Lincoln Electric POWER WAVE IM713-B manual

P o w er W a ve 655/R ® OPERA TOR’S MANUAL IM713-B December, 2009 Safety Depends on You L i n c o l n a r c w e l d i n g a nd c u t t i n g 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, OPER- ATE OR REPAIR THIS [...]

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. ________________________________________________[...]

ii SAFETY ii ARC R A Y S can bur n. 4.a. 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[...]

iii SAFETY iii FOR ELECTRIC ALL Y pow er ed 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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. [...]

iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

V V T T h h a a n n k k Y Y o o u u For selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company prod- uct ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy [...]

Vi Vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave® 655/r ....................................................A-1 Safety Precautions..........................................................................[...]

A-1 INST ALLA TION POWER WAVE® 655/R A-1 TECHNICAL SPECIFICA TIONS - Power W ave® 655/r (K1519-1, K1519-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 460/575V - 60HZ. 400V - 50HZ. 460/575V - 60HZ. CODE NUMBERS 10630 10863 11410 OPEN CIRCUIT VOLTAGE 7[...]

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. ST ACKING Power Wave® machines can be stacked to a maxi- mum of 3 high. The bottom machine must always be placed on a firm, secure, level surface. There is a danger of mac[...]

A-3 INST ALLA TION POWER WAVE® 655/R A-3 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 electrica l codes and the connection dia- gram located on the inside of the reconnect/input access door of the machine. Failure to do so may [...]

A-4 INST ALLA TION POWER WAVE® 655/R A-4 WELDING WITH MUL TIPLE Power W aves® Special care must be taken when more than one Power Wave® is welding simultaneously on a sin- gle 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 [...]

A-5 INST ALLA TION POWER WAVE® 655/R A-5 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 [...]

VOL T AGE SENSING T he b e st a r c p e r f o rm a n c e oc c u r s wh e n th e Po w e r Wave® s has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the contact tip. Voltage sense leads improve the accuracy of the arc conditions and can[...]

POWER W A VE® / 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 conve nienc[...]

HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (high torque) gear is installed on the feeder. To change Gear ratio see Power Feed 10/R Instruction Manual. ELECTRIC SHOCK can kill[...]

A-9 INST ALLA TION POWER WAVE® 655/R A-9 DIP Switch Settings and L ocations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave®. To access the DIP switches: • Turn off power at the disconnect switch. ------------------------------------------------------------- • Remove the top four screws securing the front acce[...]

A-10 INST ALLA TION POWER WAVE® 655/R A-10 Bank (S2) : Switch Description 1 Devicenet Baud Rate 2( see table 4 ) T ABLE 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 S24958-6 and later software Switch 1 switch 2 Baud rate Off off 125K Off on 250K On off 500K On on Programmabl[...]

B-1 OPERA TION B-1 POWER WAVE® 655/R SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always elec- trically energized and could remain energized several seconds after t[...]

B-2 OPERA TION B-2 POWER WAVE® 655/R INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT VOL T AGE INPUT VOL T AGE OUTPUT VOL T AGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND W ARNING GRAPHIC SY[...]

RECOMMENDED EQUIPMENT • Automatic Operation All welding programs and procedures are set through software for the robotic Power Wave® s. FAUN robots equipped with RJ-3 controllers may communi- cate directly to the Power Wave®. Other pieces of equipment such as ply or computers can communi- cate to the Power Wave® using DeviceNET. All wire weldi[...]

B-4 OPERA TION POWER WAVE® 655/R B-4 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave®. (See Figure B.1) 1 . POWER SWITCH: Controls input power to the Power Wave®. 2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green light. Error conditions ar[...]

B-5 OPERA TION B-5 CONST ANT VOL T AGE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware 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 [...]

B-6 OPERA TION B-6 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed [...]

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED There are no factory installed options available for the Power Wave®. FIELD INST ALLED Gas Guard Regulator (K659-1) The Gas Guard regulator is availabl e as an optional accessory for Power Feed™ Robotic wire drive unit. Install the 5/8-18 male outlet on the regulator to the proper 5/8-1[...]

D-1 MAINTENANCE D-1 POWER WAVE® 655/R SAFETY PRECAUTIONS 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. • Do not touch electrically hot parts. ROUTINE MAINTENANCE Routine maintenance consists of periodically[...]

E-1 TROUBLESHOOTING E-1 POWER WAVE® 655/R If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repa[...]

E-2 TROUBLESHOOTING E-2 POWER WAVE® 655/R USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Status LED on the power source case front can help diagnose problems down to the system c o m p o n e n t ( p o w e r s o u r c e , w i r e f e e d e r, w i r e drive, etc.) level. If, for any reason, the system does not appear to be working proper[...]

E-3 TROUBLESHOOTING E-3 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. PROBLEMS (SYMPTOMS) POSSIBLE[...]

E-4 TROUBLESHOOTING E-4 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. PROBLEMS (SYMPTOMS) POSSIBLE[...]

E-5 TROUBLESHOOTING E-5 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. PROBLEMS (SYMPTOMS) POSSIBLE[...]

E-6 TROUBLESHOOTING E-6 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROB[...]

E-7 TROUBLESHOOTING E-7 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ERRO[...]

E-8 TROUBLESHOOTING E-8 POWER WAVE® 655/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION Erro[...]

F-1 DIAGRAMS F-1 POWER WAVE® 655/R[...]

F-2 DIAGRAMS F-2 POWER WAVE® 655/R NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code [...]

F-3 DIAGRAMS F-3 POWER WAVE® 655/R NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code [...]

T ABLE 5 DEVICENET CONNECTOR S5 Pin Lead # Function 2 894 +24vdc Devicenet 3 893 Common Devicenet+ 4 892 Devicenet H 5 891 Devicenet L F-4 PIN, LEAD CONNECT OR DIAGRAMS F-4 POWER WAVE® 655/R T ABLE 1 INTERF ACE CONNECTOR S6 Pin Lead # Function A 841 +15vdc T ach voltage B 844 T ach common C 842 T ach 1A differential signal D 843 T ach 1B different[...]

F-5 CONNECTION DIAGRAM F-5 POWER WAVE® 655/R Hard Automation and Electrode Positive Configuration - + WO R K SE NSE LEA D K940 W AT ERC O O LE D TO RCH E L E CTRO DE LE A D CO N NE C TI ON DI AG RA M , HA R D AU T O M AT I O N CO NTRO L CA B LE K 179 5 WAT E R COO LER PO WER CO NNE CT ION S HIE L DIN G G A S TO S HIE LDIN G G A S DE V ICE NE T CA [...]

F-6 CONNECTION DIAGRAM F-6 POWER WAVE® 655/R K1796 COAXIAL WELD CABLE User supplied work lead U ser supplied electrode lead - + PO WER W A VE CONTROL CABLE K1805-1 WORK SENSE LEAD K940 DEVICENET CABLE K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE CONTROL CABLE K1805-1 User supplied electrode lead User supplied work lead Robotic Set [...]

F-7 DIAGRAMS F-7 POWER WAVE® 655/R M 182 41 A .01 32. 88 14. 62 19. 16 19. 90 9.4 8 12. 35 19. 00 22. 63 26 .10 23. 12 23 .51 4.2 1 12. 90 6.7 5 3.4 7 10°[...]

NOTES POWER WAVE® 655/R[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head ou t of f umes. ● Use ventil ation o r exha ust to remo ve fum[...]

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