 V ARC LINK
POWER
BOARD
40 VDC
WATER
COOLER
+5V SPI
THERMOSTATS
CONTROL
BOARD
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
40 VDC
-15 V
Auxiliary
Fan
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VOLT
SENSE
BOARD
ARC LINK
2
4
V
A
C
230 VAC
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WORK
TERMINAL
S1
T1
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OUTPUT
CHOKE
67A
INPUT
BOARD
A
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
380415
440460
550575
+
IGBT DRIVE
FROM
CT CURRENT
CONTROL
TO CONTROL
BOARD
BOARD
NEG
AUX
RECONNECT
ELECTRODE
TERMINAL
LEFT
SWITCH
BOARD
C
A
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
MAIN
TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
POWER WAVE 655/R
POS
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E-7
FIGURE E.6 – CONTROL BOARD
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E-7
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
S1
ARC LINK
WIRE
FEEDER
RECP.
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 (PWM) signals
are then sent to the gates of the Switch Board IGBTs to
create the high-speed, digitally controlled welding
waveform. (See PULSE WIDTH MODULATION discussion in this section).
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
In addition, the Control Board monitors the thermostats, 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 contactor will be de-energized.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
THEORY OF OPERATION
POWER WAVE 655/R
INPUT
RECTIFIER
HARMONIC
FILTER
SW1
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67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
VOLT
SENSE
BOARD
VOLTAGE SENSE
OUTPUT
VOLTAGE SENSE SELECT
FROM CONTROL
BOARD
FEED
HEAD
BOARD
40 VDC
115 VAC
FAN
RELAY
ETHERNET/
GATEWAY
BOARD
DEVICE NET
S5
CONNECTION
TO
ROBOT
TO
LEFT
S.B.
TO
RIGHT
S.B.
C
U
R
R
E
N
T
F
B
40 VDC
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
ARC LINK
115 VAC
+5V RS232
65 VDC
52 VAC
T2
115 VAC
S6
DC
BUS
BOARD
BUS BOARD
RECTIFIER
115 VAC
RECP.
CONNECTION
TO WIRE
DRIVE
+5 V ARC LINK
POWER
BOARD
40 VDC
WATER
COOLER
40 VDC
+5V SPI
THERMOSTATS
CONTROL
BOARD
S2 WORK
SENSE
+15V SPI
S3
RS232
+5 V
+15 V
-15 V
Auxiliary
Fan
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S6
ARC LINK
2
4
V
A
C
230 VAC
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WORK
TERMINAL
S1
T1
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OUTPUT
CHOKE
67A
INPUT
BOARD
A
+
RIGHT
SWITCH
BOARD
CAP. V/F
FEEDBACK
380415
440460
550575
+
IGBT DRIVE
FROM
CT CURRENT
CONTROL
TO CONTROL
BOARD
BOARD
NEG
AUX
RECONNECT
ELECTRODE
TERMINAL
LEFT
SWITCH
BOARD
C
A
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK
CR1
MAIN
TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD
POS
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E-8
FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD
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E-8
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
40 VDC
S1
ARC LINK
WIRE
FEEDER
RECP.
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 terminals to the welding arc.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 655/R
LEFT CT
CURRENT
FB
RIGHT CT
CURRENT
FB
STATUS
LIGHT
THERMAL
LIGHT
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E-9
THEORY OF OPERATION
THERMAL PROTECTION
Three normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are connected to the control board. One of the thermostats is
located on the heat sink of the output rectifier, one on
the DC bus, and one on the output choke. Excessive
temperatures may be caused by a lack of cooling air or
by operating the machine beyond its duty cycle or output rating. 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 turning or the intake air louvers are obstructed, the power
must be removed from the machine and the fan condition 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) system is controlled by the Control Board via a solid state
relay.
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PROTECTIVE CIRCUITS
Protective circuits are designed into the Power Wave
655/R to sense trouble and shut down the machine
before damage occurs to the machineʼs internal components. Error Codes will be flashed out by the
Red/Green Status LED on the front panel and LEDʼs 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.
E-9
OVER CURRENT PROTECTION
If the average weld current exceeds 880 amps, the
peak current will be limited to 100 amps until the average 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 circuit will de-energize the input contactor. Machine output 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 period 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. (This
would be due to improper input voltage connections.)
4. Internal component damage.
POWER WAVE 655/R
THEORY OF OPERATION
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E-10
FIGURE E.9 – IGBT OPERATION
POSITIVE
VOLTAGE
APPLIED
SOURCE
n+
GATE
SOURCE
n+
n+
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GATE
n+
p
BODY REGION
p
BODY REGION
n-
DRAIN DRIFT REGION
n-
DRAIN DRIFT REGION
n+
BUFFER LAYER
n+
BUFFER LAYER
p+
INJECTING LAYER
p+
INJECTING LAYER
DRAIN
DRAIN
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E-10
B. ACTIVE
A. PASSIVE
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors 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.
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 will allow the IGBT to
conduct and supply current to circuit components coupled to the source. Current will flow through the conducting 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
THEORY OF OPERATION
E-11
FIGURE E.10 – TYPICAL IGBT OUTPUTS
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E-11
25
sec
sec
sec
50
sec
sec
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MINIMUM OUTPUT
24 sec
24 sec
1 sec
1 sec
50 sec
MAXIMUM OUTPUT
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PULSE WIDTH MODULATION
The term PULSE WIDTH MODULATION (PWM) is
used to describe how much time is devoted to conduction 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 signal possible over a 50-microsecond time period.
1
The shaded portion of the signal represents one IGBT
group1, conducting for 1 microsecond. The negative portion 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 darkened area under the minimum output curve can be compared to the area under the maximum output curve. The
more darkened area, the more power is present.
An IGBT group consists of the sets of IGBT modules grouped onto
one switch board.
POWER WAVE 655/R
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E-12
NOTES
POWER WAVE 655/R
E-12
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F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures
Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
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Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Input Rectifier Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21
DC Bus Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Input Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
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Auxiliary Transformer No. 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
Auxiliary Transformer No. 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
Component Removal and Replacement Procedure
Input Rectifier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45
Input Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Auxiliary Transformer No. 1 Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
Auxiliary Transformer No. 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
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Power Wave Current Transducer Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-57
Output Rectifier Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59
Switch Board and Filter Capacitor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-63
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-67
Retest after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F71
POWER WAVE 655/R
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F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
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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 possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, wire feeding problems, and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component 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
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
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POWER WAVE 655/R
F-2
TROUBLESHOOTING & REPAIR
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F-3
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
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CAUTION
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F-3
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems 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.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- Remove your bodyʼs static
charge before opening the staticshielding 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.
- If you donʼt 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.
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Donʼt set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board canʼt be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
donʼt 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 proper 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
substitute 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 not the 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.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
POWER WAVE 655/R
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F-4
TROUBLESHOOTING & REPAIR
important if the user interface displays "Err 006" or
"Err 100" .
USING THE STATUS LED TO
TROUBLESHOOT SYSTEM
PROBLEMS
The Power Wave / Power Feed are best diagnosed as
a system. Each component (power source, user interface, and feed head) has a status light, and when a
problem occurs it is important to note the condition of
each. 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.
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Therefore, 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.
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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.
2. Occurs during a reset, and indicates the Power
Wave 455M (CE) is mapping (identifying) each component in the system. Normal for first 1-10 seconds
after power is turned on, or if the system configuration is changed during operation.
3. 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 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.
Status LED is solid red (no blinking).
Not Applicable
Status LED is blinking red.
Not applicable.
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Status LED is blinking red and green.
F-4
POWER WAVE 655/R
TROUBLESHOOTING & REPAIR
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F-5
The following is a list of possible error codes that the Power Wave 655 can output via the status light If connected to a PF-10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.
11
12
Error Code #
CAN communication bus off.
User Interface time out error.
21
Unprogrammed Weld Mode.
23
Weld Table checksum error.
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22
31
32
33
34
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36
37
41
Empty Weld Table.
Primary overcurrent error.
Capacitor "A" under voltage
(Left side facing machine)
Capacitor "B" under voltage
(Right side facing machine)
Capacitor "A" over voltage
(Left side facing machine)
Capacitor "B" over voltage
(Right side facing machine)
Thermal error
Soft start error
Secondary overcurrent error
43
Capacitor delta error
49
Single phase error
Other
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ERROR CODES FOR THE POWER WAVE
F-5
Indication
Probably due to excessive number of communication errors.
UI is no longer responding to the Power Source. The most likely
cause is a fault/bad connection in the communication leads or control cable.
Contact the Service Department or powerwavesoftware.com for
instructions on reloading the Welding Software.
Contact the Service Department or powerwavesoftware.com for
instructions on reloading the Welding Software.
Contact the Service Department or powerwavesoftware.com for
instructions on reloading the Welding Software..
Excessive Primary current present. May be related to a short in the
main transformer or output rectifier.
Low voltage on the main capacitors. May be caused by improper
input configuration.
When accompanied by an overvoltage 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.
Excess voltage on the main capacitors. May be caused by improper
input configuration.
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.
Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle
limit of the machine.
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"
NOTE: The secondary limit is 570 amps for the standard stud, and
325 amps.
The maximum voltage difference between the main capacitors has
been exceeded. May be accompanied by errors 32-35.
Indicates machine is running on single phase input power. Usually
caused by the loss of the middle leg (L2).
Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the PS
Control Board. If cycling the input power on the machine does not
clear the error, 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
TROUBLESHOOTING & REPAIR
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Major physical or electrical damage
is evident when the sheet metal
covers are removed.
Contact your local authorized
Lincoln Electric Field Service
Facility for technical assistance.
Contact the Lincoln Electric Service
Department at 1-888-935-3877
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The input fuses repeatedly fail or
the input circuit breakers keep tripping.
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F-6
OUTPUT PROBLEMS
1. Make certain the fuses or breakers are properly sized.
1. Check the reconnect switches
and associated wiring. See the
Wiring Diagram.
3. The welding procedure may be
drawing too much input current
or the duty cycle may be too
high. Reduce the welding current and/or reduce the duty
cycle.
3. Perform the Switch Board
Test.
2. Make certain the reconnect
panel is configured properly for
the applied voltage.
CAUTION
2. Perform the Input Rectifier
Test.
4. Perform the Input Contactor
Test.
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
TROUBLESHOOTING & REPAIR
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The machine is dead—no lights—
no output—the machine appears to
be off.
1. Make certain the input power
switch SW1 is in the ON position.
1. Check the input power switch
SW1 for proper operation. Also
check the associated leads for
loose or faulty connections.
See the Wiring Diagram.
OUTPUT PROBLEMS
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2. Check the main input fuses (or
breakers). If open, replace or
reset.
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F-7
3. Check the 6 amp CB4 breaker
located in the reconnect area.
Reset if tripped.
4. Make certain the reconnect
panel is configured correctly for
the applied input voltage.
2. Check circuit breaker CB4 for
proper operation
3. Perform the T1
Transformer Test.
Auxiliary
4. The power board rectifier may
be faulty. Check rectifier and
associated wiring. See the
Wiring Diagram.
5. Perform the DC Buss Board
Test.
6. Perform the Power Board Test.
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7. 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
TROUBLESHOOTING & REPAIR
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The Power Wave 655/R does not
have welding output. The main
input contactor CR1 is not activating.
1. Turn the input power off and
make certain the reconnect
panel is configured correctly for
the applied input voltage.
1. Perform the Input Contactor
Test.
The thermal light is lit.
The
machine regularly "overheats."
OUTPUT PROBLEMS
2. If the Thermal light is lit, the unit
may be overheated. Let the
machine cool and adjust welding load and/or duty cycle to
coincide with the output limits of
the machine.
1. The welding application may be
exceeding the recommended
duty cycle and/or current limits
of the machine.
2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the Maint enance Section of this manual.
2. Perform the Input Board Test.
3. Perform the T1
Transformer Test.
Auxiliary
4. Perform the Input Rectifier
Test.
5. Perform the Switch Board
Test.
6. Perform the Power Board Test.
7. The Control Board may be faulty.
1. One of the thermostats may be
faulty. Also check associated
wiring for loose or faulty connections.
See the Wiring
Diagram.
3. Air intake and exhaust louvers
may be blocked due to inadequate clearance around the
machine.
4. 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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE 655/R
TROUBLESHOOTING & REPAIR
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F-9
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
The machine often "noodle welds"
when running a particular process.
The output is limited to approximately 100 amps.
1. The machine may be trying to
deliver too much power. When
the average output current
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.
The Power Wave 655/R will not
produce full output.
1. The input voltage may be too
low, limiting the output capability
of the machine. Make certain
the input voltage is correct for
the machine and the reconnect
panel configuration.
2. Make sure all three phases of
input power are being applied to
the machine.
CAUTION
F-9
RECOMMENDED
COURSE OF ACTION
1. Perform the Current
Transducer Test.
2. The Control Board may be
faulty.
1. Perform the Output Rectifier
Test.
2. Perform the Current Transducer Test.
3. Perform the Power Board Test.
4. The Control Board may be
faulty.
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
TROUBLESHOOTING & REPAIR
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F-10
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The Auxiliary Receptacle is "dead."
The 120VAC is not present at the
receptacle.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. Check the 10 amp circuit breaker (CB2) located on the case
front. Reset if necessary.
2. Check the 6 amp circuit breaker
(CB4) located in the reconnect
area. Reset if necessary.
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3. Make sure all three phases of
input power are being applied to
the machine.
The Power Wave 655/R is "triggered" for output but there is no
welding output.
1. Make sure that the triggering
method and device is correct
and operating properly.
2. Check circuit breaker CB4.
Reset if tripped.
CAUTION
F-10
RECOMMENDED
COURSE OF ACTION
1. Check the receptacle and associated wiring for loose or faulty
connections. See the Wiring
Diagram.
2. Perform the T2
Transformer Test.
Auxiliary
Use the Diagnostic Software to
locate the problem. The latest software and the Diagnostic Utilities
software is available at powerwavesoftware.com.
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
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F-11
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
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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 removing input power. This procedure is used to check that the capacitors have properly discharged.
MATERIALS NEEDED
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Misc. hand tools
Volt-ohmmeter
25-1000 ohms @ 25 watts (minimum) resistor
Electrically insulated gloves and pliers
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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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
POWER WAVE 655/R
F-11
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F-12
TROUBLESHOOTING & REPAIR
F-12
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE
SWITCH
BOARD
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CAPACITOR
TERMINALS
PROCEDURE
1. Disconnect the input power to the POWER
WAVE 655/R.
2. Remove the left and right case sides.
3. Remove the two High Voltage Protection
shields. Be careful not to touch the capacitor
terminals that are located at the bottom of the
left and right side switch boards.
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4. With a voltmeter, carefully check for a DC voltage at the capacitor terminals of both boards.
Note the polarity as marked on the PC board.
5. If any voltage is present, proceed to Step #6. If
no voltage is present, the capacitors are discharged.
NOTE: Normally the capacitors discharge with-in
about two minutes after input power is
removed.
6. Using the high wattage resistor (25-1000 ohms
@ 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.
7. Repeat procedure for the other capacitors.
8. Recheck the voltage across the capacitor terminals. 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
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F-13
TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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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 troubleshooting 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 correctly. 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
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Misc. Hand Tools
Torque Wrench
Volt-ohmmeter
Wiring Diagram
POWER WAVE 655/R
F-13
TROUBLESHOOTING & REPAIR
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F-14
SWITCH BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.2 – LEFT SIDE
NOTE: Resistance checks of the Switch Boards in this machine will vary greatly depending on
the type and model of meter being used. Comparative readings between the two sides
of a board and/or between the two Switch Boards will be more meaningful than the actual numbers. In all cases, readings of all sets of test points should be approximately the
same. If not using an ʻauto-rangingʼ meter, select the X1000 scale.
The readings in Table F.1 are representative of the meters available when this test was
developed.
PROCEDURE
1. Disconnect the input power to the POWER
WAVE 655/R.
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2. Remove the case sides.
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F-14
3. Perform the Capacitor Discharge Procedure.
4 Using the volt-ohmmeter, perform the resistance
tests detailed in Table F.1. The readings should
all be similar. One or more readings that vary
considerably will usually indicate a defective
board. Refer to Figures F.2 and F.3 for the test
points
5. If any test fails replace the Switch Board. See
Switch Board Removal and Replacement.
NOTE: Switch boards should have Identical
base numbers and dash numbers.
6. If the switch board resistance tests are OK,
check the molex pin connections and associated wiring from the switch boards to the control
board. See the Wiring Diagram.
POWER WAVE 655/R
TROUBLESHOOTING & REPAIR
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F-15
SWITCH BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.3 – RIGHT SIDE AND TEST POINTS
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(LEFT) 11
(RIGHT) 16
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NEG POS 13 12 NEG POS
NEG POS 18 15 NEG POS
14
17
TABLE F.1 – SWITCH BOARD RESISTANCE TEST POINTS
POSITIVE
METER
PROBE
NEGATIVE
METER
PROBE
DIGITAL
METER
(TYPICAL)
ANALOG
METER (X1000)
TYPICAL
POS (21)
12(15) or 14(17)
> .5 MΩ
>5kΩ
12(15) or 14(17)
POS (21)
POS (19)
11(16) or 13(18)
NEG (20)
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F-15
11(16) or 13(18)
POS (19)
11(16) or 13(18)
NEG (22)
12(15) or 14(17)
12(15) or 14(17)
NEG (22)
11(16) or 13(18)
NEG (20)
> .5 MΩ
< .5 MΩ
< .5 MΩ
< .5 MΩ
< .5 MΩ
> .5 MΩ
> .5 MΩ
>5kΩ
<2kΩ
<2kΩ
<2kΩ
<2kΩ
>5kΩ
>5kΩ
NOTE: A suspect board should be 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
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F-16
NOTES
POWER WAVE 655/R
F-16
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F-17
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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Return to Section TOC
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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 troubleshooting 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
F-17
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F-18
TROUBLESHOOTING & REPAIR
F-18
INPUT RECTIFIER TEST PROCEDURE (CONTINUED)
FIGURE F.4 – INPUT RECTIFIER TEST
INPUT
RECTIFIER
NEG (-)
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POS (+)
A
B
C
PROCEDURE
1. Disconnect the input power to the POWER
WAVE 655/R.
2. Remove the case top and Input Panel.
3. Perform the Capacitor Discharge Procedure.
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4. Locate the Input Rectifier and lead locations.
Refer to Figure F.4.
5. Use an ohmmeter to perform the tests detailed
in Table F.2.
6. If the rectifier does not meet the expected readings,remove the POS. and NEG leads and retest. If it still fails the test it should be replaced.
NOTE: Some of the RTV material will have to be
removed. The terminals should be resealed with RTV when testing or replacement is complete.
9. See the Input Rectifier Removal and
Replacement procedure for proper torque settings when re-connecting the leads to the rectifier.
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
TROUBLESHOOTING & REPAIR
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F-19
F-19
INPUT RECTIFIER TEST PROCEDURE (CONTINUED)
TABLE F.2 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS
TEST POINT TERMINALS
+ Probe
ANALOG METER X100
RANGE
- Probe
Acceptable Meter Readings
A
B
C
POS (D)
POS (D)
POS (D)
Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms
POS
POS
POS
A
B
C
A
B
C
NEG
NEG
NEG
NEG (F)
NEG (F)
NEG (F)
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
NOTE: Digital meters may not provide enough current in the “ohms” mode to achieve the readings indicated. They will, however, indicate whether the device is shorted (typical failure
mode) or open. A ʻshortedʼ device will usually read a low resistance (<100Ω) in both
polarities. An ʻopenʼ device will read as if the meter leads were not connected to anything (typically “OL”) in both polarities.
POWER WAVE 655/R
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F-20
NOTES
POWER WAVE 655/R
F-20
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F-21
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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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 troubleshooting 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
F-21
TROUBLESHOOTING & REPAIR
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F-22
F-22
INPUT CONTACTOR TEST PROCEDURE (CONTINUED)
FIGURE F.5 – INPUT CONTACTOR COIL
INPUT
CONTACTOR
601
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X4
FIGURE F.5A
CONTACTOR
TEST POINTS
PROCEDURE
1. Disconnect the input power to the POWER
WAVE 655/R.
2. Remove the input access panel and case top.
3. 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 6Ω.
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5. Check the resistance across the contacts:
Refer to Figure F.5A
L1 to T1 , L2 to T2 and L3 to T3.
