Lincoln Electric Welding System IM713 B User Manual
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IM713-B  
December, 2009  
®
Power Wave 655/R  
For use with machines having Code Numbers:  
10630; 10863; 11410  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation ...  
and thoughtful operation on your  
part. DO NOT INSTALL, OPER-  
ATE OR REPAIR THIS EQUIP-  
MENT WITHOUT READING  
THIS MANUAL AND THE SAFE-  
TY PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
EN 60974-1  
OPERATOR’S 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  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
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.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
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 within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
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.  
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 spe-  
cific 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.  
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.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
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.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.e. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
Jan ‘09  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
process used and properly operating  
regulators designed for the gas and  
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.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
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.  
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.  
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.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
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.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.  
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.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
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 cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
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. National  
Electrical Code and the manufacturer’s recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
Jan ‘09  
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SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
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:  
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 d’incendie.  
Sûreté Pour Soudage A L’Arc  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode 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 s’isoler 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.  
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  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau 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.  
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.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent 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 n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar. ‘93  
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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!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www. lincolnelectric.  
com for any updated information.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For fazing: Complete the form on the back of the warranty statement included in the literature packet  
Accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www. lincolnelectric.Com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
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TABLE OF CONTENTS  
Page  
Installation .......................................................................................................Section A  
Technical Specifications - Power Wave® 655/r ....................................................A-1  
Safety Precautions.................................................................................................A-2  
Select Suitable Location ........................................................................................A-2  
Lifting...............................................................................................................A-2  
Stacking ..........................................................................................................A-2  
Machine Grounding ...............................................................................................A-2  
High Frequency Protection ....................................................................................A-2  
Input Connection....................................................................................................A-3  
Input Fuse and Supply Wire Considerations .........................................................A-3  
Input Voltage Changeover Procedure ...................................................................A-3  
Welding with Multiple Power Wave® s..................................................................A-4  
Electrode and Work Cable Connections................................................................A-5  
Cable Inductance and its Effects on Pulse Welding........................................A-5  
Negative Electrode Polarity ..................................................................................A-6  
Voltage Sensing ....................................................................................................A-6  
Power Wave® / Power Feed Wire Feeder Interconnections.................................A-7  
Control Cable Specifications...........................................................................A-7  
External I/O Connector....................................................................................A-8  
High Speed Gear Box .....................................................................................A-8  
Dip Switch Settings and Locations.................................................................A-9  
Control Board Dip Switch................................................................................A-9  
Feed Head Board Dip Switch..........................................................................A-9  
DeviceNET/Gateway Board Dip Switch, Bank (S1) ........................................A-9  
Bank (S2) ......................................................................................................A-10  
________________________________________________________________________  
Operation .........................................................................................................Section B  
Safety Precautions.................................................................................................B-1  
Graphic Symbols that appear on this machine or in this manual...........................B-2  
General Description...............................................................................................B-3  
Recommended Processes and Equipment ...........................................................B-3  
Required Equipment..............................................................................................B-3  
Limitations..............................................................................................................B-3  
Duty Cycle and Time Period ...........................................................................B-3  
Case Front Controls........................................................................................B-4  
Constant Voltage Welding...............................................................................B-5  
Pulse Welding .................................................................................................B-6  
________________________________________________________________________  
Accessories.....................................................................................................Section C  
Optional Equipment...............................................................................................C-1  
Factory Installed..............................................................................................C-1  
Field Installed..................................................................................................C-1  
________________________________________________________________________  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Routine, Periodic, Calibration Specification...........................................................D-1  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
How to use Troubleshooting Guide .......................................................................E-1  
Troubleshooting the Power Wave® / Power Feed System using the Status LED.E-2  
Troubleshooting Guide.............................................................................E-3 thru E-6  
Error Codes for the Power Wave® ................................................................E-7, E-8  
________________________________________________________________________  
Diagrams ..........................................................................................................Section F  
Wiring Diagram’s.....................................................................................F-1, F-2, F-3  
Pin, Lead Connector, Connection Diagrams, and Dimension Print..........F-4 thru F-7  
________________________________________________________________________  
Parts Lists...................................................................................................P-392 Series  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - Power Wave® 655/r (K1519-1, K1519-2)  
INPUT AT RATED OUTPUT - THREE PHASE ONLY  
INPUT  
CURRENT  
AMPS  
CODE NUMBERS  
INPUT VOLTS  
OUTPUT  
IDLE  
POWER FACTOR  
EFFICIENCY  
@ RATED  
OUTPUT  
CONDITIONS  
POWER @ RATED OUT-  
PUT  
10630  
10863  
43/34  
53/42  
[email protected]%  
815A@44V. 60%  
460/575V - 60HZ.  
400V - 50HZ.  
40  
51  
400 Watts  
[email protected]%  
675A@44V. 60%  
Max.  
