Download Lincoln Electric 655/R Welder User Manual
Transcript
SVM180-A View Safety Info Return to Master TOC RETURN TO MAIN MENU POWERWAVE TM 655/R January, 2008 For use with machines having Code Numbers: 10630, 10863, 11410 Return to Master TOC View Safety Info Return to Master TOC View Safety Info 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. View Safety Info Return to Master TOC 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 Return to Master TOC i 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. Return to Master TOC Return to Master TOC Return to Master TOC 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 Return to Master TOC Return to Master TOC 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. Return to Master TOC 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. ii 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. Return to Master TOC 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 Return to Master TOC 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. Return to Master TOC 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. Return to Master TOC 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. Return to Master TOC 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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. iv 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 RETURN TO 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC Return to Section TOC A-2 TECHNICAL SPECIFICATIONS - POWER WAVE 655/R (K1519-1, K1519-2) Return to Master TOC 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 Return to Section TOC 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) Return to Master TOC Return to Section TOC 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 Return to Master TOC 40 VDC AT 10 AMPS 110 VAC AT 10 AMPS CURRENT MIG/MAG FCAW SMAW Pulse Return to Section TOC 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 Return to Master TOC 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 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 Return to Master TOC Return to Section TOC A-4 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM . Disconnect input power before . . . W / L3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC V / L2 Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC - + Electrode Lead - Travel Direction + Electrode Lead Connect All Work Sense Leads at the End of the Joint Return to Master TOC Connect All Welding Work Leads at the Beginning of the Joint Return to Section TOC A-5 POWER WAVE 655/R INSTALLATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 2. Remove the front cover from the power source. VOLTAGE SENSING Return to Master TOC 5. Replace the cover and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately. Return to Section TOC A-7 POWER WAVE 655/R INSTALLATION Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC • 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 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC 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 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 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC 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 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 ** 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 A-12 NOTES POWER WAVE 655/R A-12 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC Return to Master TOC Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7 POWER WAVE 655/R Return to Master TOC Return to Section TOC B-2 OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC • 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. Return to Master TOC Return to Section TOC • Wear eye, ear, and body protection. Observe additional guidelines detailed in the beginning of this manual. POWER WAVE 655/R B-2 OPERATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC U1 U2 WIRE FEEDER Return to Section TOC 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 Return to Master TOC Return to Section TOC THREE PHASE DIRECT CURRENT POWER WAVE 655/R Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC The Power Wave 655/R can be configured for either robotic or semi-automatic use. B-4 POWER WAVE 655/R Return to Master TOC 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. Return to Master TOC 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 Return to Master TOC 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 Return to Section TOC OPERATION All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) CASE FRONT CONTROLS SENSE Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Time Return to Section TOC B-6 POWER WAVE 655/R Return to Master TOC Return to Section TOC 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". Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Return to Master TOC Time Return to Section TOC B-7 POWER WAVE 655/R 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 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-1 POWER WAVE 655/R Return to Master TOC 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 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-1 POWER WAVE 655/R Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC • 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. Return to Master TOC Return to Section TOC 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. Return to Master TOC NOTE: The fan motor has sealed bearings which require no maintenance. Return to Section TOC D-2 POWER WAVE 655/R MAINTENANCE D-3 FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW) Return to Master TOC Return to Section TOC D-3 7 7 1 7 Return to Master TOC Return to Section TOC 3 Return to Master TOC Return to Section TOC 4 2 2 6 5 1. CASE FRONT ASSEMBLY 2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBLY Return to Master TOC Return to Section TOC 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 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 D-4 NOTES POWER WAVE 655/R D-4 TABLE OF CONTENTS - THEORY OF OPERATION Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master 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 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC VOLT SENSE BOARD ARC LINK 2 4 V A C 230 VAC Return to Master TOC 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 Return to Section TOC E-2 FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE Return to Master TOC Return to Section TOC 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 Return to Master TOC 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 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC S6 ARC LINK 2 4 V A C 230 VAC Return to Master TOC 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 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 Return to Section TOC E-4 FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC S6 ARC LINK 2 4 V A C 230 VAC Return to Master TOC 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 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 Return to Section TOC E-5 FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD, GATEWAY BOARD AND VOLTAGE SENSE BOARD Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC Weld Controller / Sequencer Ether net/ Gate way Board Translator Feed H ead Board PW-655R D e v ic e N et Device Net Return to Section TOC Return to Master TOC Return to Master TOC Robot Controller Return to Section TOC E-6 FIGURE E.5 – POWER WAVE 655/R COMMUNICATIONS Return to Master TOC Return to Section TOC E-6 POWER WAVE 655/R PF-10R THEORY OF OPERATION INPUT RECTIFIER HARMONIC FILTER SW1 Return to Master TOC Return to Section TOC 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 Return to Master TOC VOLT SENSE BOARD ARC LINK 2 4 V A C 230 VAC Return to Master TOC 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 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 Return to Section TOC E-7 FIGURE E.6 – CONTROL BOARD Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC S6 ARC LINK 2 4 V A C 230 VAC Return to Master TOC 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 C A CURRENT TRANSDUCER OUTPUT DIODES D1 -D4 CAP. V/F FEEDBACK CR1 MAIN TRANSFORMER IGBT DRIVE FROM CONTROL BOARD POS Return to Section TOC E-8 FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Return to Master TOC Return to Section TOC E-10 FIGURE E.9 – IGBT OPERATION POSITIVE VOLTAGE APPLIED SOURCE n+ GATE SOURCE n+ n+ Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Section TOC 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 Return to Master TOC Return to Section TOC E-11 25 sec sec sec 50 sec sec Return to Master TOC Return to Section TOC MINIMUM OUTPUT 24 sec 24 sec 1 sec 1 sec 50 sec MAXIMUM OUTPUT Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 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 E-12 NOTES POWER WAVE 655/R E-12 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC Return to Section TOC 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. --------------------------------------------------------------------------------------------------------------------------- Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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. ----------------------------------------------------------------------------------------------------------------------------------- POWER WAVE 655/R F-2 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC CAUTION Return to Section TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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. Return to Master TOC 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. Return to Master TOC Return to Section TOC Return to Section TOC Status LED is blinking red and green. F-4 POWER WAVE 655/R TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 22 31 32 33 34 Return to Master TOC 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 Return to Master TOC Return to Section TOC 35 Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC The input fuses repeatedly fail or the input circuit breakers keep tripping. Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC 2. Check the main input fuses (or breakers). If open, replace or reset. Return to Section TOC 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. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Return to Master TOC 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 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 Return to Master TOC 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 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC 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 Return to Section TOC Return to Master TOC Return to Master TOC Misc. hand tools Volt-ohmmeter 25-1000 ohms @ 25 watts (minimum) resistor Electrically insulated gloves and pliers 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. POWER WAVE 655/R F-11 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-12 TROUBLESHOOTING & REPAIR F-12 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE SWITCH BOARD Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 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. 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Misc. Hand Tools Torque Wrench Volt-ohmmeter Wiring Diagram POWER WAVE 655/R F-13 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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. Return to Master TOC 2. Remove the case sides. Return to Section TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-15 SWITCH BOARD TEST PROCEDURE (CONTINUED) FIGURE F.3 – RIGHT SIDE AND TEST POINTS Return to Master TOC Return to Section TOC (LEFT) 11 (RIGHT) 16 Return to Master TOC 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) Return to Section TOC 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 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 F-16 NOTES POWER WAVE 655/R F-16 Return to Master TOC Return to Section TOC 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 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. 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 Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR F-18 INPUT RECTIFIER TEST PROCEDURE (CONTINUED) FIGURE F.4 – INPUT RECTIFIER TEST INPUT RECTIFIER NEG (-) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC 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 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 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 F-20 NOTES POWER WAVE 655/R F-20 Return to Master TOC Return to Section TOC 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 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. 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 Return to Master TOC Return to Section TOC F-22 F-22 INPUT CONTACTOR TEST PROCEDURE (CONTINUED) FIGURE F.5 – INPUT CONTACTOR COIL INPUT CONTACTOR 601 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 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. 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 Return to Master TOC 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 Return to Section TOC 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 Return to Master TOC Return to Section TOC R10 Power Bd. Rectifier C3 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 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. 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) Return to Master TOC Return to Section TOC F-26 F-26 FIGURE F.7 – POWER BOARD TEST Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC 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 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 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 F-28 NOTES POWER WAVE 655/R F-28 Return to Master TOC Return to Section TOC 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 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. 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC INPUT CONTACTOR 1. Disconnect the input power to the POWER WAVE 655/R. Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC #232 Return to Section TOC F-31 POWER WAVE 655/R 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 F-32 NOTES POWER WAVE 655/R F-32 Return to Master TOC Return to Section TOC 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 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. 