All three readings should show “open”
If the resistance is low, the input contactor is
faulty.
L3
T3
L2
T2
L1
T1
6. Press in on the “test button” and recheck the
contacts as in Step 5.
NOTE: If a 24 vac supply is available, it can be
connected to the coil terminals to activate
the contactor, instead of using the Test
Button.
All readings should be very close to 0Ω
If the resistance is high, the input contactor is
faulty.
7. Reconnect the two leads (601, X4) to the input
contactor coil.
8. Replace the input access door and case top.
POWER WAVE 655/R
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F-23
TROUBLESHOOTING & REPAIR
DC BUS BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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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 troubleshooting 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
POWER WAVE 655/R
F-23
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TROUBLESHOOTING & REPAIR
DC BUS BOARD TEST PROCEDURE (CONTINUED)
F-24
FIGURE F.6 – DC BUS PC BOARD
LED
R4
R7
R5
R8
C14
C2
C16
R28
R21
R3
C17
J47
R22
C3
C11
R19
LED1
R20
D5
R23
X1
R14
R13
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F-24
R26
5
6
J47 7
8
1
2
3
4
D3
C8
C9
C10
D4
R29
DZ5
R27
MOV1
C15
R15
C7
X2
C5
C1
L1
MOV2
R16
C6
R25
J46
C13
DZ6
3
4
1
2
J46
1A
D1
R11
R9
D2
R12
DZ4
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R10
Power Bd.
Rectifier
C3
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PROCEDURE
1. Disconnect the input power from the machine.
2. Remove the case top.
3. Locate the DC Bus PC Board and plugs P46 and
P47. See Figure F.6.
4. Carefully apply input power to the POWER WAVE
655/R.
WARNING
ELECTRIC SHOCK can kill.
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High voltage is present when input
power is applied to the machine.
5. Turn on the POWER WAVE 655/R. The LED on the
DC Bus Board should light.
If the LED does not light, check the input voltage to
the board at the terminals of the capacitor C-3. It
should read 65-75vdc.
6. If the input voltage is correct the DC Bus Board may
be defective. If not, check the Power Board
Rectifier and the Auxiliary Transformer T1.
7. Check the Bus Board output voltages at P47 per
Table F.3.
TABLE F.3 - DC Bus Bd Output Voltages
Positive
Meter
Probe
Pin 7
Pin 8
Pin 4
Pin 3
Negative Voltage
Meter
Reading
Probe
(vdc)
Pin 6
38 to 42
to Power PC Bd.
Pin 2
38 to 42
to Feed Head Bd.
Pin 6
Pin 1
38 to42
38 to 42
to Power PC Bd.
to S1 - Wire Feeder
Receptacle
8. If any of the readings is incorrect, replace the
board.
9. Disconnect the input power and replace the case
top.
POWER WAVE 655/R
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F-25
TROUBLESHOOTING & REPAIR
POWER BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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Return to Section TOC
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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 troubleshooting 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
F-25
TROUBLESHOOTING & REPAIR
POWER BOARD TEST PROCEDURE (CONTINUED)
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F-26
F-26
FIGURE F.7 – POWER BOARD TEST
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POWER
PC BOARD
CAPACITOR
C3
6
5
4
4
3
3
2
1
2
1
PROCEDURE
1. Disconnect the input power to the POWER
WAVE 655/R.
2. Remove the case top.
3. Locate the Power Board and plugs J42 and
J43. Do not remove plugs or leads from the
Power Board. Refer to Figure F.7.
4. Carefully apply input power to the POWER
WAVE 655/R.
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WARNING
ELECTRIC SHOCK can kill. High
voltage is present when input
power is applied to the machine.
12 11 10 9
6
5
4
3
8
7
2
1
Power Bd.
Rectifier
5. Turn on the POWER WAVE 655/R. Carefully
test for the correct voltages at the Power Board
according to Table F.4.
6. If either of the 40 VDC voltages is low or not
present at plug J41, perform the DC Bus PC
Board Test. See the Wiring Diagram. Also
perform the T1 Auxiliary Transformer Test.
7. If any of the DC voltages are low or not present
at plugs J42 and/or J43, the Power Board may
be faulty.
8. Replace the case top.
POWER WAVE 655/R
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F-27
TROUBLESHOOTING & REPAIR
F-27
POWER BOARD TEST PROCEDURE (CONTINUED)
CHECK POINT
LOCATION
TABLE F.4 – POWER BOARD VOLTAGE CHECKS
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO. OR
IDENTITY
POWER BOARD
CONNECTOR
PLUG J41
CHECK 40 VDC
INPUT FROM
DC BUS BOARD
2 (+)
1 (-)
477 (+)
475 (-)
POWER BOARD
CONNECTOR
PLUG J42
CHECK +15
VDC SUPPLY FROM
POWER BOARD
POWER BOARD
CONNECTOR
PLUG J42
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
POWER BOARD
CONNECTOR
PLUG J42
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD
POWER BOARD
CONNECTOR
PLUG J43
CHECK +15 VDC
SPI SUPPLY FROM
POWER BOARD
POWER BOARD
CONNECTOR
PLUG J41
CHECK +40 VDC
INPUT FROM
DC BUS BOARD
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
POWER BOARD
CONNECTOR
PLUG J43
CHECK +20 VDC STT
SUPPLY FROM
POWER BOARD
475
477
1 (+)
5 (-)
225
+15 VDC
221 (+)
222 (-)
+5 VDC
222 (+)
223 (-)
-15 VDC
274 (+)
273 (-)
+5 VDC
226
226 (+)
228 (-)
+5 VDC
266
266 (+)
267 (-)
+15 VDC
478 (+)
476 (-)
38 – 42 VDC
268A (+)
262 (-)
+5 VDC
345 (+)
346 (-)
+20 VDC
221
222
223
2 (+)
5 (-)
222
5 (+)
10 (-)
4 (+)
9 (-)
228
6 (+)
11 (-)
4 (+)
3 (-)
476
268A
346
3 (+)
12 (-)
7 (+)
1 (-)
38 – 42 VDC
225 (+)
222 (-)
222
3 (+)
5 (-)
NORMAL
ACCEPTABLE
VOLTAGE
READING
274
273
267
478
262
345
POWER WAVE 655/R
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F-28
NOTES
POWER WAVE 655/R
F-28
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F-29
TROUBLESHOOTING & REPAIR
INPUT BOARD TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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Return to Master TOC
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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 troubleshooting 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
F-29
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F-30
TROUBLESHOOTING & REPAIR
F-30
INPUT BOARD TEST PROCEDURE (CONTINUED)
FIGURE F.8 – INPUT BOARD AND CONTACTOR
INPUT
PC BOARD
J61
J60
601
X4
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INPUT
CONTACTOR
1. Disconnect the input power to the POWER
WAVE 655/R.
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PROCEDURE
2. Remove the case top.
3. Remove lead X4 from the coil terminal of main
input contactor CR1. Insulate lead X4. Refer to
Figure F.8.
4. Carefully apply input power to the POWER
WAVE 655/R.
WARNING
ELECTRIC SHOCK can kill.
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High voltage is present when input
power is applied to the machine.
5. Turn on the POWER WAVE 655/R. Carefully
test for the correct voltages according to Table
F.5.
10 9 8 7 6
8 7 6
5
5 4
4 3 2
1
3
2 1
6. Remove input power to the POWER WAVE
655/R. If any of the voltages are low or not present, perform the Input Contactor Test. If that
checks out, the Input Board may by faulty.
7. Reconnect lead X4 to the main input contactor
CR1 coil terminal.
8. Carefully apply the correct input voltage to the
POWER WAVE 655/R.
9. Turn on the POWER WAVE 655/R. Check for
the presence of 24 VAC from lead X4 to lead
601. See Figure F. 9.
9. This 24 VAC is the coil voltage for main input
contactor CR1. It will normally be present
approximately 12 seconds after input line
switch (SW1) is activated.
10. If the voltage is not present, perform the
Auxiliary Transformer #1 Test.
11. Disconnect the input power and replace the
case top.
POWER WAVE 655/R
TROUBLESHOOTING & REPAIR
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F-31
INPUT BOARD TEST PROCEDURE (CONTINUED)
TABLE F.5 – INPUT BOARD VOLTAGE CHECKS
PLUG J61 PIN 8 (H1D)
TO
PLUG J61 PIN 6 (612)
PLUG J61 PIN 10 (T3)
TO
PLUG J61 PIN 2 (T1)
EXPECTED
VOLTAGE
READINGS
LEAD
NUMBERS
TEST POINTS
SAME AS
INPUT
VOLTAGE
J61
#612
T1
H1D
J61
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 4 (604)
J60
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 5 (232)
J60
#238
T3
COMMENTS
Present when Input
Switch SW1 is closed.
A LITTLE LESS
THAN INPUT
VOLTAGE
This is Pre-Charge Voltage and
will normally be present 6 seconds after activating Input Switch
SW1. The Pre-Charge Voltage
should remain for approximately 6
seconds and then be removed.
13 – 15 VDC
This is the Coil Voltage for the
Pre-Charge Relay. Normally this
DC Voltage will be present 6 seconds after Input Switch SW1 is
activated. This 13 - 15 VDC will
remain for approximately 6 seconds and then be removed. The
Relay is controlled by the Control
Board. See the Wiring Diagram.
13 – 15 VDC
This is the DC Coil Voltage for the
Control Relay. Normally this DC
Voltage will be present approximately 12 seconds after Input
Switch SW1 is activated. The
Relay is controlled by the Control
PC Board. See the Wiring
Diagram.
#604
#238
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#232
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F-31
POWER WAVE 655/R
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F-32
NOTES
POWER WAVE 655/R
F-32
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F-33
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
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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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Current Transducer and associated wiring is functioning 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 the
machine. It can also be accessed from the Lincoln Service Navigator or downloaded from the “web” at Powerwavesoftware.com.
POWER WAVE 655/R
F-33
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TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED)
F-34
FIGURE F.9 – CURRENT TRANSDUCER TEST
CONTROL BOARD
J8
J9
J8
211 212 213
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F-34
1
2
3 4
5
6
7 8
216
1234
P91
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CURRENT
TRANSDUCER
PROCEDURE
1. Disconnect the input power to the POWER
WAVE 655/R.
2. Remove the case top and the control box cover.
3. Locate the current transducer leads at Control
Board plug J8. See Figure F.9.
4. Carefully apply input power to the POWER
WAVE 655/R.
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WARNING
ELECTRIC SHOCK can kill.
High voltage is present when input
power is applied to the machine.
5. Turn on the POWER WAVE 655/R. Check for
the correct DC supply voltage to the current
transducer at plug J8. See Figure F.9.
A. Pin 2 (lead 212+) to pin 6 (lead 216-)
should read approximately +15 VDC.
B. Pin 3 (lead 213-) to pin 6 (lead 216+)
should read approximately -15 VDC.
NOTE: Do not attempt to check the voltages at the
Current Transducer connector. The terminals are small and delicate and may be
damaged if probed with meter leads.
If the DC supply voltages are not present, the
control board may be faulty. If the supply voltages are correct, procede to Step 6.
POWER WAVE 655/R
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F-35
TROUBLESHOOTING & REPAIR
F-35
CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED)
FIGURE F.10 – RS 232 port
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RS 232
PORT
6. Connect a laptop computer to the PW655-R via
the RS232 port on the front of the machine. See
Figure F.10.
7. Connect a Load Bank (or 50ʼ weld cable) to the
Positive and Negative Output Studs of the
PW655-R.
8. Using the “Diagnostic Utility Software:
Establish Communication with the PW655R
Select the ʻCalibrateʼ tab.
Select the ʻ50 ampʼ Current Set Point
Select ʻTurn Output ONʼ
Use an external calibrated ammeter to read
actual current
9. Check the feedback voltage at the Control
Board plug J8 per Table F.6.
Pin 1 (lead 211 +) to pin 6 (lead 216 -).
10. Repeat the test at several other current levels.
If the feedback voltage is correct for the actual
current, the Current Transducer is OK
OUTPUT CURRENT (Actual)
If the feeback voltage is not present, check the
wiring from the Control Board to the Current
Transducer, See the Wiring Diagram.
CAUTION: If using a weld cable across the output
studs instead of a Load Bank, do not
exceed the current rating of the cable.
11. If supply voltages are correct but feedback
voltages are incorrect, the Current Transducer or
wiring from P91 to the Control Board may be
defective. See the Wiring Diagram.
If the ʻactualʼ (measured) current does not match
the ʻsetʼ current but the feedback voltage is
correct for the actual current, perform the
Machine Calibration.
12. Click on “Turn Output Off”
13. Disconnect the computer.
14. Remove input power and replace the control
box cover and case top.
EXPECTED FEEDBACK VOLTAGE
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TABLE F.6 - CURRENT FEEDBACK CHART
500
450
400
350
300
250
200
150
100
50
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
0.4
POWER WAVE 655/R
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F-36
NOTES
POWER WAVE 655/R
F-36
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F-37
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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Return to Master TOC
Return to Section TOC
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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 troubleshooting 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
F-37
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F-38
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER TEST PROCEDURE (CONTINUED)
FIGURE F.11 – OUTPUT RECTIFIER TEST
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NEGATIVE (-)
OUTPUT
TERMINALS
POSITIVE (+)
OUTPUT
TERMINALS
PROCEDURE
1. Remove main input supply power to the
POWER WAVE 655/R.
2. Remove the case sides and perform the Input
Filter Capacitor Discharge procedure.
3. Remove any output cables that may be connected to the POWER WAVE 655/R.
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4. Disconnect one end of lead 206A that connects
R1 to the Positive Output Terminal.
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F-38
5. With an ohmmeter, measure the resistance
between the positive and negative output terminals. Refer to Figure F.11.
R1
IMPORTANT: The positive (+) meter probe must
be attached to the positive (+) output
terminal and the negative (-) meter
probe must be attached to the negative (-) output terminal.
6. If the reading is more than 200 ohms, the output rectifier modules are not shorted. If the
reading is less than 200 ohms, one (or more) of
the rectifier modules is shorted. Refer to the
Output Rectifier Module Replacement procedure.
7. Reconnect lead 206A.
8. Replace the case sides.
POWER WAVE 655/R
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F-39
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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Return to Master TOC
Return to Section TOC
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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 troubleshooting 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
Volt-ohmmeter
Misc. Hand Tools
Wiring Diagram
POWER WAVE 655/R
F-39
TROUBLESHOOTING & REPAIR
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F-40
F-40
AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED)
FIGURE F.12 – AUXILIARY TRANSFORMER NO. 1 TEST
+
X1
INPUT
CONTACTOR
-
X2
POWER BOARD
RECTIFIER BRIDGE
601
FAN RELAY
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X4
WHITE
X3
RED
X5
444
X3A
FAN MOTOR
WINDING
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AUXILIARY
TRANSFORMER #1
PROCEDURE
1. Remove the main input power to the POWER
WAVE 655/R machine.
2. Remove the case top and sides.
3. Perform the Capacitor Discharge procedure.
4. Locate secondary leads X1 and X2 (at power
board rectifier bridge). Refer to Figure F.12.
5. Locate secondary leads X3 and X5 (fan motor
leads).
6. Locate secondary lead X4 (at main contactor).
POWER WAVE 655/R
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F-41
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED)
7. Carefully apply the correct input voltage to the
POWER WAVE 655/R.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present at primary of
the Auxiliary Transformer.
8. Check for the correct secondary voltages according
to Table F.7.
NOTE: The secondary voltages will vary proportionally
if the input line voltage varies from nominal.
9. If the correct secondary voltages are present, the
T1 auxiliary transformer is functioning properly. If
any of the secondary voltages are missing or low,
check to make certain the primary is configured
correctly for the input voltage applied. See the
Wiring Diagram.
10. If the correct input voltage is applied to the primary, and the secondary voltage(s) are not correct,
the T1 transformer may be faulty.
11. Replace any cables ties and insulation removed
earlier.
12. Replace the case sides and top.
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TABLE F.7 – SECONDARY VOLTAGES
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F-41
LEAD IDENTIFICATION
NORMAL EXPECTED VOLTAGE
X1 to X2
X3 to X5
X3 to X4
52 VAC
115 VAC
24 VAC
POWER WAVE 655/R
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F-42
NOTES
POWER WAVE 655/R
F-42
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F-43
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
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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 troubleshooting 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
Volt-ohmmeter
Misc. HAnd Tools
Wiring Diagram
POWER WAVE 655/R
F-43
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F-44
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST PROCEDURE (CONTINUED)
F-44
FIGURE F.13 – AUXILIARY TRANSFORMER NO. 2 TEST
350
(WHITE)
3
1
4
2
(BLACK)
352
To WATER
COOLER
RECEPTACLE
(S8)
33A
(RED)
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H1
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1
2
5
3
6
H6
4
2
5
3
6
To AUX.ILIARY
TRANSFORMER
#2 PRIMARY
(P50)
To S4, CB2
& AUX. FAN
352A
(BLACK)
1. Remove the main input power to the POWER
WAVE 655/R machine.
2. Remove any load that may be connected to the
115 VAC receptacle.
3. Remove the case top and right side.
4. Locate plugs P52 and P50 at the Auxiliary
Transformer No. 2. Refer to Figure F.13.
5. Carefully apply the correct input power.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present at both
plugs.
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4
32
(WHITE)
33
(RED)
PROCEDURE
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1
6. Check for 115 VAC at plug P52 pins 1 and 4
(leads 350 to 33A). Check for 230 VAC at
plug P52 pins 1 and 2 (leads 350 to 352).
7. If 115 VAC and 230 VAC are present, Auxiliary
Transformer No. 2 is good.
8. If 115 is not present between pins 1 and 4, and
230 VAC is not present between pins 1 and 2,
check the associated leads and plugs for
loose or faulty connections.
9. Carefully test for the correct AC input voltage
applied to the primary windings at plug P50.
See the Wiring Diagram.
10. If the correct AC input voltage is applied to the
primary of the Auxiliary Transformer No. 2 and
the secondary voltage is not correct, the transformer may be faulty. Replace.
11. Replace any cables ties and insulation
removed earlier.
12. Replace the case top and side.
POWER WAVE 655/R
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F-45
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
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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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input rectifier module.
MATERIALS NEEDED
Misc. Hand Tools
Torque Wrench
POWER WAVE 655/R
F-45
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F-46
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.14 – INPUT RECTIFIER REMOVAL AND REPLACEMENT
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NEG (-)
INPUT
RECTIFIER
POS (+)
A
B
C
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE
655/R.
2. Remove the case top, sides, and input access
panel.
3. Perform the Capacitor Discharge procedure.
4. Remove the RTV sealant from the input rectifier connection terminals. See Figure F. 14.
5. Label and carefully remove the five leads from
the input rectifier terminals. Note placement for
reassembly. See Figure F.14.
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F-46
6. Using a 3/16” allen wrench, remove the two
mounting screws and washers from the rectifier
module.
7. Carefully remove the input rectifier module.
REPLACEMENT PROCEDURE
NOTE: Any instructions that are shipped with
the replacement part will supersede
these instructions.
1. Clean heat sink surfaces.
2. 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.
3. Mount the module to the heat sink and evenly
torque the mounting screws (with washers) to
44 in/lbs.
4. Assemble the leads to the correct module terminals and torque to 31 in/lbs. See Figure F.14.
5. Apply RTV sealant to the rectifier connection
terminals.
6. Replace the case top, sides, and input access
panel.
POWER WAVE 655/R
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F-47
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input contactor.
MATERIALS NEEDED
Misc. Hand Tools
POWER WAVE 655/R
F-47
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F-48
TROUBLESHOOTING & REPAIR
F-48
INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.15 – INPUT CONTACTOR REMOVAL AND REPLACEMENT
INPUT
CONTACTOR
601
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X4
REMOVAL PROCEDURE
L3
T3
L2
T2
L1
T1
1. Remove input power to the POWER WAVE
655/R.
REPLACEMENT PROCEDURE
3. Perform the Capacitor Discharge procedure
3. Replace the case top, sides and input access
panel.
2. Remove the case top, sides and input access
panel.
4. Locate the input contactor. Label and carefully
remove the leads from the input contactor terminals. Note placement for reassembly. See
Figure F.15.
1. Mount the contactor and tighten the mounting
screws.
2. Connect the leads to the correct terminals. 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.
POWER WAVE 655/R
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F-49
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary transformer No. 1.