84%  
.95 MIN.  
11410  
41/33  
53/42  
460/575V - 60HZ. [email protected]%  
815A@44V. 60%  
OUTPUT  
OPEN  
CIRCUIT  
VOLTAGE  
CURRENT  
RANGE FREQUENCY VOLTAGE BACKGROUND  
RANGE TIME RANGE  
PULSE  
PULSE  
PULSE AND  
AUXILIARY POWER  
(CIRCUIT BREAKER  
PROTECTED)  
75 VDC  
20-815  
0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. -  
3.3 SEC.  
40 VDC AT  
10 AMPS  
110 VAC AT  
10 AMPS  
PROCESS CURRENT RANGES (DC)  
CURRENT  
50-815 Average Amps  
40-815 Average Amps  
30-600 Average Amps  
15-880 Peak Amps  
MIG/MAG  
FCAW  
SMAW  
Pulse  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
TYPE 75°C  
COPPER WIRE IN  
CONDUIT AWG[MM ]  
SIZES  
TYPE 75°C  
(SUPER LAG)  
OR BREAKER  
SIZE (AMPS)  
TYPE 75°C  
GROUND WIRE IN  
CONDUIT AWG[MM ]  
SIZES  
INPUT  
VOLTAGE /  
FREQUENCY  
2
2
460V - 60HZ.  
575V - 60HZ.  
70  
60  
6 (16)  
6(16)  
8 (10)  
10 (6)  
PHYSICAL DIMENSIONS  
HEIGHT  
26.10 in  
663 mm  
WIDTH  
19.86 in  
505 mm  
DEPTH  
32.88 in  
835 mm  
WEIGHT  
306 lbs.  
139 kg.  
TEMPERATURE RANGES  
OPERATING TEMPERATURE RANGE  
STORAGE TEMPERATURE RANGE  
-20°C to +40°C  
-40°C to +40°C  
POWER WAVE® 655/R  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
LIFTING  
Read this entire installation section before you  
start installation.  
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.  
WARNING  
ELECTRIC SHOCK can kill.  
STACKING  
• Only qualified personnel  
should perform this installa-  
tion.  
Power Wave® machines can be stacked to a maxi-  
mum of 3 high.  
• 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 sys-  
tem at the disconnect switch  
or fuse box before working on  
the equipment.  
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.  
• 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.  
MACHINE GROUNDING  
-------------------------------------------------------------  
The frame of the welder must be grounded. A ground  
terminal marked with the symbol  
is located inside  
SELECT SUITABLE LOCATION  
the reconnect/input access door for this purpose. See  
your local and national electrical codes for proper  
grounding methods.  
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.  
HIGH FREQUENCY PROTECTION  
Do not mount the Power Wave® over combustible  
surfaces. Where there is a combustible surface direct-  
ly 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.  
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.  
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 cir-  
cuit conditions. The fan also runs for a period of time  
(approximately 5 minutes) after the output is disabled,  
to ensure all components are properly cooled.  
If desired, the F.A.N. feature can be disabled (causing the  
fan to run whenever the power source is on). To disable  
F.A.N., connect leads 444 and X3A together at the output of  
the solid state fan control relay, located on the back of the  
Control PC board enclosure.  
POWER WAVE® 655/R  
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A-3  
A-3  
INSTALLATION  
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR  
INPUT SUPPLY CONNECTION DIAGRAM  
.
Disconnect input power before  
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.  
W / L3  
V / L2  
U / L1  
CR1  
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.  
XA  
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.  
INPUT CONNECTION  
INPUT VOLTAGE CHANGE OVER  
(FOR MULTIPLE INPUT VOLTAGE  
MACHINES ONLY)  
Welders are shipped connected for the highest input  
voltage listed on the rating plate. To move this con-  
nection to a different input voltage, see the diagram  
located on the inside of the input access door. If the  
main reconnect switch or link position is placed in the  
wrong position, the welder will not produce output  
power.  
WARNING  
Only a qualified electrician should connect the  
input leads to the Power Wave®. Connections  
should be made in accordance with all local and  
national electrical codes and the connection dia-  
gram located on the inside of the reconnect/input  
access door of the machine. Failure to do so may  
result in bodily injury or death.  
-------------------------------------------------------------  
If the Auxiliary (A) lead is placed in the wrong position,  
there are two possible results. If the lead is placed in a  
position higher than the applied line voltage, the  
welder may not come on at all. If the Auxiliary (A) lead  
is placed in a position lower than the applied line volt-  
age, the welder will not come on, and the two circuit  
breakers in the reconnect area will open. If this  
occurs, turn off the input voltage, properly connect the  
(A) lead, reset the breakers, and try again.  
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  
Refer to the Technical Specifications at the beginning  
of this Installation section for recommended fuse and  
wire sizes. Fuse the input circuit with the recommend-  
ed super lag fuse or delay type breakers (also called  
“inverse time” or “thermal/magnetic” circuit breakers).  