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 Return to Master TOC TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) F-34 FIGURE F.9 – CURRENT TRANSDUCER TEST CONTROL BOARD J8 J9 J8 211 212 213 Return to Master TOC Return to Section TOC Return to Section TOC F-34 1 2 3 4 5 6 7 8 216 1234 P91 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR F-35 CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) FIGURE F.10 – RS 232 port Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 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 F-36 NOTES POWER WAVE 655/R F-36 Return to Master TOC Return to Section TOC 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 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. 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-38 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER TEST PROCEDURE (CONTINUED) FIGURE F.11 – OUTPUT RECTIFIER TEST Return to Master TOC Return to Section TOC 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. Return to Master TOC 4. Disconnect one end of lead 206A that connects R1 to the Positive Output Terminal. Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 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. 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC X4 WHITE X3 RED X5 444 X3A FAN MOTOR WINDING Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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. Return to Section TOC Return to Master TOC Return to Master TOC TABLE F.7 – SECONDARY VOLTAGES Return to Section TOC 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 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 F-42 NOTES POWER WAVE 655/R F-42 Return to Master TOC Return to Section TOC 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 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. 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 Return to Master TOC Return to Section TOC 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) Return to Master TOC Return to Section TOC H1 Return to Master TOC Return to Section TOC 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. Return to Master TOC 4 32 (WHITE) 33 (RED) PROCEDURE Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 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 rectifier module. MATERIALS NEEDED Misc. Hand Tools Torque Wrench POWER WAVE 655/R F-45 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-46 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.14 – INPUT RECTIFIER REMOVAL AND REPLACEMENT Return to Master TOC 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. Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC F-48 TROUBLESHOOTING & REPAIR F-48 INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.15 – INPUT CONTACTOR REMOVAL AND REPLACEMENT INPUT CONTACTOR 601 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC 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. Return to Master TOC REPLACEMENT PROCEDURE 1. Remove input power to the POWER WAVE 655/R. 4. Remove the case back. Return to Section TOC X3A FAN MOTOR WINDING 2. Remove the case top, sides and input access panel. Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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) Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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. Return to Master TOC Return to Section TOC 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. Return to Master TOC 8. Tilt back the rear of the control box to access the PC board mountings. Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Section TOC Return to Master TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC 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 + Return to Section TOC Return to Section TOC F-58 Return to Master TOC Return to Section TOC 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. Return to Master TOC 6. Using a phillips head screw driver, remove the screws and lock washers that hold the transducer to the machine base. Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC Power Switch J40/50 Output Choke Connection Front Panel Screws Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Return to Master TOC Return to Master TOC Return to Section TOC 1. Remove the leads and copper plate from one of the Diode Module pairs. (See Figure F.22). Return to Section TOC 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 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 F-62 NOTES POWER WAVE 655/R F-62 Return to Master TOC Return to Section TOC 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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. Return to Section TOC Return to Master TOC Return to Master TOC Tighten all from 40 to 48 in-lbs. Return to Section TOC 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 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 F-66 NOTES POWER WAVE 655/R F-66 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC • 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 ▲ Return to Master TOC Turn Output ON Return to Section TOC F-68 POWER WAVE 655/R Return to Master TOC Return to Section TOC 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. Return to Master TOC 2. Set the load bank for 300 amps. Return to Section TOC 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. Return to Master TOC FLASHES RED when output is ON. Return to Master TOC Return to Section TOC Return to Section TOC FIGURE F.25 - CALIBRATION SCREEN POWER WAVE 655/R 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 F-70 NOTES POWER WAVE 655/R F-70 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TEST PROCEDURE Return to Section TOC 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 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 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 Return to Master TOC 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 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 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC 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 Return to Master TOC 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 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-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. Return to Master TOC Return to Section TOC 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 Return to Master TOC Return to Master TOC 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 Return to Section TOC Return to Section TOC 1/4-20HN Return to Master TOC SCHEMATIC - AUXILIARY DRIVER 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-29 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. G-29 ELECTRICAL DIAGRAMS Return to Master TOC PC BOARD ASSEMBLY - AUXILIARY DRIVER PC BOARD L11067-1 Return to Section TOC 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, Return to Master TOC Return to Section TOC 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 Return to Master TOC C6 Q3 D1 D3 Q2 Q4 D2 D4 L2 MANUFACTURED AS: L1 C4 Q5 D7 Q8 C7 Q7 C8 Return to Section TOC 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 Return to Master TOC Return to Section TOC N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL. N.B. AFTER ENCAPSULATION, DRILL HOLES (BOTH SIDES).