MATERIALS NEEDED
Misc. Hand Tools
Wire splicing or soldering equipment
POWER WAVE 655/R
F-49
TROUBLESHOOTING & REPAIR
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F-50
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT
+
X1
INPUT
CONTACTOR
-
X2
POWER BOARD
RECTIFIER BRIDGE
601
FAN RELAY
X4
WHITE
X3
RED
X5
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444
AUXILIARY
TRANSFORMER #1
REMOVAL PROCEDURE
1. Carefully place the transformer into the
POWER WAVE 655/R.
3. Perform the Capacitor Discharge procedure.
3. Connect the primary leads H2, H3, H4, and
H5 to the proper terminals on the reconnect
panel.
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5. Disconnect lead X4 from the input contactor
coil.
6. Remove leads X1 and X2 from the power board
rectifier bridge. Refer to Figure16.
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.
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REPLACEMENT PROCEDURE
1. Remove input power to the POWER WAVE
655/R.
4. Remove the case back.
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X3A
FAN MOTOR
WINDING
2. Remove the case top, sides and input access
panel.
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F-50
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.
2. Secure the transformer to the fan baffle and
the base.
4 Connect primary lead H1 to circuit breaker
CB4.
5. Splice the X3 lead of the new transformer with
the X3 lead connected to the input board.
6. Splice X3 and X5 leads of the new transformer to the fan motor leads X3 and X5.
7. Connect lead X4 to the main contactor coil
terminal.
8. Connect leads X1 and X2 to the power board
rectifier bridge.
9. Reposition any wire leads and install cable
ties as necessary.
10. Replace the case back, sides and top.
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.
POWER WAVE 655/R
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F-51
TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary transformer No. 2.
MATERIALS NEEDED
Misc. Hand Tools
POWER WAVE 655/R
F-51
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F-52
TROUBLESHOOTING & REPAIR
F-52
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT
350
(WHITE)
3
1
4
2
(BLACK)
352
To WATER
COOLER
RECEPTACLE
(S8)
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33A
(RED)
H1
1
4
2
5
3
6
H6
32
(WHITE)
33
(RED)
1
4
2
5
3
6
To AUX.ILIARY
TRANSFORMER
#2 PRIMARY
(P50)
To S4, CB2
& AUX. FAN
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352A
(BLACK)
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
2. Remove the case top, sides and input access
panel.
2. Install the two mounting screws that hold the
transformer to the machine base using the 3/8”
nut driver.
1. Remove input power to the POWER WAVE
655/R.
3. Perform the Capacitor Discharge procedure.
4. Remove the case back.
5. Disconnect the three Molex Connectors indicated in Figure 17.
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7. Remove the transformer mounting screws from
the Fan Baffle and the base.
8. Carefully remove the transformer from the
POWER WAVE 655/R.
1. Carefully place the transformer into the
POWER WAVE 655/R.
3. Connect leads 33 and 32 to circuit breaker CB4
and the 115 V receptacle.
4. Connect plugs P50 and P52.
5. Reposition any leads and install cable ties as
necessary.
6. Replace the case back.
7. Replace the case top, sides, and input access
panel.
POWER WAVE 655/R
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F-53
TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, VOLTAGE SENSE, OR AUXILIARY
DRIVER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
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 troubleshooting assistance before you proceed. 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 bodyʼs static charge before opening the static-shielding bag.
Wear an anti-static wrist strap. For safety, use a 1 MΩ resistive cord connected to a grounded part of the equipment frame.
• If you donʼt 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
F-53
TROUBLESHOOTING & REPAIR
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Return to Master TOC
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F-54
CONTROL, FEED HEAD, VOLTAGE SENSE OR AUXILIARY
DRIVER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.18 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT
CONTROL BOARD
FEED HEAD BOARD
Removal
Step 6
Removal
Step 6
VOLTAGE
SENSE BD.
AUXILIARY
DRIVER BD.
REMOVAL PROCEDURE
1. Remove input power to the POWER WAVE
655/R.
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2. Remove the case top and sides.
3. Perform the Capacitor Discharge procedure.
Observe all static electricity precautions.
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 grommets on the sides of the control box.
7. Label and remove the molex plugs from the
Control Board and the Feed Head Board.
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8. Tilt back the rear of the control box to access
the PC board mountings.
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F-54
9. To remove the Voltage Sense Board, use a needle-nose pliers to carefully pinch the three plastic standoffs to release the board.
10. Use a Phillips screwdriver to remove the
Auxiliary Driver Bd.
REPLACEMENT PROCEDURE
1. Install the replacement board using the original
fasteners
2. Connect the Molex plugs to the Control Board
and the Feed Head Board. Be sure the lead
harnesses are securely and properly positioned.
3. Use a Phillips screwdriver to replace the
Auxiliary Driver Board.
4. Press the Voltage Sense Board onto its standoffs. Make sure the board snaps into place on
all three standoffs.
5. 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.
6. Replace any cable ties that might have been
removed.
7. Replace the PC board compartment cover.
8. Replace the case top and sides.
NOTE: If the Control Board is replaced it will be
necessary to do the Calibration
Procedure.
POWER WAVE 655/R
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F-55
TROUBLESHOOTING & REPAIR
ETHERNET/GATEWAY PC BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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
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CAUTION: PC Boards can be damaged by static electricity.
• Remove your bodyʼs static charge before opening the static-shielding bag.
Wear an anti-static wrist strap. For safety, use a 1 MΩ resistive cord connected to a grounded part of the equipment frame.
Return to Section TOC
Return to Section 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
• If you donʼt 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
F-55
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F-56
TROUBLESHOOTING & REPAIR
F-56
ETHERNET/GATEWAY PC BOARD
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.19 – GATEWAY BOARD REMOVAL AND REPLACEMENT
Ethernet/
Gateway
PC Board
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Support the Panel
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
2. Using a phillips head screw driver, remove the
six screws from the case front cover. Tilt the
cover down and support it from below to avoid
stressing the electrical connections. See
Figure F.19.
2. Reconnect the molex plugs and the network
cable.
1. Remove input power to the POWER WAVE
655/R.
3. Re-attach the cover to the case front, being
careful not to stress or pinch the wires.
3. Disconnect the four molex plugs and the network cable from the Ethernet/Gateway Board.
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Observe all static electricity precautions.
1. Install the new Ethernet/Gateway Board to the
case front cover with the self-locking nuts.
4. Remove the self-locking mounting nuts and
carefully remove the board. Refer to Figure
F.19.
POWER WAVE 655/R
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F-57
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section 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 troubleshooting 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
F-57
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TROUBLESHOOTING & REPAIR
F-58
CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.20 – POWER WAVE CURRENT TRANSDUCER REMOVAL
AND REPLACEMENT PROCEDURE
THIS SIDE
FACES
REAR
+
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F-58
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CURRENT
TRANSDUCER
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the POWER WAVE
655/R.
1. Slide the new Transducer over the 4/0 cable. Be
certain that the current flow indictor (arrow)
points towards the back of the machine. See
Figure F.20.
2. Remove the case sides.
3. Perform the Capacitor Discharge procedure.
4. Remove the 1/2” bolt that holds the 4/0 cable to
the back of the lower right (+) Output Stud.
5. Cut the tie wrap that holds the harness to the
transducer and disconnect P91.
3. Re-connect the 4/0 cable to the Output Stud.
7. Side the current transducer off of the 4/0 cable,
noting the direction of the current flow indicator
(arrow).
5. Replace the case sides.
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6. Using a phillips head screw driver, remove the
screws and lock washers that hold the transducer to the machine base.
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2. Mount the Transducer to the machine base with
the two Phillips head screws.
4. Carefully re-connect the 4 pin connector (P-91)
to the Transducer and secure the harness with
a tie wrap.
POWER WAVE 655/R
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F-59
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER MODULE REMOVAL AND REPLACEMENT
PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the output rectifier modules.
MATERIALS NEEDED
Misc. Hand tools
Penetrox A13 Thermal Joint Compound
Wiring Diagram
POWER WAVE 655/R
F-59
TROUBLESHOOTING & REPAIR
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F-60
F-60
OUTPUT RECTIFIER MODULE REPLACEMENT
PROCEDURE (CONTINUED)
FIGURE F.21 – ACCESSING THE RECTIFIER MODULE
J48
J60
Fan Relay
Front Horizontal
Divider Panel
Rear Horizontal
Divider Panel
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Power
Switch
J40/50
Output Choke
Connection
Front Panel Screws
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ACCESSING THE RECTIFIER MODULE
1. Remove input power to the POWER WAVE
655/R.
2. Remove the case top and sides.
3. Perform the Capacitor Discharge procedure.
4. Disconnect the J60 Molex connector from the
Input Board. (See Fig. F.21).
5. Disconnect J40 and J50 Molex connectors from
the Switch Boards. (See Fig.F.21).
6. Cut wire ties as necessary and pull the J40, J50
& J60 harnesses and grommets through the
panels.
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7. Disconnect the output leads (444 & X3A) from
the bottom terminals of the Fan Relay.
8. Disconnect the J48 Molex connector from the
DC Bus Board (lower connector - 4 pin).
9. Remove the two phillips head screws that hold
the Power Switch to the front panel. Cut the
wire ties as necessary and pull the switch out to
the right side of the machine.
10. Remove the 1/2” bolt that holds the Output
choke to the Negative Output Stud.
11. Loosen (do not remove) the three screws at the
bottom of the front panel.
12. Remove the four screws tha hold the Front
Horizontal Divider panel to the Rear Horizontal
panel.
13. Tilt the front panel forward far enough to
expose all four pairs of diode modules.
CAUTION: Be careful not to stress or damage
the Current Transformer leads that
are routed past the right side of the
rectifier assembly.
POWER WAVE 655/R
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F-61
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER AND RECTIFIER MODULE REMOVAL
AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.22 – RECTIFIER MODULE REPLACEMENT
Copper Plate
Original Modules may
have 1/4-20 bolts in
place of studs
RECTIFIER MODULE TESTING
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1. Remove the leads and copper plate from one of
the Diode Module pairs. (See Figure F.22).
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F-61
NOTE: Observe the placement and the mounting
sequence of the leads and hardware so
they can be put back in exactly the same
way. The assemblies may be different,
depending on the age of the machine.
2. Using an ohmmeter check the 4 diodes (2 per
module) for shorts.
If a shorted device is detected, recheck at the
output studs as directed in the Output
Rectifier test. If the short is cleared there are
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 module is defective.
NOTE: Any instructions packaged with the
replacement modules will supersede
the following instructions.
RECTIFIER MODULE REPLACEMENT
1. Remove the cap screw from the center and the
two hex-head bolts that mount the module to
the heat sink, and remove the module.
2. 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.
3. Press module against the heat sink, aligning it
with the mounting holes and start all three
screws by hand.
4. Tighten the two outer screws to between 5 and
10 in.-lbs
5. Tighten the center screw to between 12 and 18
in.-lbs.
6. Tighten the outer screws again, to between 30
and 40 in.-lbs.
7. 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.-lbs.
8. Re-assemble the machine by performing steps
2 through 13 of Accessing the Rectifier
Module procedure in reverse order.
POWER WAVE 655/R
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F-62
NOTES
POWER WAVE 655/R
F-62
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F-63
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
Return to Section TOC
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 troubleshooting 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
Return to Section TOC
Return to Master TOC
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CAUTION: PC Boards can be damaged by static electricity.
• Remove your bodyʼs 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.
• If you donʼt 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
F-63
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F-64
TROUBLESHOOTING & REPAIR
F-64
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.23 – SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT
SWITCH
BOARD
Observe all static electricity precautions.
REMOVAL PROCEDURE
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CAPACITOR
TERMINALS
Lead and plug references below use a slash (/) to
indicate machine right side/left side wire number
differences.
1. Remove input power to the POWER WAVE
655/R.
2. Remove the case top and sides.
3. Perform the Capacitor Discharge procedure.
5. Remove molex plug J40/J50 from the top of the
switch board. Refer to Figure F.22.
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4. Remove the high voltage protective shield.
6. Remove the mylar insulating shield covering
leads 13/14 or 17/18. Cut the cable tie.
7. Remove leads 13/14 or 17/18 from the Switch
Board.
8. Remove leads 11/12 or 15/16 from the Switch
Board.
9. Remove leads 19C/D(+) and 20C/D(-) from
the switch board capacitor connection bolts.
10. With a slot head screwdriver, remove the two
nylon mounting screws at the bottom of the
switch board. Note placement of the shakeproof washers and fiber spacers.
11. Using a 3/16” allen wrench, carefully remove
the four cap screws that mount the switch
board to the heat sink.
12. Carefully remove the switch board from the
heat sink.
13. If the filter capacitors are to be removed, carefully slide them out of the mounting bracket.
POWER WAVE 655/R
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F-65
TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
REPLACEMENT PROCEDURE
NOTE: Any instructions that are shipped with the
replacement part will supersede these
instructions.
1. If the filter capacitors are to be replaced, carefully
slide the new capacitors into the mounting bracket.
Position the capacitors so the correct polarity terminal is lined up with the correct hole on the switch
board.
2. All heat sink and IGBT mounting surfaces must be
clean.
3. 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.
9. Connect leads 13/14 or 17/18 to the correct terminal.
10. Install the mylar insulating shield covering leads
11/12 or 15/16. Replace the cable tie.
11. Connect molex plug J40/J50 to the top of the
switch board.
12. Replace the high voltage protective shield.
13. Replace the case top and sides.
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.
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.
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Tighten all from 40 to 48 in-lbs.
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F-65
6. Make sure the capacitor is positioned correctly.
Connect leads 19C/D+ and 20C/D- to the correct
terminals. Tighten to 55 in/lbs.
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 terminal.
POWER WAVE 655/R
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F-66
NOTES
POWER WAVE 655/R
F-66
TROUBLESHOOTING & REPAIR
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F-67
CALIBRATION PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in checking and, if necessary, adjusting the calibration 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 Cable 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 performance. Use good quality digital meters that are calibrated and traceable to
National Standards.
POWER WAVE 655/R
F-67
TROUBLESHOOTING & REPAIR
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F-68
CALIBRATION PROCEDURE (CONTINUED)
CALIBRATION SET-UP:
1. Load the Diagnostic Utility Software into the computer.
2. Use the Serial Modem or Ethernet cable to connect
the computer to the PW655-R.
NOTE: If the PW655-R is connected to an Ethernet
network, you may use an ethernet cable to
connect to the machine instead of the
Serial Modem Cable.
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3. Connect a resistive load bank to the output studs.
Calibration Tab
4. Energize the PW655-R.
5. Launch the Diagnostic Utility and establish communication 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 different depending on the software version.
FIGURE F.24 – CALIBRATION SCREEN
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.
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• 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 machine choose 300A
650A machine choose 300A
1000A machine choose 500A
Light is BLACK when OFF.
Current Weld Mode
• Will always be mode 200 (c.c.)
activated from “Turn Output On”
button
• Enables output for calibration
• Light will flash Red when output
is “ON”
CALIBRATION ADJUSTMENT
▲
• System will automaticaly adjust
output levels as changes are
made
▲
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Turn Output ON
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F-68
POWER WAVE 655/R
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F-69
TROUBLESHOOTING & REPAIR
CALIBRATION PROCEDURE (CONTINUED)
Calibration can only be done under ʻstatic loadʼ conditions.
Do not attempt to calibrate while welding.
NOTE: Incorrect calibration can and will affect welding performance. It is strongly recommended to use the “Diagnostics” screen to run and save a “Snapshot” before making
any calibration adjustments. This will allow returning to original settings if necessary.
(Refer to the Software Documentation for instructions on using the Snapshot feature).
CALIBRATION PROCEDURE
1. 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.
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2. Set the load bank for 300 amps.
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F-69
3. On the Calibration screen, select the “300 Amps”
Current Set Point.
NOTE: If the meters on the load bank are not certified, connect calibrated and traceable meters
to the machine output. (See Materials
Needed at the beginning of this section).
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 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.
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FLASHES
RED
when output is
ON.
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FIGURE F.25 - CALIBRATION SCREEN
POWER WAVE 655/R
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F-70
NOTES
POWER WAVE 655/R
F-70
TROUBLESHOOTING & REPAIR
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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
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TEST PROCEDURE
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F-71
1. Be certain that the machine is properly connected
for the input voltage being applied.
2. Turn the Power Switch ON and see that it goes
through the Start-up routine and the Status Light is
steady Green.
NOTE:Welding and/or wire feed problems may still
exist, but may only be evident after the machine
is reconnected into the weld cell.
3. Turn the Power Switch OFF, connect a resistive
load across the Output Studs and a computer to the
RS-232 port. Perform the Calibration Procedure to
be sure that the machine will produce proper weld
output.
POWER WAVE 655/R
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F-72
NOTES
POWER WAVE 655/R
F-72
TABLE OF CONTENTS - DIAGRAM SECTION
Return to Master TOC
G-1
G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram for Code 10630 (G3498)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram for Code 10863 (G3498-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram for Code 11410 (G3498-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Schematic - Complete Machine for Code 10630 (G3611) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Schematic - Complete Machine for Code 10863 (G3611-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Schematic - Complete Machine for Code 11410 (G3611-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Return to Master TOC
Schematic - Devicenet/Gateway PC Board - Sheet 1 (G3821-2)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
Schematic - Devicenet/Gateway PC Board - Sheet 2 (G3821-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9
Schematic - Ethernet/Gateway PC Board - Sheet 1 (G3893-1)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10
Schematic - Ethernet/Gateway PC Board - Sheet 2 (G3893-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
Schematic - Ethernet/Gateway PC Board - Sheet 3 (G3893-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
Schematic - Control PC Board - Sheet 1 (G3789-2)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
Schematic - Control PC Board - Sheet 2 (G3789-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-14
Schematic - Control PC Board - Sheet 3 (G3789-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-15
Schematic - Control PC Board - Sheet 4 (G3789-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-16
Schematic - Digital Power Supply PC Board (G3631-3)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-17
Return to Master TOC
Schematic - FeedHead PC Board - Sheet 1 (G3823-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-18
Schematic - FeedHead PC Board - Sheet 2 (G3823-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-19
Schematic - FeedHead PC Board - Sheet 3 (G3823-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-20
Schematic - Input PC Board (M19528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-21
PC Board Assembly - Input PC Board (L11396-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-22
Schematic - Switch PC Board (L11016) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-23
PC Board Assembly - Switch PC Board (G3501-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-24
Schematic - Voltage Sense PC Board (S24779) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-25
PC Board Assembly - Voltage Sense PC Board (M19540-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-26
Schematic - 40 VDC Bus PC Board (M19330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-27
Return to Master TOC
PC Board Assembly - 40 VDC Bus PC Board (L11745) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-28
Schematic - Auxiliary Driver PC Board (S24530) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 longer provided.
POWER WAVE 655/R
ELECTRICAL DIAGRAMS
ENGINEERING CONTROLLED
MANUFACTURER: No
TM
POWER WAVE 655 (460/ 575 )WIRING DIAGRAM
S1
WIRE
FEEDER
RECEPTACLE
C
S2
VOLTAGE
SENSE
RECEPTACLE
FRONT OF MACHINE
D
52
51
1
2
3
4
L4
21A
J72
TO
J9
J73
1
2
3
4
5
6
7
S3
RS232
CONNECTOR
J71
253
254
J74
251
TO
J2
J75
20
CB1
10A CIRCUIT
BREAKER
52
TO
L2
J47
50
J76
J2
743
741
800
840
53
54
892
893
891
894
TO
J81 J3
TO
S1
TO
S5 J4
830
J5
TO
WORK
ELECTRODE
TP3
PRINT TO 10 X 17
S4
115V
RECEPTACLE
31
J6
32
32A
TO
AUX 2
CB2
AUX FAN
J7
206A
CB2
10A CIRCUIT
BREAKER
841
844
842
843
845
846
847
67B
539
541
31
P
TO
S4
AUX 2
33
AC
TO
J4
J6
J40
J42
J50
1
2
3
4
5
6
1
2
J1
TO
J83
886
522
J2
J10B
512
67
511
67A
67B
J9
J10A
VOLTAGE SENSE
SELECT BOARD
880
AC
J8
222
222A
503
506
302
225
225A
403
406
301
D6
+40VDC
DIODE
TO
J83
J84
J2VS
J11
TO
J9
J85
251
253
254
267
266
268
228
226
227
221
405
238
505
J84
841
842
843
844
845
846
847
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
851
852
853
854
855
856
857
858
859
860
861
862
512
511
J85
TO
RECT
THERM
J86
TO
J40
J50
J60
J1AD
301
404
J87
2W
2B
3R
3W
211
212
213
813
811
216
816
812
206
202
67
21A
414 R
418 W
514 R
518 W
154
273
274
TO
J11
J47
1
2
3
4
5
6
7
8
604
1W
1B
153
154
500
540
J83
231
232
504
302
1
2
3
4
539
541
521
522
886
880
222A
223
225A
224
220
TO
J72
1
2
3
4
5
6
TO
S3
TO
J1AD
J42
J43
R5
743
741
800
840
TO
LED
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
J42
J41
TO
S6
D6
J43
TO
S6
225
223
221
227
222
TO
J4
J1AD
475
477
476
478
TO
J47
+
4
3
812
813
811
816
1
2 P90
3 (NOT USED)
4
AUXILIARY TRANSFORMER #1
-
1
2
TO
J4
J11
R5
1
2
3
4
5
6
7
8
9
10
11
12
851
852
853
854
855
856
857
858
859
860
861
862
GND-B
GND-A
2B
TO
J85
2W
N.A.