Choose an input and grounding wire size according to  
local or national electrical codes. Using fuses or circuit  
breakers smaller than recommended may result in  
“nuisance” shut-offs from welder inrush currents, even  
if the machine is not being used at high currents.  
POWER WAVE® 655/R  
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A-4  
A-4  
INSTALLATION  
For the best results when pulse welding, set the wire  
size and wire feed speed the same for all the Power  
Wave® s.  
WELDING WITH MULTIPLE Power  
Waves®  
When these parameters are identical, the pulsing fre-  
quency will be the same, helping to stabilize the arcs.  
CAUTION  
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.  
Every welding gun requires a separate shielding gas  
regulator for proper flow rate and shielding gas cover-  
age.  
Do not attempt to supply shielding gas for two or more  
guns from only one regulator.  
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. Performing 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.  
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 Wave® S  
POWERWAVE  
POWERWAVE  
-
+
-
+
Travel  
Direction  
Electrode Lead  
Electrode Lead  
Connect All Work  
Sense Leads at the End  
the Joint  
of  
Connect All Welding  
Work Leads at the  
Beginning of the Joint  
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A-5  
A-5  
INSTALLATION  
be considered to keep the total welding loop length  
less than ft.(m). (See Figure A.4.)  
FOR A DETAILED CONNECTION DIAGRAM USING  
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.  
FIGURE A.4  
POWER  
WAVE  
A
A
C
WORK  
C
B
B
SLIDING GROUND  
K1796 COAXIAL CABLE  
MEASURE FROM END  
OF OUTER JACKET OF  
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)  
400 Amps  
MINIMUM COPPER  
2/0 (67mm2)  
K1796 COAXIAL CABLE, SEE PAGE F-4.  
500 Amps  
3/0 (85mm2)  
600 Amps  
3/0 (85mm2)  
CAUTION  
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 cop-  
per 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.  
When pulsing, the pulse current can reach very  
high levels. Voltage drops can become excessive,  
leading to poor welding characteristics, if under-  
sized welding cables are used.  
------------------------------------------------------------------------  
Most welding applications run with the electrode being posi-  
tive (+). For those applications, connect one end of the elec-  
trode cable to the positive (+) output stud on the power  
source (located beneath the spring loaded output cover near  
the bottom of the case front). Connect the other end of the  
electrode cable to the wire drive feed plate using the stud,  
lockwasher, and nut provided on the wire drive feed plate.  
The electrode cable lug must be against the feed plate. Be  
sure the connection to the feed plate makes tight metal-to-  
metal electrical contact. The electrode cable should be sized  
according to the specifications given in the work cable con-  
nections section. Connect a work lead from the negative (-)  
power source output stud to the work piece. The work piece  
connection must be firm and secure, especially if pulse weld-  
ing is planned. Excessive voltage drops caused by poor work  
piece connections often result in unsatisfactory welding per-  
formance.  
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 ft.(m), traditional  
welding cables may be used without any effects on  
welding performance. For the total welding loop length  
greater than ft.(m), the K1796 Coaxial Welding Cables  
are recommended. The welding loop length is defined  
as the total of electrode cable length (A) + work cable  
length (B) + work length (C) (See Figure A.3).  
FIGURE A.3  
POWER  
WAVE  
A
C
WORK  
B
NEGATIVE ELECTRODE POLARITY  
For long work piece lengths, a sliding ground should  
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A-6  
A-6  
INSTALLATION  
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).  
VOLTAGE SENSING  
The best arc performance occurs when the Power  
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  
have a dramatic effect on performance.  
When operating with electrode polarity negative the  
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.  
CAUTION  
Set the Negative Polarity switch on Wire Feed Head  
PC board as follows:  
If the voltage sensing is enabled but the sense  
leads are missing or improperly connected,  
extremely high welding outputs may occur.  
Do not tightly bundle the work sense lead to the work  
lead.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
or electrodes with your skin or wet  
clothing.  
The ELECTRODE sense lead (67) is built into the  
K1795 control cable. The WORK sense lead (21) con-  
nects to the Power Wave® at the four-pin connector  
located underneath the output stud cover.  
Enable the voltage sense leads as follows:  
TABLE 2  
• Insulate yourself from the work and  
ground.  
Process Electrode Voltage  
Sensing 67 lead *  
GMAW 67 lead required  
GMAW-P 67 lead required  
FCAW 67 lead required  
Work Voltage  
• Always wear dry insulating gloves.  
Sensing 21 lead  
21 lead optional**  
21 lead optional**  
21 lead optional**  
------------------------------------------------------------------------  
1. Turn off power to the power source at the discon-  
nect switch.  
GTAW Voltage sense at studs Voltage sense at studs  
SAW 67 lead required 21 lead optional**  
2. Remove the front cover from the power source.  
3. The wire feed head board is on the right side of the  
power source. Locate the 8-position DIP switch and  
look for switch 7 of the DIP switch.  
* 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.  
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.  
5. Replace the cover and screws. The PC  
board will “read” the switch at power up,  
and configure the work voltage sense lead appro-  
priately.  
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A-7  
A-7  
INSTALLATION  
POWER WAVE® / POWER FEED  
WIRE FEEDER  
INTERCONNECTIONS  
Work Voltage Sensing  
The Power Wave® s are shipped from the factory with  
the work sense lead enabled.  
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 processes requiring work voltage sensing, con-  
nect 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:  
For convenience sake, 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.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
or electrodes with your skin or wet  
clothing.  
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.  
• Insulate yourself from the work and ground.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
1. Turn off power to the power source at the discon-  
nect switch.  
2. Remove the front cover from the power source.  
A work lead must be run from the negative (-) power  
source output connection to the work piece. The work  
piece connection must be firm and secure, especially  
if pulse welding is planned.  
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.  
CAUTION  
4. Using a pencil or other small object,  
slide the switch right to the OFF position  
if the work sense lead is NOT connect-  
ed. Conversely, slide the switch left to  
the ON position if the work sense lead is  
present.  
Excessive voltage drops at the work piece con-  
nection often result in unsatisfactory pulse weld-  
ing 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.  
5. Replace the cover and screws. The PC board will  
(read) the switch at power up, and configure the  
work voltage sense lead appropriately.  
CAUTION  
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.  
The use of non-standard cables, especially in  
lengths greater than 25 ft(.m), can lead to commu-  
nication 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  
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A-8  
A-8  
INSTALLATION  
HIGH SPEED GEAR BOX  
EXTERNAL I/O CONNECTOR  
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.  
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  
‘slave’ on the DeviceNet network, the Trigger and  
Cold Inch Groups are disabled when the DeviceNet /  
Gateway is active.  
WARNING  
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)  
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.  
FIGURE A.5  
• Always wear dry insulating gloves.  
-------------------------------------------------------------  
1. Set the High/Low switch code on Wire Drive PC  
board as follows:  
• Turn off power to the power source at the discon-  
nect switch.  
• Remove the front cover from the power source.  
• The wire feed head board is on the right  
side of the power source. Locate the 8-  
position DIP switch and look for position  
8 of the DIP switch.  
4
9
10  
11  
7
8
1
3
6
2
5
12  
• Using a pencil or other small object,  
slide the switch right to the OFF posi-  
tion, when the low speed gear is  
installed. Conversely, slide the switch  
left to the ON position when the high  
speed gear is installed.  
A
D
G
B
E
H
C
F
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  
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A-9  
A-9  
INSTALLATION  
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:  
Feed Head Board DIP Switch:  
Switch 1 = Object Instance LISE (see table 3)  
Switch 2 = Object Instance msp (see table 3)  
Switch 3 = Equipment Group 1 Select  
Switch 4 = Equipment Group 2 Select  
Switch 5 = Equipment Group 3 Select  
Switch 6 = Equipment Group 4 Select  
Switch 7 = negative polarity switch  
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.  
Switch 7  
Off  
On  
Electrode polarity  
Positive (default)  
negative  
• 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.  
Switch 8 = high speed gear  
Switch 8  
Off  
Wire drive gear  
Low speed gear (default)  
high speed gear  
On  
DeviceNET/Gateway Board DIP Switch:  
Bank (S1)  
:
Switch 1 = Object Instance LISE (see table3)  
Switch 2 = Object Instance msp (see table 3)  
Switch 3 = Equipment Group 1 Select  
Switch 4 = Equipment Group 2 Select  
Switch 5 = Equipment Group 3 Select  
Switch 6 = Equipment Group 4 Select  
Switch 7 = Reserved for future use  
Switch 8 = Reserved for future use  
TABLE 3  
Object Instance  
Switch 2 switch 1  
Instance  
Off  
Off  
On  
On  
Off  
On  
off  
on  
0 (default)  
1
2
3
Control Board DIP Switch:  
1
Switch 1 = Object Instance LSB (see table 3)  
2
Switch 2 = Object Instance MSB (see table 3)  
Switch 3 = Equipment Group 1 Select  
Switch 4 = Equipment Group 2 Select  
Switch 5 = Equipment Group 3 Select  
Switch 6 = Equipment Group 4 Select  
Switch 7 = reserved for future use  
Switch 8 = work sense lead  
1
LEASE SIGNIFICANT BIT  
2
MOST SIGNIFICANT BIT  
Switch 8 work sense lead  
Off  
On  
work sense lead not connected  
work sense lead connected  
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A-10  
A-10  
INSTALLATION  
SWITCH 4 SWITCH 3  
SWITCH 8 SWITCH 7 SWITCH 6 SWITCH 5  
Bank (S2)  
:
Switch  
Description  
Devicenet Baud Rate  
(see table 4)  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
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
1
2
TABLE 4  
Prior to S24958-6 software  
Switch 1 switch 2 Baud rate  
Off  
On  
Off  
On  
off  
off  
on  
on  
Programmable value  
125K  
250K  
500K  
S24958-6 and later software  
Switch 1 switch 2 Baud rate  
Off  
Off  
On  
On  
off  
on  
off  
on  
125K  
250K  
500K  
Programmable value  
Bank (S2)  
Switch  
3
Thru  
8
:
Description  
Devicenet Mac ID  
(see table 5)  
TABLE 5  
SWITCH 4  
SWITCH 3  
SWITCH 8 SWITCH 7 SWITCH 6 SWITCH 5  
0
1
2
3
4
5
6
7
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
*
8
9
10  
11  
12  
13  
14  
15  
16  
17  
**  
*Software Selectable (Line 0)  
**Default Setting (Line 62)  
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B-1  
B-1  
OPERATION  
SAFETY PRECAUTIONS  
Read this entire section of operating instructions  
before operating the machine.  