STATUS LED (R/G)
TO J7
TP4
X3
X3
X3A
TO
CR1
J60
TO POWER BD. RECTIFIER
TO AUX#1
MAIN CHOKE
L1
TO RECONNECT PANEL
A
TO J61
H1D
TO CONTACTOR
L3A
TO CB3
612B
A
H2
H1
TO J61
CB3
612A
612
H1
TO AUX #1
H3A
H2A
TO
S7
J1VS
J46
J47
1
2
3
4
5
6
7
8
9
10
POS
POS
NEG
NEG
51
500
50
540
475
476
477
478
TO
C3
.022
800V
TO
CB1
J41
J82
S1
SECONDARY
(TOP
LEFT)
FAN
18
TO SW1
S4
2.7
10W
.022
800V
S4
12
S3
SECONDARY
(BOTTOM
LEFT)
S3
N.B.
CURRENT
TRANSFORMER
#1
TO J5
220
224
AC
224A
2.7
10W
TO
CHOKE
THERM
X2
291
N.B.
CURRENT
TRANSFORMER
#2
RECT.
THERM.
.022
800V
S2
S2
SECONDARY
(BOTTOM
RIGHT)
S8
414
RED
418
WHITE
12
15
TO J1 VOLTAGE SENSE
WORK
ELECTRODE
S2
NEG
NEG
NEG
2.7
10W
POS
POS
POS
J61
1
2
3
4
5
6
7
8
9
10
SWITCH BOARD #2 (RIGHT)
PRIMARY
(BOTTOM
RIGHT)
17
.022
800V
J60
1
2
3
4
5
6
7
8
THIS AREA VIEWED FROM RIGHT SIDE OF MACHINE
1
2
3
4
5
6
J50
S2
C3
INPUT BOARD
TO
J10A
16
D2B
X1
TO J1AD
503
504
505
506
TO J6
S2
D1A
11
S1
TO
J46
POWER BD RECT
S1
TO CT #1
SECONDARY
(TOP
RIGHT)
C6
16
HARMONIC
FILTER
231
NEG
T1
T2
TO
CR1
SW1
CB4
612
H1D
TO TP3
AC3
AC1
NEG
18
C
15
17
NEG
T3
T2
T1
L3
L2
L1
CR1
X4
C
TO AUX #1
TO SW1
L3A
TO SW1
L1A
W
32
1
33
4
352A
6
V
U
TO SUPPLY LINES
1
350
33A
352
4
2
TO S4,
CB2,
AUX. FAN
W
(115V) R
(230V)
H6
(550-575)
H5
(440-460)
H4
(380-415)
H3
(220-230)
H2
(200-208)
H1
P50
5
H6A
6
H5A
3
H4A
2
H3A
4
H2A
1
H1A
G
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
TO
CB3
AUX #1
J10A, J10B,
J2VS, J7
1
AUXILIARY TRANSFORMER #2
J2,J5,J11,
J41,J46,J72
J73,J76,J81
J82
1 2
2
3
RIGHT SIDE OF MACHINE
LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE
J1VS,J9,
J14,J40,J42,
J50,J75,J83,J711
4
J8,
J47,J60
J84,J712
1
3
1
4
J1AD ,J3
J61,J77,
J79,J86
1
5
4
6
5
8
6
10
J4,J13,
J43,J71
ELECTRICAL SYMBOLS PER E1537
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.
AC2
601
C7
TO
S8
NOTES:
POS
T3
TO
J10B
+
INPUT POS
RECTIFIER
NEG
RIGHT SIDE
P91
CURRENT
TRANSDUCER
TO SWITCH
BD #1
POS
NEG
TO J61
S1
AUX.
FAN
WATER
COOLER
RECEPTACLE
L6
TO
CR1
AUX #1
J6
TO J60
13
S1
TO
J43
J82
TO SWITCH
BD #2
601
X3
238
604
232
PRIMARY
(TOP
RIGHT)
D1B
TO CT #2
1
2
3
4
350
352
33A
TO AUX #2
11
514 518
RED WHITE
D2A
NEG
TO
P90
P91
N.C.
TO AUX #1
POS
C
440-460V
550-575V
14
14
S3
POS
12
POS
C
12
268
268A
TO
C3
AUX 1
13
'A'
H5
H6
C5
11
PRIMARY
(BOTTOM
LEFT)
D3B
TO
J4
J43
C4
S3
220A
AC
TO J6
S4
292
POWER BD
RECTIFIER
THIS AREA VIEWED FROM REAR OF MACHINE
RECONNECT PANEL
TO J1AD
403
404
405
406
D4B
262
TO
SSR
PRIMARY
(TOP
LEFT)
D3A
R5
1
2
3
4
5
6
J40
16
S4
292
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
MAIN TRANSFORMER
LEFT SIDE
D4A
220A
DC BUS
THERM
OUTPUT RECT
2.7
10W
352A
C2
.05/600V
CB4
6A CIRCUIT
BREAKER
TO SOLID STATE RELAY
444
X5
TO AUX#1
SWITCH BOARD #1 (LEFT)
1
2
3
4
1
2
3
4
5
6
7
8
N.B. CTs MUST BE ORIENTED IN THE PROPER DIRECTION. TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED
SIDE OF CT TO THE SWITCH BOARD. THE ARROW ON THE CT SHOULD POINT FROM THE SWITCH BOARD TO THE TRANSFORMER.
L1A
H3
H1A
TO AUX #2
TO
AUX #2
CB4
RECONNECT PANEL
291
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE) ALIGNS WITH BLACK LEAD OF LED SOCKET.
SW1
POWER
H5A
H4A
X3A
TO SOLID STATE RELAY
CHOKE
THERM.
TO RECT THERM
DC BUS
BOARD
32A
TO J9
206
ELECTRODE
(TOP)
LOAD LINE
(115V) R
X5
H6A
H4
H3
(220-230)
H2
(200-208)
H1
(24V) N
X4
H5
TO FAN
TO
J8
TO R1
206A
W
H6
224A
228
273
267
262
TO
S1
S6
TP2
N.A.
THERMAL LED (Y)
TO J7
H6
(550-575)
H5
(440-460)
H4
(380-415)
(51V)
U
CB3
10A CIRCUIT
BREAKER
TO CB4
612A
THIS AREA VIEWED FROM LEFT SIDE OF MACHINE
1
2
3
4
12 PIN
CONNECTOR
1
2
3
4
5
6
7
8
9
10
11
12
1W
+
1B
W
X1
444
TO SW1
612B
LEFT SIDE OF MACHINE
X2
TO FAN
268A
226
274
266
TO
J8
3W
GND-A
S7
COMPONENT VALUES:
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
1
6
1
7
7
12
8
14
1
J710
8
1
J1,J6,J7
J10,J70,J85
J87
8
16
9
CONNECTOR CAVITY NUMBERING SEQUENCE
A
G3498
(VIEWED FROM COMPONENT SIDE OF BOARD)
CLEVELAND, OHIO, U.S.A.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
lwimbley
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER: K.JUSTICE
DO NOT SCALE THIS DRAWING
APPROVED:
EAE
REFERENCE:
G3792
SCALE:
NONE
INVERTER WELDERS
WIRING DIAGRAM
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
12/4/02
PROJECT
NUMBER:
CRM34209
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3498
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.
DOCUMENT
REVISION:
A
STRP
SOLID EDGE
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EN-170
Return to Master TOC
1
2
3
4
5
6
7
8
9
10
J1AD
521
R
S
T
U
V
W
X
Return to Section TOC
TO
WORK
ELECTRODE
R 50
1
+
Return to Master TOC
TO
J75
AUX. DRIVER BOARD
S6
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
A
B
C
D
E
F
G
H
I
J
K
L
M
N
202A
J82
1
2
3
4
TO
J7
3R
SOLID
STATE
RELAY
REAR OF MACHINE
Return to Section TOC
S5
DEVICENET
CONNECTOR
1
894
+24V
2
+24V GND 3
893
892
4
CAN_H
891
CAN_L
5
J81
DIGITAL POWER
SUPPLY BOARD
212
213
211
216
Return to Master TOC
67A
E
3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE
TO
J2VS
J73
J47
CB1
53
54
FEED HEAD
BOARD
+
A
B
J1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
1
2
1
2
3
4
+
J70
L2
CONTROL BOARD
+
DEVICE NET
GATEWAY
BOARD
L5
TP1
-
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
1
2
3
4
1
2
3
4
1
2
1
2
3
4
5
6
1
2
3
4
+
TO
CB1
J47
202A
TO R1
C1
.05/600V
WORK
Return to Section TOC
CHANGE DETAIL: RELEASED FROM X A.02
TO J9
202
-
G-2
+
Return to Master TOC
WIRING DIAGRAM - CODE 10630
G3498
Return to Section TOC
G-2
ELECTRICAL DIAGRAMS
S2
VOLTAGE
SENSE
RECEPTACLE
FRONT OF MACHINE
53
54
C
67A
D
52
E
51
1
2
3
4
3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE
L4
21A
J72
TO
J9
J73
1
2
3
4
5
6
7
S3
RS232
CONNECTOR
J71
253
254
J74
251
TO
J2
J75
20
CB1
10A CIRCUIT
BREAKER
52
TO
L2
J47
50
J76
TO
WORK
ELECTRODE
TP3
N.E.
J77
EARLIER MODEL
115V
RECEPTACLE
(NEUTRAL FLOATING)
S4
115V
RECEPTACLE
(NEUTRAL BONDED)
31
32
32A
J79
32A
32
34
CB2
TO
S4
AUX 2
AUX FAN
33
TO
AUX 2
CB2
AUX FAN
J710
34
33
1
2
3
4
5
6
7
8
9
10
J1AD
TO
S4
AUX 2
880
521
AC
AC
891
894
TO
J81 J3
TO
S1
TO
S5 J4
830
J5
J6
N.E.
J7
J8
TO
J4
J6
J40
J42
J50
1
2
3
4
5
6
1
2
J1
TO
J83
886
522
J2
J10B
512
67B
511
67A
67
J9
J10A
VOLTAGE SENSE
SELECT BOARD
D6
+40VDC
DIODE
TO
J83
J84
J2VS
892
893
222
222A
503
506
302
225
225A
403
406
301
J11
TO
J9
J85
TO
J72
1
2
3
4
153
154
500
540
TO
J11
J47
J83
1
2
3
4
5
6
539
541
521
522
886
880
J84
1
2
3
4
5
6
7
8
841
842
843
844
845
846
847
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
851
852
853
854
855
856
857
858
859
860
861
862
512
511
J82
253
254
267
266
268
228
226
227
221
TO
S3
TO
J1AD
J42
J43
R5
J85
222A
223
225A
224
220
TO
RECT
THERM
231
232
504
302
405
238
505
J86
TO
J40
J50
J60
J1AD
604
301
404
J87
1W
1B
2W
2B
3R
3W
211
212
213
813
811
216
816
812
206
202
67
21A
414 R
418 W
514 R
518 W
154
273
274
TO
LED
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
J42
J41
TO
S6
D6
J43
TO
S6
225
223
221
227
222
475
477
476
478
+
4
3
812
813
811
816
LEFT SIDE OF MACHINE
1
2 P90
34 (NOT USED)
-
TO
J47
444
TO
J4
J11
R5
12 PIN
CONNECTOR
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
851
852
853
854
855
856
857
858
859
860
861
862
GND-B
GND-A
1W
1B
2B
2W
TO
J85
N.D.
STATUS LED (R/G)
TO J7
1
TP4
X3
X3
X3A
TO
CR1
J60
TO POWER BD. RECTIFIER
TO AUX#1
MAIN CHOKE
L1
N.A.
THERMAL LED (Y)
TO J7
228
273
267
262
TO RECONNECT PANEL
A
TO J61
H1D
SW1
POWER
ELECTRODE
(TOP)
LOAD LINE
TO CONTACTOR
L3A
C
L1A
H5A
TO
AUX #2
CB4
RECONNECT PANEL
H4A
H3
H2
H1
TO J61
CB3
612A
612
H1
TO AUX #2
H3A
H2A
CB4
3.5A CIRCUIT
BREAKER
TO SOLID STATE RELAY
444
X5
TO AUX#1
X3A
TO SOLID STATE RELAY
FAN
291
TO
S7
J1VS
J46
J47
1
2
3
4
5
6
7
8
9
10
POS
POS
NEG
NEG
51
500
50
540
475
476
477
478
TO
C3
.022
800V
TO
CB1
J41
J82
S1
SECONDARY
(TOP
LEFT)
18
TO SW1
S4
2.7
10W
.022
800V
S4
12
S3
SECONDARY
(BOTTOM
LEFT)
S3
N.B.
CURRENT
TRANSFORMER
#1
TO J5
220
224
AC
224A
2.7
10W
TO
CHOKE
THERM
X2
291
N.B.
CURRENT
TRANSFORMER
#2
RECT.
THERM.
.022
800V
S2
S2
SECONDARY
(BOTTOM
RIGHT)
11
S8
414
RED
418
WHITE
12
15
TO J1 VOLTAGE SENSE
WORK
ELECTRODE
S2
NEG
NEG
NEG
2.7
10W
POS
POS
POS
J61
1
2
3
4
5
6
7
8
9
10
SWITCH BOARD #2 (RIGHT)
PRIMARY
(BOTTOM
RIGHT)
17
.022
800V
J60
1
2
3
4
5
6
7
8
THIS AREA VIEWED FROM RIGHT SIDE OF MACHINE
1
2
3
4
5
6
J50
S2
C3
INPUT BOARD
TO
J10A
16
D2B
X1
TO J1AD
503
504
505
506
TO J6
S2
D1A
11
S1
TO
J46
POWER BD RECT
S1
TO CT #1
SECONDARY
(TOP
RIGHT)
L6
TO
CR1
AUX #1
J6
HARMONIC
FILTER
231
NEG
T1
T2
TO
CR1
SW1
CB4
612
H1D
C6
16
NEG
NEG
AC3
18
C
17
NEG
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH BLACK LEAD OF LED SOCKET.
N.E. ON SYNCHRONIZED TANDEM MIG APPLICATIONS J77, J712 OF THE ETHERNET BOARD AND J3, J7 OF THE CONTROL BOARD ARE USED.
SEE S26631 FOR DETAILS.
T3
T2
T1
L3
L2
L1
CR1
15
X4
C
TO AUX #1
TO SW1
L1A
W
32
1
33
4
352A
6
V
U
TO SUPPLY LINES
TO
S8
+
AC1
601
C7
TO
J10B
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE) ALIGNS WITH BLACK LEAD OF LED SOCKET.
N.B. CTs MUST BE ORIENTED IN THE PROPER DIRECTION. TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED
SIDE OF CT TO THE SWITCH BOARD. THE ARROW ON THE CT SHOULD POINT FROM THE SWITCH BOARD TO THE TRANSFORMER.
AC2
TO SW1
L3A
TO
J8
TO TP3
POS
T3
RIGHT SIDE
P91
CURRENT
TRANSDUCER
INPUT POS
RECTIFIER
TO J61
S1
AUX.
FAN
WATER
COOLER
RECEPTACLE
TO SWITCH
BD #1
POS
NEG
TO J60
13
S1
TO
J43
J82
TO SWITCH
BD #2
601
X3
238
604
232
PRIMARY
(TOP
RIGHT)
D1B
TO CT #2
1
2
3
4
350
352
33A
TO AUX #2
514 518
RED WHITE
D2A
NEG
TO
P90
P91
N.C.
TO AUX #1
POS
C
440-460V
550-575V
14
14
S3
POS
12
POS
C
12
268
268A
TO
C3
AUX 1
13
'A'
H5
H6
C5
11
PRIMARY
(BOTTOM
LEFT)
D3B
TO
J4
J43
C4
S3
220A
AC
TO J6
S4
292
POWER BD
RECTIFIER
THIS AREA VIEWED FROM REAR OF MACHINE
RECONNECT PANEL
TO J1AD
403
404
405
406
D4B
262
TO
SSR
PRIMARY
(TOP
LEFT)
D3A
R5
1
2
3
4
5
6
J40
16
S4
292
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
MAIN TRANSFORMER
LEFT SIDE
D4A
220A
DC BUS
THERM
OUTPUT RECT
2.7
10W
352A
C2
.05/600V
JUMPER (H1A)
H1A
TO AUX #1
TO FAN
CHOKE
THERM.
TO RECT THERM
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.
TO CB3
612B
(115V) R
X5
H6A
H4
H3
(220-230)
H2
(200-208)
H1
(24V) N
X4
H5
SWITCH BOARD #1 (LEFT)
1
2
3
4
1
2
3
4
5
6
7
8
32A
TO J9
206
TO R1
206A
W
H6
224A
DC BUS
BOARD
TO
S1
S6
TP2
H6
(550-575)
H5
(440-460)
H4
(380-415)
(51V)
U
CB3
5A CIRCUIT
BREAKER
TO CB4
612A
THIS AREA VIEWED FROM LEFT SIDE OF MACHINE
1
2
3
4
S7
W
X1
X2
2
TO SW1
612B
AUXILIARY TRANSFORMER #1
TO
J4
J1AD
TO FAN
268A
226
274
266
TO
J8
3W
GND-A
+
PRINT DIAGRAM TO 11X17
CB2
10A CIRCUIT
BREAKER
67B
539
541
P
J712
206A
841
844
842
843
845
846
847
R
S
T
U
V
W
X
1
350
33A
352
TO S4,
CB2,
AUX. FAN
4
2
W
(115V) R
(230V)
H6
(550-575)
H5
(440-460)
H4
(380-415)
H3
(220-230)
H2
(200-208)
H1
AUXILIARY
TRANSFORMER #2
5
5
H6A
6
H5A
G
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
3
3
H4A
2
2
H3A
J10A, J10B,
J2VS, J7
4
4
H2A
1
1 H1A
1
H1A
ELECTRICAL SYMBOLS PER E1537
RIGHT SIDE OF MACHINE
H6A
6
LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE
J2,J5,J11,
J41,J46,J72
J73,J76,J81
J82
1 2
2
P50 JUMPER
(MAY NOT BE PRESENT
ON EARLIER MACHINES)
3
06/16/2006
4
J8,
J47,J60
J84,J712
1
3
1
4
J1AD ,J3
J61,J77,
J79,J86
1
5
4
6
5
8
6
10
J4,J13,
J43,J71
COMPONENT VALUES:
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
1
6
7
12
1
7
8
14
1
J710
8
1
J1,J6,J7
J10,J70,J85
J87
8
16
9
CONNECTOR CAVITY NUMBERING SEQUENCE
C
G3498-1
(VIEWED FROM COMPONENT SIDE OF BOARD)
CLEVELAND, OHIO, U.S.A.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
lwimbley
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER: K.JUSTICE
DO NOT SCALE THIS DRAWING
APPROVED:
-
REFERENCE:
G3498
SCALE:
NONE
INVERTER WELDERS
WIRING DIAGRAM
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
6/16/2006
PROJECT
NUMBER:
CRM37721
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3498-1
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.
DOCUMENT
REVISION:
C
STRP
SOLID EDGE
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EN-170
Return to Master TOC
N.E.