WARNING  
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 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 dan-  
gerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
WELDING SPARKS can cause fire  
or explosion.  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
Observe additional guidelines detailed in the begin-  
ning of this manual.  
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B-2  
B-2  
OPERATION  
GRAPHIC SYMBOLS THAT APPEAR ON  
THIS MACHINE OR IN THIS MANUAL  
SMAW  
INPUT POWER  
ON  
GMAW  
FCAW  
GTAW  
OFF  
HIGH TEMPERATURE  
MACHINE STATUS  
CIRCUIT BREAKER  
WIRE FEEDER  
POSITIVE OUTPUT  
NEGATIVE OUTPUT  
3 PHASE INVERTER  
INPUT POWER  
THREE PHASE  
DIRECT CURRENT  
OPEN CIRCUIT  
VOLTAGE  
U
U
U
I
0
1
2
INPUT VOLTAGE  
OUTPUT VOLTAGE  
INPUT CURRENT  
OUTPUT CURRENT  
1
I
2
PROTECTIVE  
GROUND  
WARNING  
POWER WAVE® 655/R  
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B-3  
B-3  
OPERATION  
GENERAL DESCRIPTION  
RECOMMENDED EQUIPMENT  
• Automatic 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.  
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.  
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.  
All wire welding processes require a robotic Power  
Feed™ wire feeder.  
• semiautomatic Operation  
Operating the Power Wave® 655/r in the semi-auto-  
matic mode requires an Arc-Link compatible wire  
feeder and user interface.  
Robotic systems can communicate with other industri-  
al machines via DeviceNET. The result is highly  
intrigued and flexible welding cell.  
REQUIRED EQUIPMENT  
• Control Cables (22 pin to 22 pin), K1795-10ft.,-25ft.,-50ft.,  
-100ft.  
• Control Cables for use on FAUN robot arm, 22 pin to 14  
pin, ft.(m), K1804-1  
• Control Cables for use on FAUN robot arm, 22 pin to 14  
pin, 18in.(457mm), K1805-1  
• Control Cables for use on FAUN robot arm, 22 pin to 14  
pin, 18in.(457mm), K1804-2  
The Power Wave® 655/r is a high performance, digi-  
tally 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 car-  
ries an output rating of either 650 amps, 44 volts (at  
100% duty cycle) and 800 amps, 44 volts (at 60%  
duty cycle).  
LIMITATIONS  
If the duty cycle is exceeded, a thermostat will shut off  
the output until the machine cools to a reasonable  
operating temperature.  
• Power Wave® s are not to be used in outdoor envi-  
ronments.  
• 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.  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
DUTY CYCLE AND TIME PERIOD  
The Power Feed™ wire feeders are capable of weld-  
ing 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.  
RECOMMENDED PROCESSES  
The Power Wave® 655/r can be set up in a number of  
configurations, some requiring optional equipment or  
welding programs. Each machine is factory prepro-  
grammed with multiple welding procedures, typically  
including GMAW, GMAW-P, FCAW, GTAW, CAC-A,  
and SMAW for a variety of materials, including mild  
steel, stainless steel, cored wires, and aluminum.  
The Power Wave® 655/r can be configured for either  
robotic or semi-automatic use.  
POWER WAVE® 655/R  
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B-4  
B-4  
OPERATION  
3. HIGH TEMPERATURE LIGHT (thermal overload):  
A yellow light that comes on when an over temper-  
ature situation occurs. Output is disabled until the  
machine cools down. When cool, the light goes out  
and output is enabled.  
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 are indicated per table 4.  
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.  
NOTE: The robotic Power Wave’s® status light will  
flash green, and sometimes red and green, for up to  
one minute when the machine is first turned on. This  
is a normal situation as the machine goes through a  
self test at power up.  