TO
WORK
ELECTRODE
R 50
1
+
Return to Master TOC
TO
J75
AUX. DRIVER BOARD
S6
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
A
B
C
D
E
F
G
H
I
J
K
L
M
N
202A
743
741
800
840
53
54
743
741
800
840
TO
J7
3R
SOLID
STATE
RELAY
"H1A TO AUX. #2
CONNECTED HERE
ON EARLIER MACHINES
REAR OF MACHINE
Return to Section TOC
S5
DEVICENET
CONNECTOR
1
894
+24V
2
+24V GND 3
893
892
4
CAN_H
891
CAN_L
5
J2
N.E.
1
2
3
4
J81
251
DIGITAL POWER
SUPPLY BOARD
212
213
211
216
Return to Master TOC
A
B
TO
J2VS
J73
J47
CB1
J1
FEED HEAD
BOARD
+
TP1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
1
2
1
2
3
4
+
J70
L2
L5
CONTROL BOARD
+
C1
.05/600V
-
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
1
2
3
4
1
2
3
4
1
2
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
ETHERNET
BOARD
TO
CB1
J47
202A
TO R1
-
S1
WIRE
FEEDER
RECEPTACLE
Return to Section TOC
POWER WAVE 655TM(460 / 575) WIRING DIAGRAM
TO J9
202
WORK
Return to Section TOC
CHANGE DETAIL: ADDED NOTE N.E.
+
ENGINEERING CONTROLLED
MANUFACTURER: No
G-3
+
Return to Master TOC
WIRING DIAGRAM - CODE 10863
G3498-1
Return to Section TOC
G-3
ELECTRICAL DIAGRAMS
S2
VOLTAGE
SENSE
RECEPTACLE
FRONT OF MACHINE
53
54
C
67A
D
52
E
51
1
2
3
4
3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE
L4
21A
J72
TO
J9
J73
1
2
3
4
5
6
7
S3
RS232
CONNECTOR
J71
253
254
J74
TO
J2
251
J75
20
CB1
10A CIRCUIT
BREAKER
52
TO
L2
J47
50
J76
TO
WORK
ELECTRODE
TP3
N.E.
J77
EARLIER MODEL
115V
RECEPTACLE
(NEUTRAL FLOATING)
S4
115V
RECEPTACLE
(NEUTRAL BONDED)
31
32
32A
J79
32A
32
34
CB2
TO
S4
AUX 2
AUX FAN
33
TO
AUX 2
CB2
AUX FAN
J710
CB2
10A CIRCUIT
BREAKER
67B
539
541
34
33
1
2
3
4
5
6
7
8
9
10
J1AD
TO
S4
AUX 2
TO
J83
J84
J2VS
AC
891
894
TO
J81 J3
TO
S1
TO
S5 J4
830
J5
J6
N.E.
J7
J8
TO
J4
J6
J40
J42
J50
1
2
3
4
5
6
1
2
J1
TO
J83
886
522
J2
J10B
512
67B
511
67A
67
J9
J10A
VOLTAGE SENSE
SELECT BOARD
880
AC
892
893
222
222A
503
506
302
225
225A
403
406
301
D6
+40VDC
DIODE
521
P
J712
206A
841
844
842
843
845
846
847
R
S
T
U
V
W
X
J11
TO
J9
J85
253
254
267
266
268
228
226
227
221
1
2
3
4
5
6
539
541
521
522
886
880
J84
1
2
3
4
5
6
7
8
841
842
843
844
845
846
847
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
851
852
853
854
855
856
857
858
859
860
861
862
512
511
J85
222A
223
225A
224
220
TO
RECT
THERM
231
232
504
302
405
238
505
J86
TO
J40
J50
J60
J1AD
604
301
404
J87
1W
1B
2W
2B
3R
3W
211
212
213
813
811
216
816
812
206
202
67
21A
414 R
418 W
514 R
518 W
154
273
274
153
154
500
540
J83
TO
S3
TO
J1AD
J42
J43
R5
1
2
3
4
TO
LED
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
TO
J72
J42
TO
J11
J47
J41
TO
S6
D6
J43
TO
S6
225
223
221
227
222
TO
J4
J1AD
475
477
476
478
TO
J47
+
4
3
AUXILIARY TRANSFORMER #1
-
1
444
TO
J4
J11
R5
TP4
X3
X3
X3A
TO
CR1
J60
TO POWER BD. RECTIFIER
TO AUX#1
MAIN CHOKE
L1
1
2
3
4
5
6
7
8
9
10
11
12
851
852
853
854
855
856
857
858
859
860
861
862
GND-B
GND-A
1B
2B
2W
TO
J85
N.D.
STATUS LED (R/G)
TO J7
228
273
267
262
TO RECONNECT PANEL
A
TO J61
H1D
SW1
POWER
ELECTRODE
(TOP)
LOAD LINE
TO CONTACTOR
L3A
A
L1A
FUSE
H1
TO AUX #1
H3
H2
H1
TO SOLID STATE RELAY
444
X5
TO AUX#1
X3A
TO SOLID STATE RELAY
FAN
291
TO
S7
J1VS
J46
J47
1
2
3
4
5
6
7
8
9
10
POS
POS
NEG
NEG
51
500
50
540
475
476
477
478
TO
C3
.022
800V
TO
CB1
J41
J82
S1
SECONDARY
(TOP
LEFT)
18
TO SW1
S4
2.7
10W
.022
800V
S4
12
S3
SECONDARY
(BOTTOM
LEFT)
S3
N.B.
CURRENT
TRANSFORMER
#1
S3
TO J5
220
224
224A
2.7
10W
TO
CHOKE
THERM
POS
AC
X2
291
N.B.
CURRENT
TRANSFORMER
#2
RECT.
THERM.
.022
800V
S2
S2
SECONDARY
(BOTTOM
RIGHT)
TO J1 VOLTAGE SENSE
WORK
ELECTRODE
S2
2.7
10W
POS
POS
POS
418
WHITE
12
INPUT BOARD
J60
1
2
3
4
5
6
7
8
J61
1
2
3
4
5
6
7
8
9
10
TO
J10A
16
15
THIS AREA VIEWED FROM RIGHT SIDE OF MACHINE
SWITCH BOARD #2 (RIGHT)
PRIMARY
(BOTTOM
RIGHT)
17
.022
800V
1
2
3
4
5
6
J50
TO J1AD
503
504
505
506
TO J6
S2
D1A
11
S1
TO
J46
POWER BD RECT
S1
TO CT #1
SECONDARY
(TOP
RIGHT)
C6
16
NEG
HARMONIC
FILTER
231
NEG
T1
T2
612
H1D
TO
CR1
SW1
CB4
NEG
AC3
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WITH BLACK LEAD OF LED SOCKET.
N.E. ON SYNCHRONIZED TANDEM MIG APPLICATIONS J77, J712 OF THE ETHERNET BOARD AND J3, J7 OF THE CONTROL BOARD ARE USED.
SEE S26631 FOR DETAILS.
AC2
AC1
18
C
T2
T1
L3
L2
L1
CR1
15
17
NEG
T3
601
C7
X4
C
TO AUX #1
TO SW1
L1A
W
32
1
33
4
352A
6
V
U
G
TO SUPPLY LINES
TO
S8
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE) ALIGNS WITH BLACK LEAD OF LED SOCKET.
N.B. CTs MUST BE ORIENTED IN THE PROPER DIRECTION. TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED
SIDE OF CT TO THE SWITCH BOARD. THE ARROW ON THE CT SHOULD POINT FROM THE SWITCH BOARD TO THE TRANSFORMER.
POS
T3
TO
J10B
+
INPUT POS
RECTIFIER
TO SW1
L3A
TO
J8
TO TP3
POS
L6
RIGHT SIDE
P91
CURRENT
TRANSDUCER
WATER
COOLER
RECEPTACLE
TO J61
S1
AUX.
FAN
TO
CR1
AUX #1
J6
TO SWITCH
BD #1
NEG
TO J60
13
S1
TO
J43
J82
TO SWITCH
BD #2
601
X3
238
604
232
PRIMARY
(TOP
RIGHT)
D1B
TO CT #2
1
2
3
4
350
352
33A
S8
414
RED
S2
NEG
NEG
NEG
N.C.
TO AUX #1
11
D2B
X1
C3
550-575V
14
POS
C
380-415V
440-460V
TO AUX #2
514 518
RED WHITE
D2A
NEG
TO
P90
P91
12
14
12
268
268A
TO
C3
AUX 1
13
POS
C
'A'
H4
H5
H6
C5
11
PRIMARY
(BOTTOM
LEFT)
D3B
TO
J4
J43
C4
S3
220A
AC
TO J6
S4
292
POWER BD
RECTIFIER
THIS AREA VIEWED FROM REAR OF MACHINE
RECONNECT PANEL
TO J1AD
403
404
405
406
D4B
262
TO
SSR
PRIMARY
(TOP
LEFT)
D3A
R5
1
2
3
4
5
6
J40
16
S4
292
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
MAIN TRANSFORMER
LEFT SIDE
D4A
220A
DC BUS
THERM
OUTPUT RECT
2.7
10W
352A
C2
.05/600V
10A
612
TO
AUX #2
CB4
RECONNECT PANEL
N.L.
TO INPUT SWITCH
TO J61
TO FAN
CHOKE
THERM.
TO RECT THERM
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.
TO CB3
612B
H5
SWITCH BOARD #1 (LEFT)
1
2
3
4
1
2
3
4
5
6
7
8
32A
TO J9
206
TO R1
206A
(115V) R
612B
H4
H3
(220-230)
H2
(200-208)
H1
(24V) N
X4
X5
H6
H6A
224A
DC BUS
BOARD
TO
S1
S6
TP2
N.A.
THERMAL LED (Y)
TO J7
W
TO AUX #2
H1B
H6
(550-575)
H5
(440-460)
H4
(380-415)
(51V)
U
H1A
CIRCUIT
BREAKER
THIS AREA VIEWED FROM LEFT SIDE OF MACHINE
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
1W
+
S7
W
X2
2
CB3
3.5A
LEFT SIDE OF MACHINE
1
2 P90
34 (NOT USED)
X1
TO FAN
268A
226
274
266
812
813
811
816
GND-A
12 PIN
CONNECTOR
1
350
33A
352
TO S4,
CB2,
AUX. FAN
4
2
W
H6
(550-575)
5
H6A
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
(115V) R
P50
(230V) B
H1
AUXILIARY
TRANSFORMER #2
1
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
H1A
ELECTRICAL SYMBOLS PER E1537
RIGHT SIDE OF MACHINE
FRONT
FAN RECONNECT RECONNECT
REAR
HORIZONTAL HORIZONTAL SHROUD
SHELL
BRACKET
BAFFLE
BAFFLE
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
COMPONENT VALUES:
W=WHITE
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
1 2
6
7
12
CASE
FRONT
REAR
UPPER
BASE
FRONT
UPPER
BASE
AUX.
1
AUX.
2
LATCH
PROTECTIVE BONDING CIRCUIT
VIEW OF CONNECTOR ON PC BOARD
B
G3498-2PRINT
CLEVELAND, OHIO, U.S.A.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
RAS
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
MATERIAL TOLERANCE (" t ") TO AGREE
PW
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED:
SCALE:
EQUIPMENT TYPE:
POWERWAVE 655/R
WIRING DIAGRAM
NONE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
7-13-2007
PROJECT
NUMBER:
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
CRM38675
G3498-1
G3498-2
DOCUMENT
REVISION:
B
Insight
SOLID EDGE
PRINT DIAGRAM TO 10 X 15.5 ON E3269-9 LABEL SHEET
EN-170
Return to Master TOC
TO
WORK
ELECTRODE
R 50
1
+
Return to Master TOC
TO
J75
N.E.
AUX. DRIVER BOARD
S6
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
A
B
C
D
E
F
G
H
I
J
K
L
M
N
202A
743
741
800
840
53
54
251
743
741
800
840
TO
J8
3W
REAR OF MACHINE
Return to Section TOC
S5
DEVICENET
CONNECTOR
1
894
+24V
2
+24V GND 3
893
892
4
CAN_H
891
CAN_L
5
J2
N.E.
J82
1
2
3
4
TO
J7
3R
SOLID
STATE
RELAY
212
213
211
216
Return to Master TOC
A
B
TO
J2VS
J73
J47
CB1
J1
J81
DIGITAL POWER
SUPPLY BOARD
+
TP1
FEED HEAD
BOARD
+
L2
L5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
1
2
1
2
3
4
+
J70
CONTROL BOARD
+
C1
.05/600V
-
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
1
2
3
4
1
2
3
4
1
2
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
ETHERNET
BOARD
TO
CB1
J47
202A
TO R1
S1
WIRE
FEEDER
RECEPTACLE
Return to Section TOC
POWER WAVE 655/R TM WIRING DIAGRAM
TO J9
202
WORK
Return to Section TOC
CHANGE DETAIL: ADDED LABEL SHEET TO PRINT NOTE.
ENGINEERING CONTROLLED
MANUFACTURER: No
-
G-4
+
Return to Master TOC
WIRING DIAGRAM - CODE 11410
G3498-2
Return to Section TOC
G-4
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.
ELECTRICAL DIAGRAMS
ENGINEERING CONTROLLED
MANUFACTURER: No
G-5
CHANGE DETAIL: RELEASED FROM X A.02
N.A.
INPUT
RECTIFIER
CR1
AC3
L1
POS
T1
POS
POS
U
N.A.
AC2
L2
N.A.
FEED HD BD
.022u
800V
MAIN TRANSFORMER T1
SWITCH BOARD #1 (LEFT)
S3 RS232
CONNECTOR
CONTROL BOARD
HARMONIC
FILTER
RS232 RECEIVE
3J2
253
2
RS232 TRANSMIT
4J2
254
3
2.7
10W
4
+ELECTRODE VOLTAGE SENSE
1J9
206
NEG
ELECTRODE
T2
V
521
3J83
SOLENOID +40VDC
522
4J83
SOLENOID INPUT
5
+
+
6
AC1
OUTPUT DIODES
D1-D8
NEG
NEG
T3
L3
NEG
W
1J83
539
CR1
POS
.022u
800V
11
C4
2800uF
500V
MOTOR "+"
+
2.7
10W
RS232 COMMON
206A
251
1J2
7
TP2
320V
160J
C2
.05uF
600V
20
F
G
MOTOR "-"
R1
50
S
.022u
800V
3J84
TACH 1B DIFF. INPUT
INPUT BOARD
844
4J84
TACH COMMON
2J60
X3
845
5J84
TACH 2A DIFF. INPUT
5J60
232
846
6J84
TACH 2B DIFF. INPUT
847
7J84
SINGLE TACH INPUT
851
1J85
TRIGGER +15VDC
852
2J85
TRIGGER INPUT
853
3J85
DUAL PROC. INPUT
854
4J85
1J60
IGBT DRIVE (+)
TP3
150V
80J
CURRENT
TRANSDUCER
2.7
10W
+
11
- ELECTRODE VOLTAGE SENSE
3J9
202
202A
ELECTRODE
404
N.A.
601
3J40
4J40
V/F (+)
414 418
RED WHITE
405
5J40
V/F (-)
406
6J40
IGBT DRIVE (-)
800V
2.7
10W
P91
MAIN
CHOKE
L1
GND
843
403
I OUT
TACH 1A DIFF. INPUT
-15V
+15VDC TACH
2J84
4J91
1J84
842
+15V
841
2J91
X4
3J91
2J83
541
13
C
1J91
Return to Master TOC
COMPLETE MACHINE SCHEMATIC - CODE 10630
G3611
Return to Section TOC
G-5
-
S2 VOLTAGE SENSE
RECEPTACLE
TP1
320V
160J
C1
.05uF
600V
216
6J8
211
1J8
CURRENT FEEDBACK
213
3J8
-15V
CONTROL BOARD COMMON
1
H1D
8J61
10J61
T3
6J61
2J61
T1
OFF
Return to Master TOC
Return to Section TOC
SW1
POWER
612
A
+13V
4J60
612B
3J60
238
N.A.
N.A.
5J85
COLD INCH +15VDC
856
6J85
COLD IN. FORWARD
SINGLE PHASE DETECT
8J60
(LOW=1 PHASE)
A
H5
H6
7J85
COLD IN. REVERSE
858
8J85
GAS PURGE INPUT
C6
2800uF
500V
1J73
ARCLINK -
54
2J73
ARCLINK +
440-460V
SHUTDOWN +15VDC
9J85
860
10J85
SHUTDOWN 1 INPUT
861
11J85
SHUTDOWN 2 INPUT
862
12J85
INPUT B
AUX DRIVER BD
841
844
842
843
845
846
847
A
B
C
D
E
F
G
I
J
K
N
1
2
T
/
0
5
/
2
0
0
2
67B
539
541
521
522
8J1AD
403
9J1AD
406
3J1AD
503
4J1AD
506
COMMON
154
2J82
ARCLINK H
153
1J82
ARCLINK L
741
2J81
ARCLINK H
743
1J81
ARCLINK L
800
3J81
COMMON
840
4J81
+40VDC
500
3J82
COMMON
540
4J82
+40VDC
503
3J50
IGBT DRIVE (+)
4J72
+40VDC
4J50
V/F (+)
5J50
V/F (-)
506
6J50
IGBT DRIVE (-)
514 518
RED WHITE
5J75
+24VDC
893
2J75
+24V GND
892
1J75
CAN_H
891
4J75
CAN_L
404
16J6
V/F (+)
405
8J6
V/F (-)
504
5J6
505
10J6
302
2J1AD
222A
7J1AD
225A
1J1AD
222
6J1AD
225
291
220A
292
OUTPUT RECTIFIER
THERMOSTAT
14J85
VOLTAGE SENSE
SELECT (-)
512
13J85
VOLTAGE SENSE
SELECT (+)
D6
H5
(440-460)
2W
YELLOW
THERMAL
LED
STATUS LED (HI FOR RED)
1W
3J7
RED/GREEN
STATUS
LED
ARC LINK H
2J11
4J7
1B
ARC LINK L
301
14J6
IGBT DRIVE (-)
302
6J6
IGBT DRIVE (+)
}
224
2J5
THERMOSTAT
220
3J5
THERMOSTAT
3W
16J7
FAN CONTROL (-)
3R
15J7
FAN CONTROL (+)
268
3J4
(NORMALLY CLOSED)
DCBUS
THERMOSTAT
262
+40VDC
5J83
886
+40VDC
6J83
880
VOLT SENSE BD
2J2
67B
H6
(550-575)
7J7
+5V SPI
268A
+
X3A
H5A
V/F (+)
1J11
238
9J6
604
12J6
PRECHARGE CONTROL
3R
N.A.
ROBOTIC VOLTAGE SENSE
262
VOLTAGE SENSE SELECT (-)
4J1
511
1J6
232
2J6
MAIN CONTACTOR CONTROL
67
4J9
VOLTAGE SENSE SELECT (+)
1J1
512
VOLTAGE SENSE OUTPUT
3J1
67
WIRE FEEDER VOLTAGE SENSE
1J2
67A
TP4
POWER BOARD
12J43
VOLTAGE SENSE
SPI COMMON
1J42
225
SPI +5V
CONTROL BOARD COMMON
5J42
222
+15V SPI
6J43
266
2J4
+15V
3J43
+13V
SINGLE PHASE DETECT
(LOW=1 PHASE)
231
H6A
THERMAL LED
R5
10
N.A.
AUXILIARY
TRANSFORMER T1
2B
S
511
851
852
853
854
855
856
857
858
859
860
861
862
8J7
V/F (-)
F
5J1AD
THERMAL LED
224A
CHOKE
THERMOSTAT
15
17
C
268A
225A
12J4
222A
10J4
+15V
CONTROL BOARD COMMON
+15V SPI
11J43
267
1J4
SPI COMMON
POWER DOWN INTERUPT
4J42
227
7J4
POWER DOWN INTERUPT
+5V
3J42
221
8J4
+5V
-15V
2J42
223
11J4
-15V
+5V ARCLINK +5V
SPI COMMON
FAN
DC BUS BD
N.A.
X3
0V
X3
24V
X4
H4
500
2J47
115V
H3
CB4
POWER BD. RECT.
X5
X1
(220-230)
COMMON
274
4J11
1J41
ARCLINK +5V
+40V COMMON
5J43
475
4J47
COMMON
+40VDC POWER
5J47
540
ARCLINK COMMON
10J43
273
3J11
POS
1J46
+40VDC POWER
7J47
477
2J41
+40V
RS232 +5V
4J43
226
6J4
RS232 +5V
POS
2J46
COMMON
6J47
476
3J41
+40V COMMON
RS232 COMMON
9J43
228
5J4
RS232 COMMON
+40VDC POWER
8J47
478
4J41
+40V
NEG
3J46
NEG
4J46
COMMON
1J47
+40VDC FEEDER
3J47
(380-415)
H4A
H2
POS
65VDC
(200-208)
H2A
52V
H1
H1
X2
C3
24000uF/100V
NEG
AUXILIARY
TRANSFORMER T2
H6A
5
H5A
6
H4A
3
2
H2A
4
230V
352
115V
33A
51
67A
RECEPTACLE
H3
4
32
1
33
0V
350
53
A ARCLINK -
54
B ARCLINK +
S5 DEVICENET
CONNECTOR
1
3
(200-208)
10A
32
1
E 0VDC
C ELECTRODE SENSE
L5
2
4
D +40VDC
52
50
10A
33
(220-230)
H1A
52
L2
51
CB2
H4
H2
S1 WIRE FEEDER
RECEPTACLE
10A
S8 WATER COOLER
H6
(380-415)
H3A
ARCLINK COMMON
CB1
352A
(550-575)
H5
(440-460)
CB3
CT CURRENT (+)
153
894
+
3W
612A
2J10B
3
15
C7
2800uF
500V
444
6A
CT CURRENT (-)
518
STATUS LED (HI FOR GREEN)
16
504
505
POS
SOLID STATE RELAY
612
CT CURRENT (+)
1J10B
154
301
10J1AD
GND-A
TRIGGER +15VDC 1
TRIGGER INPUT 2
DUAL PROC. INPUT 3
4 STEP INPUT 4
COLD INCH +15VDC 5
COLD IN. FORWARD 6
COLD IN. REVERSE 7
GAS PURGE INPUT 8
SHUTDOWN +15VDC 9
SHUTDOWN 1 INPUT 10
SHUTDOWN 2 INPUT 11
INPUT B 12
Return to Master TOC
ARCLINK L
3J72
S
N.A.
2J10A
514
21A
6J9
830
18
550-575V
S6 ROBOTIC
INTERFACE
RECEPTACLE
612B
1J72
F
859
418
+15
ARCLINK H
2J72
+
C
H3A
NOTES :
31
H1
S4
115V
RECEPTACLE
FAN
32A
894
2 +24VDC
893
3 +24V GND
892
4 CAN_H
891
5 CAN_L
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
ELECTRICAL SYMBOLS PER E1537
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
EN-170
Return to Master TOC
53
3J76
857
CT CURRENT (-)
16
POS
231
S7 I/O
RECEPTACLE
Return to Section TOC
GATEWAY BD
1J76
+13V
AUX. RECONNECT
TACH +15VDC
TACH COMMON
TACH 1A DIFF SIGNAL
TACH 1B DIFF SIGNAL
TACH 2A DIFF SIGNAL
TACH 2B DIFF SIGNAL
SINGLE TACH INPUT
VOLTAGE SENSE
MOTOR "+"
MOTOR "-"
SOLENOID +40VDC
SOLENOID INPUT
Return to Section TOC
S
SWITCH BOARD #2 (RIGHT)
855
2J8
1J10A
4
14
4 STEP INPUT
WORK VOLTAGE SENSE
212
414
12
F
604
T2
+
C
PRECHARGE RELAY
4J61
216
212
C5
2800uF
500V
ON
2
L4
12
POS
MAIN CONTACTOR CONTROL
213
L3A
211
+13V
L1A
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
lwimbley
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
TK
DO NOT SCALE THIS DRAWING
APPROVED:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
TK
REFERENCE:
G4009
SCALE:
NONE
INVERTER WELDERS
PW575/STT 208-575 MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
12/5/02
PROJECT
NUMBER:
CRM34209
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3611
DOCUMENT
REVISION:
A
ELECTRICAL DIAGRAMS
G-6
CHANGE DETAIL: REVISED CB2 AND RECEPTACLE GRAPHICS
ENGINEERING CONTROLLED
MANUFACTURER: No
N.A.
INPUT
RECTIFIER
CR1
AC3
L1
POS
T1
POS
POS
U
N.A.
AC2
L2
N.A.
FEED HD BD
.022u
800V
MAIN TRANSFORMER T1
SWITCH BOARD #1 (LEFT)
S3 RS232
CONNECTOR
CONTROL BOARD
HARMONIC
FILTER
RS232 RECEIVE
3J2
253
2
RS232 TRANSMIT
4J2
254
3
2.7
10W
1J9
206
4
+ELECTRODE VOLTAGE SENSE
NEG
ELECTRODE
T2
V
521
3J83
SOLENOID +40VDC
522
4J83
SOLENOID INPUT
5
+
+
6
AC1
NEG
NEG
T3
L3
NEG
W
1J83
539
CR1
.022u
800V
11
POS
C4
2800uF
500V
MOTOR "+"
+
OUTPUT DIODES
D1-D8
2.7
10W
RS232 COMMON
206A
251
1J2
7
TP2
320V
160J
C2
.05uF
600V
20
F
G
13
C
MOTOR "-"
843
3J84
TACH 1B DIFF. INPUT
844
4J84
TACH COMMON
.022u
800V
403
2J60
X3
845
5J84
TACH 2A DIFF. INPUT
5J60
232
846
6J84
TACH 2B DIFF. INPUT
1J60
CURRENT
TRANSDUCER
2.7
10W
+
11
4J40
3J9
202
202A
V/F (+)
414 418
RED WHITE
405
5J40
V/F (-)
406
6J40
IGBT DRIVE (-)
+15V
INPUT BOARD
IGBT DRIVE (+)
TP3
150V
80J
- ELECTRODE VOLTAGE SENSE
ELECTRODE
404
N.A.
601
3J40
800V
2.7
10W
P91
MAIN
CHOKE
L1
GND
TACH 1A DIFF. INPUT
I OUT
+15VDC TACH
2J84
-15V
1J84
842
S
X4
4J91
841
R1
50
2J91
2J83
3J91
541
1J91
Return to Master TOC
COMPLETE MACHINE SCHEMATIC - CODE 10863
G3611-1
Return to Section TOC
G-6
-
S2 VOLTAGE SENSE
RECEPTACLE
TP1
320V
160J
C1
.05uF
600V
216
6J8
211
1J8
CURRENT FEEDBACK
213
3J8
-15V
CONTROL BOARD COMMON
1
MAIN CONTACTOR CONTROL
847
7J84
SINGLE TACH INPUT
851
1J85
TRIGGER +15VDC
852
2J85
TRIGGER INPUT
853
3J85
DUAL PROC. INPUT
854
4J85
612
A
8J61
10J61
T3
6J61
2J61
T1
+13V
4J60
4J61
T2
3J60
238
S
N.A.
N.A.
SWITCH BOARD #2 (RIGHT)
5J85
855
SINGLE PHASE DETECT
8J60
(LOW=1 PHASE)
A
COLD INCH +15VDC
856
6J85
COLD IN. FORWARD
857
7J85
COLD IN. REVERSE
858
8J85
GAS PURGE INPUT
440-460V
H6
550-575V
C6
2800uF
500V
S6 ROBOTIC
INTERFACE
RECEPTACLE
N.A.
A
B
C
D
E
F
G
I
J
K
N
841
844
842
843
845
846
847
T
GND-A
AUX DRIVER BD
67B
539
541
521
522
Return to Master TOC
SHUTDOWN 1 INPUT
861
11J85
SHUTDOWN 2 INPUT
8J1AD
403
9J1AD
406
3J1AD
503
4J1AD
506
862
12J85
INPUT B
154
2J82
ARCLINK H
153
1J82
ARCLINK L
741
2J81
ARCLINK H
743
1J81
ARCLINK L
800
3J81
COMMON
1J72
ARCLINK L
503
3J50
IGBT DRIVE (+)
3J72
COMMON
4J72
+40VDC
302
2J1AD
222A
7J1AD
225A
222
6J1AD
225
504
4J50
V/F (+)
505
5J50
V/F (-)
506
B
514 518
RED WHITE
IGBT DRIVE (-)
POS
5J75
+24VDC
893
2J75
+24V GND
892
1J75
CAN_H
891
4J75
CAN_L
291
840
4J81
+40VDC
500
3J82
COMMON
540
4J82
+40VDC
OUTPUT RECTIFIER
THERMOSTAT
511
14J85
VOLTAGE SENSE
SELECT (-)
512
13J85
VOLTAGE SENSE
SELECT (+)
D6
AUXILIARY
TRANSFORMER T1
505
10J6
YELLOW
THERMAL
LED
1J11
V/F (+)
STATUS LED (HI FOR RED)
2J11
1W
3J7
V/F (-)
RED/GREEN
STATUS
LED
ARC LINK H
4J7
1B
ARC LINK L
301
14J6
IGBT DRIVE (-)
302
6J6
IGBT DRIVE (+)
220A
}
224
2J5
THERMOSTAT
220
3J5
THERMOSTAT
3W
16J7
FAN CONTROL (-)
3R
15J7
FAN CONTROL (+)
268
3J4
(NORMALLY CLOSED)
DCBUS
THERMOSTAT
262
+5V SPI
+40VDC
5J83
886
+40VDC
6J83
880
VOLT SENSE BD
3J1
+
3R
N.A.
ROBOTIC VOLTAGE SENSE
262
VOLTAGE SENSE SELECT (-)
4J1
511
VOLTAGE SENSE SELECT (+)
1J1
512
VOLTAGE SENSE OUTPUT
2J2
67
WIRE FEEDER VOLTAGE SENSE
1J2
67A
TP4
POWER BOARD
12J43
9J6
604
12J6
231
1J6
SINGLE PHASE DETECT
(LOW=1 PHASE)
B
2J6
MAIN CONTACTOR CONTROL
67
4J9
PRECHARGE CONTROL
VOLTAGE SENSE
SPI COMMON
1J42
225
SPI +5V
CONTROL BOARD COMMON
5J42
222
+15V SPI
6J43
266
2J4
+15V
3J43
+13V
238
225A
12J4
222A
10J4
+15V
CONTROL BOARD COMMON
+15V SPI
11J43
267
1J4
SPI COMMON
POWER DOWN INTERUPT
4J42
227
7J4
POWER DOWN INTERUPT
+5V
3J42
221
8J4
+5V
-15V
2J42
223
11J4
-15V
+5V ARCLINK +5V
SPI COMMON
FAN
DC BUS BD
N.A.
X3
0V
X3
X4
H4
500
2J47
115V
H3A
POWER BD. RECT.
X5
X1
(220-230)
COMMON
274
4J11
1J41
ARCLINK +5V
+40V COMMON
5J43
475
4J47
COMMON
+40VDC POWER
5J47
540
ARCLINK COMMON
10J43
273
3J11
POS
1J46
+40VDC POWER
7J47
477
2J41
+40V
RS232 +5V
4J43
226
6J4
RS232 +5V
POS
2J46
COMMON
6J47
476
3J41
+40V COMMON
RS232 COMMON
9J43
228
5J4
RS232 COMMON
+40VDC POWER
8J47
478
4J41
+40V
NEG
3J46
NEG
4J46
01/13/200
5
1J47
+40VDC FEEDER
3J47
(380-415)
CB4
H2
POS
65VDC
(200-208)
H2A
52V
H1
H1
X2
C3
24000uF/100V
NEG
AUXILIARY
TRANSFORMER T2
H6A
5
H5A
6
H4A
3
2
H2A
4
230V
33A
4
H1A
1
E 0VDC
52
50
67A
C ELECTRODE SENSE
10A
L5
CB2
RECEPTACLE
FAN
H3
33
4
32
1
4
33
53
A ARCLINK -
54
B ARCLINK +
33
0V
H1
D +40VDC
10A
350
(220-230)
(200-208)
51
2
352
115V
H4
5A
52
51
S8 WATER COOLER
H6
H2
S1 WIRE FEEDER
RECEPTACLE
CB1
(380-415)
H3A
ARCLINK COMMON
L2
352A
(550-575)
H5
(440-460)
1
3
CB2
S5 DEVICENET
CONNECTOR
1
32
NOTES :
31
32
10A
894
2 +24VDC
893
3 +24V GND
892
4 CAN_H
891
5 CAN_L
34
S4
115V
RECEPTACLE
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
ELECTRICAL SYMBOLS PER E1537
(earlier version)
32A
32A
115V
RECEPTACLE
(Neutral Floating)
(Neutral Bonded)
AUX FAN
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
EN-170
2W
24V
H3
CB3
V/F (-)
5J6
7J7
268A
268A
612A
8J6
504
THERMAL LED
R5
10
3W
612
405
2B
224A
CHOKE
THERMOSTAT
15
17
292
444
3.5A
V/F (+)
8J7
S
SOLID STATE RELAY
H5
(440-460)
16J6
153
894
+
C
X3A
H6
(550-575)
404
THERMAL LED
15
C7
2800uF
500V
67B
H5A
CT CURRENT (+)
STATUS LED (HI FOR GREEN)
16
N.A.
H6A
2J10B
F
5J1AD
1J1AD
CT CURRENT (-)
518
154
301
10J1AD
CT CURRENT (+)
1J10B
3
830
18
SHUTDOWN +15VDC
9J85
10J85
851
852
853
854
855
856
857
858
859
860
861
862
TRIGGER +15VDC 1
TRIGGER INPUT 2
DUAL PROC. INPUT 3
4 STEP INPUT 4
COLD INCH +15VDC 5
COLD IN. FORWARD 6
COLD IN. REVERSE 7
GAS PURGE INPUT 8
SHUTDOWN +15VDC 9
SHUTDOWN 1 INPUT 10
SHUTDOWN 2 INPUT 11
INPUT B 12
612B
ARCLINK H
S
H4A
Return to Master TOC
+
2J72
F
860
2J10A
514
21A
6J9
ARCLINK +
2J73
54
3J76
859
418
+15
16
POS
C
H5
CT CURRENT (-)
ARCLINK -
1J73
53
231
S7 I/O
RECEPTACLE
Return to Section TOC
ETHERNET BD
1J76
+13V
AUX. RECONNECT
TACH +15VDC
TACH COMMON
TACH 1A DIFF SIGNAL
TACH 1B DIFF SIGNAL
TACH 2A DIFF SIGNAL
TACH 2B DIFF SIGNAL
SINGLE TACH INPUT
VOLTAGE SENSE
MOTOR "+"
MOTOR "-"
SOLENOID +40VDC
SOLENOID INPUT
Return to Section TOC
14
4 STEP INPUT
2J8
1J10A
4
C
604
WORK VOLTAGE SENSE
212
414
12
F
PRECHARGE RELAY
612B
+
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
jbarto
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
TK
DO NOT SCALE THIS DRAWING
APPROVED:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
-
REFERENCE:
G4009
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
INVERTER WELDERS
PW655/R MACHINE SCHEMATIC
APPROVAL
DATE:
01/13/2005
PROJECT
NUMBER:
CRM 36674
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3611-1
DOCUMENT
REVISION:
B
SOLID EDGE
Return to Master TOC
Return to Section TOC
H1D
OFF
216
212
C5
2800uF
500V
ON
2
L4
12
POS
SW1
POWER
213
L3A
211
+13V
L1A
ELECTRICAL DIAGRAMS
G-7
CHANGE DETAIL: RELEASED A.01 FROM X.
ENGINEERING CONTROLLED
MANUFACTURER: No
N.A.
INPUT
RECTIFIER
CR1
AC3
L1
POS
T1
POS
POS
U
N.A.
AC2
L2
N.A.
FEED HD BD
.022u
800V
MAIN TRANSFORMER T1
SWITCH BOARD #1 (LEFT)
S3 RS232
CONNECTOR
CONTROL BOARD
HARMONIC
FILTER
RS232 RECEIVE
3J2
253
2
RS232 TRANSMIT
4J2
254
3
2.7
10W
1J9
206
4
+ELECTRODE VOLTAGE SENSE
NEG
ELECTRODE
T2
V
521
3J83
SOLENOID +40VDC
522
4J83
SOLENOID INPUT
5
+
+
6
AC1
NEG
NEG
T3
L3
NEG
W
1J83
539
CR1
.022u
800V
11
POS
C4
2800uF
500V
MOTOR "+"
+
OUTPUT DIODES
D1-D8
2.7
10W
RS232 COMMON
206A
251
1J2
7
TP2
320V
160J
C2
.05uF
600V
20
F
G
13
C
MOTOR "-"
843
3J84
TACH 1B DIFF. INPUT
844
4J84
TACH COMMON
.022u
800V
403
1J60
2J60
X3
845
5J84
TACH 2A DIFF. INPUT
5J60
232
846
6J84
TACH 2B DIFF. INPUT
CURRENT
TRANSDUCER
2.7
10W
+
11
4J40
3J9
202
202A
V/F (+)
414 418
RED WHITE
405
5J40
V/F (-)
406
6J40
IGBT DRIVE (-)
+15V
INPUT BOARD
IGBT DRIVE (+)
TP3
150V
80J
- ELECTRODE VOLTAGE SENSE
ELECTRODE
404
N.A.
601
3J40
800V
2.7
10W
P91
MAIN
CHOKE
L1
GND
TACH 1A DIFF. INPUT
I OUT
+15VDC TACH
2J84
-15V
1J84
842
S
X4
4J91
841
R1
50
2J91
2J83
3J91
541
1J91
Return to Master TOC
COMPLETE MACHINE SCHEMATIC - CODE 11410
G3611-2
Return to Section TOC
G-7
-
S2 VOLTAGE SENSE
RECEPTACLE
TP1
320V
160J
C1
.05uF
600V
216
6J8
211
1J8
CURRENT FEEDBACK
213
3J8
-15V
CONTROL BOARD COMMON
1
MAIN CONTACTOR CONTROL
847
7J84
SINGLE TACH INPUT
851
1J85
TRIGGER +15VDC
852
2J85
TRIGGER INPUT
853
3J85
DUAL PROC. INPUT
854
4J85
Return to Master TOC
Return to Section TOC
H1D
8J61
10J61
T3
6J61
2J61
T1
OFF
612
A
+13V
4J60
T2
3J60
238
S
N.A.
N.A.
SWITCH BOARD #2 (RIGHT)
ETHERNET BD
COLD INCH +15VDC
SINGLE PHASE DETECT
8J60
(LOW=1 PHASE)
A
H4
380-415V
H5
440-460V
H6
550-575V
6J85
COLD IN. FORWARD
857
7J85
COLD IN. REVERSE
858
8J85
GAS PURGE INPUT
C6
2800uF
500V
231
+
2J72
ARCLINK H
1J72
ARCLINK L
F
10J85
SHUTDOWN 1 INPUT
861
11J85
SHUTDOWN 2 INPUT
3J72
COMMON
4J72
+40VDC
S
N.A.
A
B
C
D
E
F
G
I
J
K
N
841
844
842
843
845
846
847
T
GND-A
AUX DRIVER BD
67B
539
541
521
522
8J1AD
403
9J1AD
406
3J1AD
503
4J1AD
506
12J85
INPUT B
154
2J82
ARCLINK H
153
1J82
ARCLINK L
741
2J81
ARCLINK H
743
1J81
ARCLINK L
800
3J81
COMMON
3J50
IGBT DRIVE (+)
504
4J50
V/F (+)
505
5J50
V/F (-)
302
2J1AD
222A
7J1AD
225A
222
6J1AD
225
506
A
16J6
V/F (+)
405
8J6
V/F (-)
504
5J6
505
10J6
153
894
5J75
+24VDC
893
2J75
+24V GND
892
1J75
CAN_H
891
4J75
CAN_L
15
291
17
4J81
+40VDC
500
3J82
COMMON
540
4J82
+40VDC
2B
THERMAL LED
7J7
2W
YELLOW
THERMAL
LED
1J11
V/F (+)
STATUS LED (HI FOR RED)
2J11
1W
3J7
V/F (-)
RED/GREEN
STATUS
LED
ARC LINK H
4J7
1B
ARC LINK L
301
14J6
IGBT DRIVE (-)
302
6J6
IGBT DRIVE (+)
}
224
2J5
THERMOSTAT
220
3J5
THERMOSTAT
3W
16J7
FAN CONTROL (-)
3R
15J7
FAN CONTROL (+)
268
3J4
(NORMALLY CLOSED)
S
OUTPUT RECTIFIER
THERMOSTAT
511
14J85
VOLTAGE SENSE
SELECT (-)
512
13J85
VOLTAGE SENSE
SELECT (+)
DCBUS
THERMOSTAT
R5
10
D6
262
+5V SPI
268A
+40VDC
5J83
886
+40VDC
6J83
880
+
X3A
VOLT SENSE BD
3J1
3R
N.A.