6. LEAD CONNECTOR S2 (SENSE LEAD)  
7. 5-PIN ARC LINK S1  
TABLE 6  
Light  
Condition  
Meaning  
8. 5-PIN DEVICENET CONNECTOR S5  
9. I / O CONNECTOR  
Steady Green System OK. Power source communicating normal-  
ly withwirefeederanditscomponents.  
10. NEGATIVE STUD  
Blinking  
Green  
Occurs during a reset, and indicates the PW-  
655/R is mapping (identifying) each component  
in the system. Normal for first 1-10 seconds  
after power is turned on, or if the system con-  
figuration is changed during operation.  
11. INTERFACE CONNECTOR S6  
12. POSITIVE STUD  
13. AUXILIARY OUTPUT  
Alternating Non-recoverable system fault. If the PS  
Green and Status light is flashing any combination of  
Red  
red and green, errors are present in the PW-  
655/R. Read the error code before the  
machine is turned off.  
FIGURE B.1  
3
2
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 sepa-  
rated by a green light.  
POWERWAVE  
1
6
7
To clear the error, turn power source off, and  
back on to reset. See Troubleshooting  
Section.  
8
9
11  
12  
Steady Red Not applicable.  
Blinking Red Not applicable.  
+
10  
-
13  
5
4
Case Front Layout  
Power Wave 655/R (Domestic/Canadian Version)  
POWER WAVE® 655/R  
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B-5  
B-5  
OPERATION  
CONSTANT VOLTAGE 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 adjust  
the voltage correspondingly.  
Wave control adjusts the inductance of the wave-  
shape. (This adjustment is often referred to as "pinch".  
Inductance is inversely proportional 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  
Current  
Time  
POWER WAVE® 655/R  
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B-6  
B-6  
OPERATION  
PULSE WELDING  
The Power Wave® utilizes "adaptive control" to com-  
pensate for changes in electrical stick-out while weld-  
ing. (Electrical stick-out is the distance from the con-  
tact tip to the work piece.) The Power Wave® wave-  
forms are optimized for a 0.75" (19mm) stick-out. The  
adaptive behavior supports a range of stinkpots 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.  
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 impracti-  
cal, and instead the arc length is set by adjusting  
"trim".  
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 con-  
trol 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)  
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 synetic. As the wire  
feed speed is adjusted, the Power Wave® will auto-  
matically recalculate the waveform parameters to  
maintain similar arc properties.  
FIGURE B.3  
Current  
Time  
POWER WAVE® 655/R  
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C-1  
C-1  
ACCESSORIES  
* Water Flow Sensor (K1536-1)  
OPTIONAL EQUIPMENT  
Water cooled guns can be damaged very quickly if  
they are used even momentarily without water flow-  
ing. Recommend practice is to install a water flow  
sensor such as on the water return line of the torch.  
When fully integrated into the welding system, the  
sensor will prevent welding if no water flow is pre-  
sent.  
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.  
• Dual Cylinder Undercarriage, K1570-1*  
*The Dual Cylinder Undercarriage, K1570-1 is not  
compatible in combination with the Power Wave®  
Water Cooler K1767-1.  
Voltage Sense Leads (K490-10, -25 or -50)  
The voltage sense leads connect at the front of the  
machine. (See Section A-6 for use and Section F-3  
Connection Diagram).  
• Coaxial welding Cable, K1796  
(See Section F-4 Connection Diagram)  
Cool Arc 40 (K1813-1)  
(See Section F-3 Connection Diagram)  
POWER WAVE® 655/R  
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D-1  
D-1  
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.  
•
Do not touch electrically hot parts.  
ROUTINE MAINTENANCE  
Routine maintenance consists of periodically  
blowing out the machine, using a low pressure  
airstream, to remove accumulated dust and dirt  
from the intake and outlet louvers, and the cool-  
ing channels in the machine.  
PERIODIC MAINTENANCE  
Calibration of the Power Wave® 655/R is critical  
to its operation. Generally speaking the calibra-  
tion 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.  
CALIBRATION SPECIFICATION  
Output Voltage and Current are calibrated at the  
factory. Generally speaking the machine calibration  
will not need adjustment. However, if the weld per-  
formance changes, or the yearly calibration check  
reveals a problem, contact the Lincoln Electric  
Company for the calibration software utility.  
The calibration procedure itself requires the use  
of a grid, and certified actual meters for voltage  
and current. The accuracy of the calibration will  
be directly affected by the accuracy of the mea-  
suring equipment you use. Detailed instructions  
are available with the utility.  
POWER WAVE® 655/R  
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E-1  
E-1  
TROUBLESHOOTING  
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.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that best  
describes the symptom that the machine is exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
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.  