ROBOTIC VOLTAGE SENSE
262
VOLTAGE SENSE SELECT (-)
4J1
511
VOLTAGE SENSE SELECT (+)
1J1
512
VOLTAGE SENSE OUTPUT
2J2
67
WIRE FEEDER VOLTAGE SENSE
1J2
67A
3W
POWER BOARD
12J43
3J43
+13V
238
9J6
604
12J6
231
1J6
SINGLE PHASE DETECT
(LOW=1 PHASE)
A
2J6
MAIN CONTACTOR CONTROL
67
4J9
PRECHARGE CONTROL
VOLTAGE SENSE
SPI COMMON
1J42
225
SPI +5V
CONTROL BOARD COMMON
5J42
222
+15V SPI
6J43
266
2J4
+15V
268A
TP4
444
AUXILIARY
TRANSFORMER T1
220A
292
840
8J7
224A
CHOKE
THERMOSTAT
+
C
SOLID STATE RELAY
225A
12J4
222A
10J4
+15V
CONTROL BOARD COMMON
+15V SPI
11J43
267
1J4
SPI COMMON
POWER DOWN INTERUPT
4J42
227
7J4
POWER DOWN INTERUPT
+5V
3J42
221
8J4
+5V
-15V
2J42
223
11J4
-15V
+5V ARCLINK +5V
SPI COMMON
FAN
DC BUS BD
N.A.
X3
0V
X3
H5
(440-460)
24V
X4
H4
500
2J47
115V
H3
POWER BD. RECT.
X5
X1
COMMON
274
4J11
1J41
ARCLINK +5V
+40V COMMON
5J43
475
4J47
COMMON
+40VDC POWER
5J47
540
ARCLINK COMMON
10J43
273
3J11
POS
1J46
+40VDC POWER
7J47
477
2J41
+40V
RS232 +5V
4J43
226
6J4
RS232 +5V
POS
2J46
COMMON
6J47
476
3J41
+40V COMMON
RS232 COMMON
9J43
228
5J4
RS232 COMMON
+40VDC POWER
8J47
478
4J41
+40V
NEG
3J46
NEG
4J46
03/01/200
7
1J47
+40VDC FEEDER
3J47
(380-415)
H2
10A FUSE
POS
65VDC
52V
612B
404
THERMAL LED
15
C7
2800uF
500V
67B
H6
(550-575)
CT CURRENT (+)
STATUS LED (HI FOR GREEN)
514 518
RED WHITE
IGBT DRIVE (-)
N.A.
H6A
2J10B
F
5J1AD
1J1AD
CT CURRENT (-)
518
154
16
POS
851
852
853
854
855
856
857
858
859
860
861
862
TRIGGER +15VDC 1
TRIGGER INPUT 2
DUAL PROC. INPUT 3
4 STEP INPUT 4
COLD INCH +15VDC 5
COLD IN. FORWARD 6
COLD IN. REVERSE 7
GAS PURGE INPUT 8
SHUTDOWN +15VDC 9
SHUTDOWN 1 INPUT 10
SHUTDOWN 2 INPUT 11
INPUT B 12
503
301
10J1AD
S7 I/O
RECEPTACLE
862
CT CURRENT (+)
1J10B
3
830
18
SHUTDOWN +15VDC
9J85
860
2J10A
514
21A
6J9
ARCLINK +
2J73
54
3J76
859
418
+15
16
POS
C
S6 ROBOTIC
INTERFACE
RECEPTACLE
Return to Master TOC
856
CT CURRENT (-)
ARCLINK -
1J73
53
1J76
+13V
AUX. RECONNECT
TACH +15VDC
TACH COMMON
TACH 1A DIFF SIGNAL
TACH 1B DIFF SIGNAL
TACH 2A DIFF SIGNAL
TACH 2B DIFF SIGNAL
SINGLE TACH INPUT
VOLTAGE SENSE
MOTOR "+"
MOTOR "-"
SOLENOID +40VDC
SOLENOID INPUT
Return to Section TOC
5J85
855
2J8
1J10A
4
14
4 STEP INPUT
WORK VOLTAGE SENSE
212
414
12
C
604
4J61
+
F
PRECHARGE RELAY
612B
216
212
C5
2800uF
500V
ON
2
L4
12
POS
SW1
POWER
213
L3A
211
+13V
L1A
H1
H1
X2
C3
24000uF/100V
NEG
ARCLINK COMMON
S1 WIRE FEEDER
RECEPTACLE
612
AUXILIARY
TRANSFORMER T2
H6A
5
52
L2
51
51
67A
230V
L5
2
352
115V
33A
4
C ELECTRODE SENSE
10A
S8 WATER COOLER
H6
(550-575)
H1B
E 0VDC
52
50
CB1
352A
D +40VDC
CB2
RECEPTACLE
53
A ARCLINK -
54
B ARCLINK +
10A
4
32
1
H1A
1
H1
33
33
350
1
3
CB2
3.5A
4
S5 DEVICENET
CONNECTOR
1
32
32
10A
894
2 +24VDC
893
3 +24V GND
892
4 CAN_H
891
5 CAN_L
34
S4
115V
RECEPTACLE
NOTES :
31
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
ELECTRICAL SYMBOLS PER E1537
(earlier version)
32A
32A
115V
RECEPTACLE
(Neutral Floating)
(Neutral Bonded)
AUX FAN
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
RAS
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
PW
DO NOT SCALE THIS DRAWING
APPROVED:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
-
REFERENCE:
G3611-1
SCALE:
NONE
POWERWAVE 655/R
MACHINE SCHEMATIC
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
03/01/2007
PROJECT
NUMBER:
CRM38677
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3611-2
DOCUMENT
REVISION:
A
SOLID EDGE
33
0V
CB3
EN-170
Return to Master TOC
Return to Section TOC
FAN
Return to Master TOC
SCHEMATIC - DEVICENET/GATEWAY PC BOARD (SHEET 1)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-8
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-8
Return to Master TOC
SCHEMATIC - DEVICENET/GATEWAY PC BOARD (SHEET 2)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-9
Return to Master TOC
SCHEMATIC - ETHERNET/GATEWAY PC BOARD (SHEET 1)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-10
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-10
Return to Master TOC
SCHEMATIC - ETHERENET/GATEWAY PC BOARD (SHEET 2)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-11
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-11
Return to Master TOC
SCHEMATIC ETHERNET/GATEWAY PC BOARD (SHEET 3)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-12
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-12
ENGINEERING CONTROLLED
MANUFACTURER: Yes
ELECTRICAL DIAGRAMS
G-13
CHANGE DETAIL: PAGE 3, R65, REVISED VALUE
23
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
G3789-1E2
SCALE:
SUBJECT:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
FEI
.
NONE
MATERIAL
DISPOSITION:
UF
INVERTER WELDER
SCHEMATIC DIGITAL CONTROL
APPROVAL
DATE:
10/26/2006
PROJECT
CRM22115-GA
NUMBER:
4
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3789-2FO
DOCUMENT
REVISION:
B
SOLID EDGE
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EN-170
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Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
SCHEMATIC - CONTROL PC BOARD (SHEET 1)
G3789-2FO
Return to Section TOC
G-13
Return to Master TOC
ENGINEERING CONTROLLED
MANUFACTURER: Yes
ELECTRICAL DIAGRAMS
G-14
CHANGE DETAIL: PAGE 3, R65, REVISED VALUE
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
G3789-1E2
SCALE:
SUBJECT:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
FEI
.
NONE
MATERIAL
DISPOSITION:
UF
INVERTER WELDER
SCHEMATIC DIGITAL CONTROL
APPROVAL
DATE:
10/26/2006
PROJECT
CRM22115-GA
NUMBER:
21 OF ___
4
PAGE ___
DOCUMENT
NUMBER:
G3789-2FO
DOCUMENT
REVISION:
B
SOLID EDGE
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EN-170
Return to Master TOC
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Return to Section TOC
Return to Section TOC
Return to Section TOC
SCHEMATIC - CONTROL PC BOARD (SHEET 2)
G3789-2FO
Return to Section TOC
G-14
ELECTRICAL DIAGRAMS
ENGINEERING CONTROLLED
MANUFACTURER: Yes
G-15
CHANGE DETAIL: PAGE 3, R65, REVISED VALUE
47.5K
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
G3789-1E2
SCALE:
SUBJECT:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
FEI
.
NONE
MATERIAL
DISPOSITION:
UF
INVERTER WELDER
SCHEMATIC DIGITAL CONTROL
APPROVAL
DATE:
10/26/2006
PROJECT
CRM22115-GA
NUMBER:
31 OF ___
4
PAGE ___
DOCUMENT
NUMBER:
G3789-2FO
DOCUMENT
REVISION:
B
SOLID EDGE
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EN-170
Return to Master TOC
Return to Master TOC
Return to Master TOC
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Return to Section TOC
Return to Section TOC
Return to Section TOC
SCHEMATIC - CONTROL PC BOARD (SHEET 3)
G3789-2FO
Return to Section TOC
G-15
Return to Master TOC
ENGINEERING CONTROLLED
MANUFACTURER: Yes
ELECTRICAL DIAGRAMS
G-16
CHANGE DETAIL: PAGE 3, R65, REVISED VALUE
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
G3789-1E2
SCALE:
SUBJECT:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
FEI
.
NONE
MATERIAL
DISPOSITION:
UF
INVERTER WELDER
SCHEMATIC DIGITAL CONTROL
APPROVAL
DATE:
10/26/2006
PROJECT
CRM22115-GA
NUMBER:
41 OF ___
4
PAGE ___
DOCUMENT
NUMBER:
G3789-2FO
DOCUMENT
REVISION:
B
SOLID EDGE
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EN-170
Return to Master TOC
Return to Master TOC
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Return to Section TOC
Return to Section TOC
Return to Section TOC
SCHEMATIC - CONTROL PC BOARD (SHEET 4)
G3789-2FO
Return to Section TOC
G-16
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL POWER SUPPLY PC BOARD
G-17
+5V
Machine Control Power Supply
R50
D18
6A
200V
10
R9
10.0K
D22
1.0A
30V
11
Vref 1
12
D3
1A
600V
2
OUT
6
8
VREF
VFB
2
4
RT/CT
COMP 1
5
GND
CS
J41
3
100K
100K
J42
X8
2
4
R8
OV1
C11
22
35V
T1
Vfb1
475
C14
0.1
50V
C47
1.0
35V
1.21K
.33W
R52
1.82K
221K
R14
D21
1.0A
30V
R3
6.19K
7
4
6
C45
150p
100V
R39
R12
56.2K
5.62K
3W
0.05
C32
10p
100V
J41
C42
R11
C7
0.1
50V
C6
4.7
35V
C8
820p
50V
Return to Master TOC
6
ADJ
T1
R13
2700p
50V
10.0K
3
1
J41
8
X1
TL431 REF
GND
1
5
C44
0.1
50V
8
DZ1
24V
3W
R36
30.1
30.1
R35
IN
1
D25
1
C31
.0015
2000V
D23
1.0A
30V
OCI2
D10
D
G
R34
221K
5
C26
1
200V
150p
100V
6
VREF
VFB
2
RT/CT
COMP 1
GND
Overvoltage
Shutdown
3
Vfb2
75K
C53
.1
R29
C4
820p
50V
R28
56.2K
5.62K
ADJ
3
C23
1.0
35V
C25
0.1
50V
C24
4.7
35V
T2
C28
10p
100V
249
3
+t
.13
60V
LED1
2
C34
0.1
50V
150
.33W
R64
C35
100
16V
13
R63
C36
100
16V
R62
+5Volts, 3 Amps
C37
100
16V
T2
D13
150
.33W
150
.33W
SPI
Vref 2
332
C33
4.7
35V
5
OUT
C5
0.1
50V
C30
1.0
35V
+5Volts, .100 Amp
R44
C1
4.7
35V
T2
5
1
GND
J43
R17
OCI3
CNY17-3
8
150
.33W
CAN
11
6
+t
D7
1A
600V
6
4
Vfb2
+20Volts
.200 Amps
Gate Drive
C17
4.7
35V
C18
4.7
35V
C21
0.1
50V
R19
10
9
2
.24
J43
T2
R42
X7
IN
1A
600V
44.2K
J43
D15
4
15
R18
Return to Master TOC
J43
R40
D16
16A
200V
D17
DZ4
3.3V
3W
15Volts, .250Amps
SPI
3W
0.05
OV1
D14
1.21K
.33W
12
> 55 VDC
OV2
OUT
D9
1A
600V
DZ7
18V
3W
C52
150p
R38
6
IN
100K
OV2
D20
1.0A
30V
J43
X3
S
R31
X4
C2
0.1
50V
C3
4.7
35V
CS
R32
15.0
R33
R45
gnd_mcps
R1
C27
DZ3
27V
.5W
4
OUT
VCC
15.0K
C49
.022
R56
DZ2
27V
.5W
8
R30
7
Vref 2
5.62K
Q2
21A
200V
2
43.2K
6
4
R43
4
6
gnd_mcps
CNY17-3
J42
J42
2
D8
1A
600V
R37
R26
5
Operation
30-55 VDC
D2
1A
600V
5
J42
J42
OUT
X9
14
T2
1.00K
6
1.21K
.33W
ADJ
+5V
Undervoltage
Detect
<30VDC
-15Volts, .100Amp
C40
1.0
35V
R48
C38
4.7
35V
T1
R41
DC Input (-)
10.0K
2.49K
.33W
475K
R21
C46
150p
100V
J43
D12
2
1.82K
J43
R24
C16
R20
Return to Section TOC
CNY17-3
OUT
9
R55
R22
X6
4
IN
T2
10
OUT
7
1A
600V
+t
D6
1A
600V
.24
GND
C10
4.7
35V
C9
0.1
50V
C29
1.0
35V
+5Volts, .100 Amp
150
.33W
T2
8
C20
4.7
35V
C19
4.7
35V
C22
0.1
50V
R23
5
2700p
50V
10.0K
7
J43
D1
R25
Return to Section TOC
OCI1
1
IN
3A
600V
X5
Machine Control
Shut Down
Capacitor
5
1
R5
D19
DZ8
18V
3W
Vfb1
R10
4
+t
.750 Amp
D24
S
10.0
R46
J41
DC Input (+)
VCC
R51
G
R61
7
44.2K
+15Volts
Q1
21A
200V
R49
R60
D
Vref 1
33.2
10.0
10.0
C13
1
200V
R16
33.2
332
43.2K
R27
R2
R4
10.0K
C39
0.1
50V
3
R15
+5Volts, .750 Amp
C41
100
16V
C43
100
16V
T1
R53
R6
T1
10.0K
+t
.13
60V
LED2
47.5
47.5
R57
R7
47.5
R58
2
C12
.0015
2000V
10-55 VDC
Operation
J42
3
1
D4
6A
200V
47.5
Return to Master TOC
Return to Section TOC
G-17
2.49K
.33W
1
+20Volts
.200 Amps
Gate Drive
8
X2
TL431 REF
6
RS232
J43
11
J43
J43
9
J43
1
12
FILENAME: G3631-2D2
LAST NO. USED
ELECTRICAL SYMBOLS PER E1537
MFD ( .022/50V
CAPACITORS =
UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms (
1/4W UNLESS OTHERWISE SPECIFIED)
DIODES =
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
NOTES :
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.
RC-
LABELS
D-
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
"X" INFO.
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Chg. Sheet No.
6-2-2000A
DESIGN INFORMATION
REFERENCE:
DRAWN BY: JP\TK
10-27-2000E
ENGINEER:
APPROVED:
SUPERSEDING:
EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE
Digital Systems
Schematic, Digital Power Supply
DATE: 11-30-98 DRAWING No.:
G 3631
SOLID EDGE
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
EN-170
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Return to Section TOC
GENERAL INFORMATION
Return to Master TOC
SCHEMATIC - FEED HEAD PC BOARD (SHEET 1)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
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Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-18
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-18
Return to Master TOC
SCHEMATIC - FEED HEAD PC BOARD (SHEET 2)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-19
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-19
Return to Master TOC
SCHEMATIC - FEED HEAD PC BOARD (SHEET 3)
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-20
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-20
Return to Section TOC
Return to Master TOC
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Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
G-21
SCHEMATIC - INPUT PC BOARD
ELECTRICAL DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-21
ELECTRICAL DIAGRAMS
Return to Master TOC
PC BOARD ASSEMBLY - INPUT PC BOARD
L11396-2
Return to Section TOC
G-22
G-22
CHANGE DETAIL: REVISED MAKE SPECIFICATION
ENGINEERING CONTROLLED
MANUFACTURER: No
REFERENCES
C1
CR1, CR2
D1, D3
D2
N.C. J60
N.C. J61
OCI1
R1, R2, R3, R6, R7, R8, R9, R10
R4
R5
R11,
R17,
R23,
TP1,
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS L11396-B
( 2 LAYER BOARD PER E3281)
Return to Master TOC
N.D.
4.50 ±.04
XXXXXXXX
J61
J60
TP2
Return to Master TOC
S19400-2673
S19400-4750
S19400-3011
267K 1/4W
475 1/4W
3.01K 1/4W
T13640-23
MOV,250J,660V
REQ'D
1
1.0 OZ.
2
PART NO.
IDENTIFICATION
SEE BLANK INFO. P.C. BD. BLANK
E2861
SEALANT
S14020-7
PLASTIC EXPANSION NUT
D2
TP3
TP1
XXX X
X
X
X
R9
X
X
X
X
XXX X
X
N.B.
4
DESCRIPTION
.022/50
DPST RELAY
1N4004
DIODE,1.0A,1500V
HEADER,VERTICAL
HEADER,VERTICAL
OPTO ISOLATOR
100/1OW
R5
C1
TP4
R4
R22
R13, R14, R15, R16,
R19, R20, R21, R22,
R25
TP3, TP4
ITEM
1
2
3
XXXXXXX
D1
1
Return to Section TOC
INPUT
1
1
15
PART NO.
S16668-5
S14293-18
T12199-1
T12705-58
S24020-8
S24020-10
S15000-22
S24376-3
3
N.D.
N.A.
D3
Return to Section TOC
(MAKES 8 BOARDS PER PANEL, SEE ELECTRONIC FILE
FOR ADDITIONAL INFORMATION)
R12,
R18,
R24,
TP2,
QTY
1
2
2
1
1
1
1
8
R24
R25
R23
R21
R20
R19
R18
R11
R12
R13
R14
R15
R16
R17
R7
R6
R8
R3
R10
OCI1
CAPACITORS = MFD / VOLTS
X
X
X
X
X
X
X
X
X
X
RESISTORS = OHMS/WATTS
CR1
CR2
X
X
X
X
R1
R2
X
X
X
X
N.A.
THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH ITEM 2 PRIOR TO
ENCAPSULATION. MATERIAL MUST BE APPLIED THRU SLOTS FROM BOTTOM
SIDE TO COMPLETELY FILL TO UNDERSIDE OF DEVICE ON COMPONENT SIDE.
N.B.
P.C. BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL.
N.C.
DO NOT COAT WITH ENCAPSULATION MATERIAL.
N.D.
APPLY ITEM 2 AS SHOWN, ALL EXPOSED LEADS MUST BE COVERED. MATERIAL
MUST BE APPLIED PRIOR TO ENCAPSULATION.
N.E.
APPLY ITEM 2 ON NON-COMPONENT SIDE OF BOARD PRIOR TO
ENCAPSULATION. ALL EXPOSED PINS MUST BE COVERED.
L11396-2
0
0
N.D.
N.D.
6.00 ±.04
MAKE PER E1911-ROHS
ENCAPSULATE WITH E1844
TEST PER E3647-I
SCHEMATIC REFERENCE: M19528-2B0
MAN U FACT U RED AS:
L11396-2B0
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
NOTE:
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
L11396-1
SCALE:
SUBJECT:
1:1
MATERIAL
DISPOSITION:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
FEI
-
UF
INVERTER WELDERS
INPUT P.C. BOARD ASSEMBLY
APPROVAL
DATE:
3/16/2007
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11396-2
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 provided 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
machine.
DOCUMENT
REVISION:
B
STRP
SOLID EDGE
Return to Master TOC
Return to Section TOC
I DEN T IFICA T I ON CODE
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
G-23
SCHEMATIC - SWITCH PC BOARD
ELECTRICAL DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-23
ELECTRICAL DIAGRAMS
Return to Master TOC
PC BOARD ASSEMBLY - SWITCH PC BOARD
G3501-1
Return to Section TOC
G-24
CHANGE DETAIL: REMOVED MFG OPERATION AND W/C TABLE
ENGINEERING CONTROLLED
MANUFACTURER: No
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. SEE E2454 BEFORE HANDLING.
N.B. PC BOARD AND MODULE MOUNTING HOLES TO BE FREE OF ENCAPSULANT MATERIAL
FOR A CENTERED 0.50” MIN. DIA. AND 0.55” MAX. DIA. (8 HOLES). MASK PER
APPROPRIATE MANUFACTURING WORK INSTRUCTIONS. TO BE CENTERED WITHIN 0.100”
(DO NOT GET ON MATING SURFACES).
N.D. FEMALE EYELET TO BE AGAINST THE OPPOSITE COMPONENT
SIDE AS SHOWN. EYELET MUST NOT SPIN AFTER CLINCHING.
VENDOR CODE
VCE (SAT)
VGE (TH)
N.M. DO NOT COAT WITH ENCAPSULATION MATERIAL. TOP AND BOTTOM, FOR 0.80” MIN. DIA. AND
0.85” MAX. DIA. MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
TO BE CENTERED WITHIN 0.100” (DO NOT GET ON THE MATING SURFACES).
N.F. BAR MUST BE FREE OF ENCAPSULATION MATERIAL ON BOTH
SURFACES AROUND MOUNTING HOLES AND ENTIRE LENGTH OF
MOUNTING SURFACES. ENCAPSULATION MATERIAL MUST NOT
EXTEND BEYOND THE MOUNTING SURFACE PLANE (4 PLACES).
OPPOSITE COMPONENT
SIDE ENCAPSULATION
N.N. ENCAPSULATE COMPONENT SIDE OF P.C. BOARD TO A THICKNESS OF .30 +.12/-.00 IN AREA SHOWN.
N.P. 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
(4 TERMINALS). MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
N.T.
8
N.J.
(4 PLACES)
2
N.F.
N.E., N.M.
(4 PLACES)
P.C. BOARD
B
2.50
1.32
N.C.
1.32
.116 MAX. CRIMP HEIGHT
+.12
-.00
10.75 ±.04
R79
C31
L11
C1
6
L13
C1
4
D2
1
D21
L15
C1
3
D1
2
D12
R36
R16
ZENER DIODE, 1W, 20V, 5% IN4747A
8
T12702-29
ZENER DIODE, 1W, 15V, 5% IN4744A
4
T12702-40
ZENER DIODE, 1W, 6.2V, 5% IN4735A
20 T12705-32
DIODE, T220, 15A, 600V, FR, MUR1560
4
DIODE, AXLDS, 1A, 1000V, FR, 818
T12705-44
10 T14648-9
RESISTOR, WW, 5W, 2.5K, 5% , SQ.
ITEM QTY PART NO.
1
1 SEE ABOVE
2
4 M16100-46
3
4 T9147-15
4
4 T9147-11
5
4 S23006
6 430g E2527
7
1 S24869-1
8
1 S24869-2
DESCRIPTION
P.C. BOARD BLANK
ELECTRONIC MODULE (A1,A2,A3,A4) (SS)
EYELETS (MALE) (B2,B3,B6,B7)
EYELETS (FEMALE)
POWER TERMINAL (B1,B4,B5,B8)
EPOXY ENCAPSULATING RESIN
PC BOARD SHIELD
PC BOARD SHIELD
G3501-1F0
N.N.,N.P.,N.R.
C2
5
D2 C2
2
4
D3
D4
R43
C24
R43
D2
D1
C1
2
D2
3
D22
C21
C2
1
C12
1
T12702-4
C25
L6
C9
R37
C2
0
C13
R10
D11
R30
R17
D1
1
L5
C
9
CHOKE, RF, FERRITE BEAD, 180 OHM
1
C26
D23
C20
L7
D1
3
20 T12218-15
L18
R38
D20
L14
D13
R29
D2
0
C14
R9
D10
C8
CAPACITOR, PPMF, .022, 100V, BOX, 5%
CONNECTOR, MOLEX, MINI,PCB, 6-PIN, TIN
S20500-14
S24020-6
IDENTIFICATION CODE
D2 C2
4
6
D24
R44
L8
R18
D1
0
C2
7
C27
C19
L4
C
8
L20
R40
D19
D1
4
D14
MANUFACTURED AS:
D2
5
L19
R39
C1 D1
9
9
MAKE PER E1911
POT PER E1911-E
TEST PER E3826-SW
C2
8
R27
L12
D25
R28
R44
C7
CAPACITOR, PPMF, 0.1, 1000V, 10% , BOX
1
1
R .045
N.S.
C28
D18
C18
C15
R8
D9
C1
5
L9
R19
D
9
20 S20500-1
EYELET DETAIL
DZ11
A4
D26
L3
C
7
RESISTOR, MF, 1/4W, 100, 1%
RESISTOR, MF, 1/4W, 1.00K, 1%
RESISTOR, MF, 1/4W, 10.0K, 1%
RESISTOR, MF, 1/4W, 100K, 1%
RESISTOR, MF, 1/4W, 2.00K, 1%
RESISTOR, MF, 1/4W, 221K, 1%
RESISTOR, MF, 1/4W, 6.19K, 1%
RESISTOR, MF, 1/4W, 6.81K, 1%
S19400-1000
S19400-1001
S19400-1002
S19400-1003
S19400-2001
S19400-2213
S19400-6191
S19400-6811
L17
D15
C6
RESISTOR, MF, 1/4W, 10.0, 1%
1
4
2
3
2
1
1
1
L16
R7
D1
8
C1
8
C16
D1
5
DZ12
D2
6
C17
L10
R20
R21
DZ7
D17
R26
R45
R11
DZ6
DZ5
DZ4
R12
C2
L1
A2
D16
D8
D1
A3 7
C1
7
D1
6
L2
Return to Master TOC
Return to Section TOC
D
8
+.12
-.00
C4
R32
R45
B
C5
C
6
C
C3
R22
T1
1.36
N.A., N.H., N.L.
R6
D7
25 S19400-10R0
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
DZ8
A
D
7
A1
DESCRIPTION
IC, CONVERTER, V/F, 654
TRANSFORMER, PCB;
CAPACITOR, TAEL, 27, 35V, 10%
OPTOCOUPLER, PHOTO-Q, 70V, CNY17-3/VDE
VOLTAGE REF, ADJ, PERCISION, 431I
TRIMMER, MT, 1/2W, 10K, 10% , LINEAR
CAPACITOR, CEMO, .022, 50V, 20%
CAPACITOR, CEMO, 4700p, 50V, 10%
CAPACITOR, CEMO, 0.1, 50V, 10%
DZ9
C2
9
DZ2
C
5
DZ13
R77
C29
DZ3
C1
R2
R75
R76
R69
J40/J5
0
R78
R77
C32
R46
D
DZ10
J40
R31
C3
3
R47
R1
DZ1
OCI1
R74
X1
C30
R70
R73
SH1
C33
N.B.
3
T1
SH1
R72
FR
X2
R71
.285
.275
PART NO.
M13552-3
S13000-46
S13490-93
S15000-22
S15128-10
S16296-5
S16668-5
S16668-6
S16668-11
N.T.
7
+.12
-.00
COMPONENT SIDE
ENCAPSULATION
QTY
1
1
1
1
1
1
1
5
1
OPPOSITE
COMPONENT
SIDE
5.90
N.S.
N.S.
N.D.
4
PW-655
SWITCH
G35011
BUY BLANK COMPLETE AS G3501-F
(4 LAYER BOARD PER E3281)
(MAKES 2 BOARDS PER PANEL, SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
PANEL SIZE PER E1911
N.L. ELECTRONIC MODULES ON A COMMON P.C. BOARD ASSEMBLY TO
HAVE VGE (TH) AND VCE (SAT) IN SAME SORT CODE (0.1 VSPAN) AND THE SAME
VENDOR CODE.
e.g. M16100-46 X XX XXX……
N.C. MOLEX CAVITIES AND AREA AROUND LOCKING TAB TO BE FREE OF ENCAPSULANT
MATERIAL. MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS.
Return to Master TOC
N.T. ITEM 8 MOUNTS AND SOLDERS TO SAME HOLES AS ITEM 7. ITEM 8 IS MOUNTED ON
NON-COMPONENT SIDE OF P.C. BOARD.
N.K. INSPECT POWER TERMINAL PER E1880.
N.E. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND
ALL AROUND EYELET ON OPPOSITE COMPONENT SIDE ONLY. NO
ICICLES OR SOLDER BLOBS PERMITTED.
Return to Section TOC
N.S. ENCAPSULATE OPPOSITE COMPONENT SIDE OF P.C. BOARD IN AREAS SHOWN TO A MAXIMUM
THICKNESS OF .20.
N.J. THESE SURFACES MUST BE MAINTAINED CO-PLANAR WITHIN .010”
THROUGH ENTIRE SOLDERING AND SEALING PROCESS (4 PLACES).
ITEM
X1
T1
C29
OC11
X2
R77
C30
C1,C2,C3,C4,C31
C32
R1,R6,R7,R8,R9,R10,R11,R16,
R17,R18,R19,R20,R21,R26,
R27,R28,R29,R30,R31,R36,
R37,R38,R39,R40,R69
R78
R2,R12,R22,R32
R46,R74
R70,R71,R72
R47,R75
R79
R73
R76
C5,C6,C7,C8,C9,C12,C13,C14,
C15,C16,C17,C18,C19,C20,
C21,C24,C25,C26,C27,C28
C33
J40
L1,L2,L3,L4,L5,L6,L7,L8,L9,
L10,L11,L12,L13,L14,L15,L16,
L17,L18,L19,L20
DZ13
DZ2,DZ3,DZ5,DZ6,DZ8,DZ9,
DZ11,DZ12
DZ1,DZ4,DZ7,DZ10
D7,D8,D9,D10,D11,D12,D13,
D14,D15,D16,D17,D18,D19,
D20,D21,D22,D23,D24,D25,D26
D1,D2,D3,D4
R41,R42,R43,R44,R45,R63,
R64,R65,R66,67
P.C. BOARD BLANK REFERENCE INFORMATION
N.R. ENCAPSULATION MATERIAL MUST EXTEND BEYOND EDGES OF P.C. BOARD .12 +.12/-.00.
N.H. ELECTRONIC MODULES TO BE ASSEMBLED, SOLDERED, AND SEALED TO
PC BOARD PER E3875.
G-24
SCHEMATIC REFERENCE: L11016-1F0
R63
R67
1.15
2.25
R42
R41
R63
2.25
R67
2.25
R65
R64
R41
R42
R64
DO NOTOPERATE WITH PANELSREM OVED.
N.K.
N.G.
DANGER
R66
R66
DISCONNECTINPUTPOWER AND DISCHARGE
1
INPUT CAPACITORSBEFORE
2
OR
1
SERVICING. DO NOTTOUCH
5
ELECTRICALLY LIVE PARTS.
1
3
OR
1
8
B5
HIGH VOLTAGE CAN KILL
2.70 ±.12
B1
B8
B2
B3
B6
FOR PARTS ORDERS OR SUBSIDIARY ORDERS:
INCLUDE (1) S25254PRINT, (1) S25191-1PRINT,
(1) T12837-1 AND (4) S25347-2.
B7
11 OR 16
14 OR 17
2
0
1
9
2
2
2
1
0
NOTE:
9.00 ±.04
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
REFERENCE:
-
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
lwimbley
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
TK
SCALE:
DO NOT SCALE THIS DRAWING
APPROVED:
-
1:1
INVERTER WELDERS
SWITCH P.C. BD. AS'BLY
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
3/10/2005
PROJECT
NUMBER:
CRM35906
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3501-1
DOCUMENT
REVISION:
B
STRP
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 provided 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
machine.
SOLID EDGE
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
0
EN-170
Return to Master TOC
Return to Section TOC
5
B4
R65
Return to Master TOC
SCHEMATIC - VOLTAGE SENSE PC BOARD
ELECTRICAL DIAGRAMS
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-25
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-25
ELECTRICAL DIAGRAMS
Return to Master TOC
PC BOARD ASSEMBLY - VOLTAGE SENSE PC BOARD
M19540-3
Return to Section TOC
G-26
G-26
CHANGE DETAIL: REVISED MAKE SPECIFICATION
ENGINEERING CONTROLLED
MANUFACTURER: No
N.A.
N.A.
REQD
C1
D1
1
1
S20500-4
T12199-1
.0047 1000V
1N4004
J1
J2
L1
1
1
1
S24020-6
S24020-2G
T12218-7
HEADER
HEADER
330uH
OCI1,OCI2
R1,R2
R3
TP1,TP2
2
2
1
2
S15000-20
S19400-4750
S18380-1
T13640-18
PHOTO FET
475 1/4W
THERMISTOR,PTC
160J
PART NO.
IDENTIFICATION
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
INDUCTANCE = HENRYS
(MAKES 54 BOARDS PER PANEL, SEE ELECTRONIC FILE
FOR ADDITIONAL INFORMATION)
Return to Master TOC
Return to Section TOC
P.C. BOARD BLANK INFORMATION
BUY COMPLETE AS M19540-C
( 2 LAYER BOARD PER E3281)
ITEM
ITEM
1
REQD
1
PART NO.
SEE BLANK INFO
DESCRIPTION
P.C. BOARD BLANK
SCHEMATIC REFERENCE: S24779-3CO
N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL.
1.80
N.A.
±.04
1.75
1.55
M 19540-3
0
J2
TP1
MAKE PER E1911-ROHS
ENCAPSULATE WITH E1844 (2 DIPS)
TEST PER E3689-VS
R2
TP2
C1
D1
L1
MANUFACTURED AS
R3
OCI1
.20
0
VOLTAGE SENSE SELECT
J1
OCI2
Return to Master TOC
R1
1.00
N.B.
±.04
2.00
M19540-3CO
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
Return to Master TOC
Return to Section TOC
IDENTIFICATION CODE
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
NOTE:
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
ON 2 PLACE DECIMALS IS ± .02
FEI
M19540-2
SCALE:
SUBJECT:
-
1:1
MATERIAL
DISPOSITION:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
EQUIPMENT TYPE:
UF
COMMON DIGITAL CONTROLS
VOLTAGE SENSE PC BRD AS'BLY
APPROVAL
DATE:
3/16/2007
PROJECT
NUMBER:
CRM34409
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
M19540-3
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 provided 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
machine.
DOCUMENT
REVISION:
C
STRP
SOLID EDGE
Return to Section TOC
.20
N.B. DO NOT COAT WITH ENCAPSULATION MATERIAL
.23 MIN. DIA. (3 PLACES) ON NON COMPONENT SIDE.
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
G-27
SCHEMATIC - 40VDC BUS PC BOARD
ELECTRICAL DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-27
ELECTRICAL DIAGRAMS
Return to Master TOC
PC BOARD ASSEMBLY - 40VDC BUS PC BOARD
L11745-1
Return to Section TOC
G-28
ENGINEERING CONTROLLED
MANUFACTURER: No
G-28
ITEM PART NO.
1 M19559
L11078-2
S25930-1
2 S9262-23
CF000017
E2529
* 3 E1777-2
T13359-12
4 S8025-80
E2529
CHANGE DETAIL: NEW
NOTES:
DESCRIPTION
HEAT SINK
40V DC BUS P.C. BD. ASSEMBLY
TORZ BUTTON HEAD SCREW
PLAIN WASHER
1/4-20HN
JOINT COMPOUND
RETAINING COMPOUND (LOCTITE 242)
THERMOSTAT
SELF TAPPING SCREW
ELECTRICAL JOINT COMPOUND
QTY
1
1
2
2
2
.004 OZ.
2 cc
1
2
.001 .OZ
* THESE ITEMS NOT SHOWN
N.A. ASSEMBLE ITEM 2 WITH HEADERS LOCATED AS SHOWN.
N.B. MOUNT THE DC BUS & 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.
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N.E. APPLY FILM OF COMPOUND TO MOUNTING SURFACE OF ITEM 4 THERMOSTAT.
MOUNT WITH TERMINALS POSITIONED AS SHOWN.
N.E.
1
4
N.A., N.B., N.C.
PLAIN WASHER
2
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FOR PARTS ORDERS ONLY
CAUTION:THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454 BEFORE HANDLING.
INCLUDE S25251 INSULATION
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
NOTE:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
FEI
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED:
SCALE:
1:1
IF PRINTED
@ A2 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
INVERTER WELDERS
EXCITER BOARD MODULE ASSEMBLY
NA
APPROVAL
DATE:
8/9/2006
PROJECT
NUMBER:
CRM38081
REFERENCE:
L11745
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11745-1
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 provided 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
machine.
DOCUMENT
REVISION:
A
STRB
SOLID EDGE
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1/4-20HN
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SCHEMATIC - AUXILIARY DRIVER PC BOARD
ELECTRICAL DIAGRAMS
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G-29
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-29
ELECTRICAL DIAGRAMS
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PC BOARD ASSEMBLY - AUXILIARY DRIVER PC BOARD
L11067-1
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G-30
ENGINEERING CONTROLLED
MANUFACTURER: No
G-30
CHANGE DETAIL: RELEASED FROM X A.03
ITEM
1
2
3
P.C. BOARD BLANK REFERENCE INFORMATION
MAKE FROM S19399
(MAKES 14 BOARDS PER PANEL. SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
REQ'D
1
1
1 OZ.
PART No.
SEE BLANK
S24016-10
E2861
DESCRIPTION
P. C. BOARD BLANK
HEADER (J1)
SEALANT
FOR ITEMS BELOW, REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS
BLANK PART NUMBER: L11067-C
C1
1
S13490-71
CAPACITOR,ALEL,100,50V,+75/-10%
C2
1
S13490-66
CAPACITOR,TAEL,47,35V 10%
C3,C4
2
S13490-25
CAPACITOR,TAEL,4.7,35V 10%
C5,C6,C7,C8
4
S16668-11
CAPACITOR,CEMO,0.1, 50V,10%
8
T12705-37
DIODE,AXLDS,3A,40V,SCHOTTKY
D1,D2,D3,D4,D5,
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D6,D7,D8
L1,L2
2
T12218-15
CHOKE,RF,FERRITE BEAD,180 OHM
Q1,Q3,Q5,Q7
4
T12704-41
TRANSISTOR,N,T220,8A,150V,MJE15030
Q2,Q4,Q6,Q8
4
T12704-49
TRANSISTOR,P,T220,8A,150V,MJE15031
N.A.
2
1
N.B.
(4 PLACES)
5.50 ±.04
5.30
UNLESS OTHERWISE SPECIFIED:
CAPACITANCE = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
J1
CR
3
XXXXXXX
XXXXXXX
L11067-1
AUX DRIVER
C2
C1
C3
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C6
Q3
D1
D3
Q2
Q4
D2
D4
L2
MANUFACTURED AS:
L1
C4
Q5
D7
Q8
C7
Q7
C8
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C5
Q1
L 1 1 0 6 7 - 1 C 0
PART NUMBER
D5
D8
D6
.20
MAKE PER E1911
ENCAPSULATE WITH E1844,3 TIMES
TEST PER E3826-AD
0
.20
0
IDENTIFICATION CODE
Q6
2.30
2.50 ±.04
NOTES:
NOTE:
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
Reference
SCALE:
SUBJECT:
1:1
MATERIAL
DISPOSITION:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
TJP
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
TK
DO NOT SCALE THIS DRAWING
APPROVED:
-
NA
INVERTER WELDERS
AUXILIARY DRIVER P.C.BD. ASSEMBLY
APPROVAL
DATE:
12/3/02
PROJECT
NUMBER:
CRM34209
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
L11067-1
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 provided 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
machine.
DOCUMENT
REVISION:
A
STRP
SOLID EDGE
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
EN-168
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N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL.
N.B. AFTER ENCAPSULATION, DRILL HOLES (BOTH SIDES).