POWER WAVE® 655/R  
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E-2  
E-2  
TROUBLESHOOTING  
USING THE STATUS LED TO  
If, for any reason, the system does not appear to  
be working properly, always check the color of  
the Status LED, and refer to the following chart to  
help you determine which system component  
(power source, wire feeder, wire drive, etc.) may  
be faulty. Replace the components identified as  
potentially faulty with known good components,  
and the system should operate normally.  
TROUBLESHOOT SYSTEM PROBLEMS  
The Status LED on the power source case front  
can help diagnose problems down to the system  
component (power source, wire feeder, wire  
drive, etc.) level.  
Steady Green  
Blinking Green  
System OK. Power source communicating normally  
with wire feeder and its components.  
Occurs during a reset, and indicates the Power Wave®  
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 opera-  
tion  
Alternating Green and Red  
Non-recoverable system fault. If the PS Status light is  
flashing any combination of red and green, errors are  
present in the Power Wave®. 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 sepa-  
rated by a green light.  
To clear the error, turn power source off, and back on  
to reset.  
Steady Red  
Not applicable.  
Not applicable.  
Blinking Red  
.
POWER WAVE® 655/R  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage 1. Contact your local authorized  
is evident when the sheet metal  
covers are removed.  
Lincoln Electric Field Service  
facility for technical assistance.  
Input fuses keep blowing, or input  
breaker keeps tripping.  
1. Make certain that fuses or  
breakers are properly sized.  
See Installation section of this  
manual for recommended  
fuse and breaker sizes.  
2. Welding procedure is drawing  
too much output current, or  
duty cycle is too high.  
Reduce output current, duty  
cycle, or both.  
3. There is internal damage to  
the power source. Contact an  
authorized Lincoln Electric  
Service facility.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
Machine will not power up (no  
lights, no fan, etc.)  
1. Make certain that the Power  
Switch (SW1) is in the “ON”  
position.  
Authorized Field Service Facility.  
2. Circuit breaker CB4(Codes  
10630, 10863) (in reconnect  
area) may have opened.  
Reset.  
10A Fuse(Code 11410) (in  
reconnect area) may have  
blown out. Replace.  
Also, check input voltage  
selection, below.  
3. Input voltage selection made  
improperly. Power down,  
check input voltage reconnect  
according to diagram on  
reconnect cover.  
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.  
POWER WAVE® 655/R  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Thermal LED is lit.  
1. Fan thermostat has opened.  
Check for proper fan operation.  
(Fan should run whenever main  
power is on.) Check for material  
blocking intake or exhaust lou-  
vers, or for excessive dirt clog-  
ging cooing channels in  
machine.  
2. Secondary rectifier thermostat  
has opened. After machine has  
cooled, reduce load, duty cycle,  
or both. Check for material  
blocking intake or exhaust lou-  
vers.  
Machine won’t weld, can’t get any  
output. (CR1 will not pull in.)  
1. Input voltage is too low or too  
high. Make certain that input  
voltage is proper, according to  
the Rating Plate located on the  
rear of the machine.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
2. If the Thermal LED is also lit,  
see “Yellow Thermal LED is Lit”  
section.  
Authorized Field Service Facility.  
Arc loss fault on robot  
Possibly caused by wire feeding  
problem.  
Possible  
caus-  
es/solutions are:  
1. Problem - Conduit leading to the  
wire feeder has bends or twists,  
which can reduce the wire feed  
speed.  
Solution - Remove bends and  
twists from conduit.  
2. Problem – Conduit leading up to  
the wire feeder from the wire reel  
is too long.  
Solution – Use a shorter length of  
conduit  
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.  
POWER WAVE® 655/R  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
1. Secondary current limit has  
been exceeded, and the  
machine has phased back to  
protect itself. Adjust procedure  
or reduce load to lower current  
draw from the machine.  
Machine often “noodle welds” (out-  
put is limited to approximately 100  
amps) when running a particular  
procedure  
1. Input voltage may be too low,  
limiting output capability of the  
power source. Make certain  
that the input voltage is proper,  
according to the Rating Plate  
located on the rear of the  
machine.  
Machine won’t produce full output.  
2. Input may be “single phased”.  
Make certain the input voltage  
is proper on all three input  
lines.  
1. Check for proper Wire Feed  
Speed setting. In CV MIG and  
FCAW modes, check for prop-  
er Voltage setting. In the  
MIG/MAG pulse modes, check  
the Trim setting. These con-  
trols are on the wire feeder.  
For no apparent reason, the weld-  
ing characteristics have changed.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
Authorized Field Service Facility.  
2. Check for proper shielding gas  
mix and flow.  
3. Check for loose or faulty weld  
cables and cable connections.  
1. Circuit breaker CB2 (on case  
front) may have opened.  
Reset.  
Auxiliary receptacle is “dead” — no  
auxiliary voltage .  
2. Circuit breaker CB4(Codes  
10630, 10863) (in reconnect  
area) may have opened.  
Reset.  
10A Fuse(Code 11410) (in  
reconnect area) may have  
blown out. Replace.  
1. Check for fault signals from the  
I/O connector. Possible faults  
are lack of water flow  
The PowerWave is triggered to  
weld, but there is no output.  
2. Circuit breaker CB4 (in recon-  
nect area) may have opened.  
Reset.  
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.  
POWER WAVE® 655/R  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
1. Check for fault signals from the  
I/O connector. Possible faults are  
lack of water flow/ water flow  
turned off.  
The PowerWave is triggered to weld,  
but there is no output.  
1. Check for fault signals from the  
I/O connector. Possible faults are  
lack of water flow/ water cooler  
turned off.  
The feeder will not cold inch wire  
Arc loss fault on robot  
1. Possibly caused by wire feeding  
problem.  
2 Problem - Conduit leading to the  
wire feeder has bends or twists,  
which can reduce the wire feed  
speed.  
Solution - Remove bends and  
twists from conduit.  
3. Problem – Conduit leading up to  
the wire feeder from the wire reel  
is too long.  
Solution – Use a shorter length of  
conduit.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
Authorized Field Service Facility.  
CAUTION  
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.  
POWER WAVE® 655/R  
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E-7  
E-7  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
ERROR CODES FOR THE POWERWAVE  
The following is a list of possible error codes that the PW-455 can output via the status light (see  
"Troubleshooting the PowerWave / Power Feed System Using the Status LED").  
Error Code #  
Indication  
11  
12  
CAN communication bus off.  
User Interface time out error.  
Probably due to excessive number of communication errors.  
User Interface is no longer responding to the Power Source. The most  
likely cause is a fault/bad connection in the communication leads or  
control cable.  
21 Un-programmed Weld Mode.  
22 Empty Weld Table.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
23 Weld Table checksum error.  
31 Primary overcurrent error.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
Excessive Primary current present. May be related to a switch board or  
output rectifier failure.  
32  
33  
34  
35  
Capacitor "A" under voltage  
(Left side facing machine)  
Low voltage on the main capacitors. May be caused by improper input  
configuration.  
When accompanied by an overvoltage error on the same side, it indi-  
cates no capacitor voltage present on that side, and is usually the result  
of an open or short in the primary side of the machine.  
Capacitor "B" under voltage  
(Right side facing machine)  
Capacitor "A" over voltage  
(Left side facing 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 indi-  
cates no capacitor voltage present on that side, and is usually the result  
of an open or short in the primary side of the machine.  
Capacitor "B" over voltage  
(Right side facing machine)  
36 Thermal error  
37 Soft start error  
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.  
CAUTION  
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.  
POWER WAVE® 655/R  
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E-8  
E-8  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
Error Code #  
Indication  
41 Secondary overcurrent error  
The secondary (weld) current limit has been exceeded. When this  
occurs the machine output will phase back to 100 amps, typically result-  
ing in a condition referred to as "noodle welding"  
NOTE: For The Power Wave® 655 the secondary limit is 880 Amps.  
43 Capacitor delta error  
49 Single phase error  
Other  
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 operating system. If this fails, replace the control board.  
CAUTION  
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.  
POWER WAVE® 655/R  
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F-1  
F-1  
DIAGRAMS  
POWER WAVE® 655/R  
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F-2  
F-2  
DIAGRAMS  
POWER WAVE® 655/R  
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F-3  
F-3  
DIAGRAMS  
POWER WAVE® 655/R  
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F-4  
TABLE 1 INTERFACE CONNECTOR S6  
F-4  
PIN, LEAD CONNECTOR DIAGRAMS  
TABLE 4 RS232 CONNECTOR S3  
Pin  
A
B
C
D
E
F
G
H
I
Lead #  
841  
844  
842  
843  
845  
846  
847  
Function  
+15vdc Tach voltage  
Tach common  
Pin  
2
3
4
5
6
20  
7
Lead #  
253  
254  
#
#
##  
Function  
RS232 Receive  
RS232 Transmit  
S3 Pin5  
Tach 1A differential signal  
Tach 1B differential signal  
Tach 2A differential signal  
Tach 2B differential signal  
Single Tach Input  
Reserved for future use  
Voltage sense lead  
Motor "+"  
S3 Pin4  
S3 Pin20  
S3 Pin6  
RS232 Common  
##  
251  
67B  
539  
541  
J
K
L
TABLE 5 DEVICENET CONNECTOR S5  
Motor "-"  
Reserved for future use  
Reserved for future use  
+40vdc for solenoid  
solenoid input  
Reserved for future use  
Reserved for future use  
Shield ground to case  
Reserved for future use  
Reserved for future use  
Reserved for future use  
Reserved for future use  
Pin  
2
3
4
5
Lead #  
894  
893  
892  
891  
Function  
+24vdc Devicenet  
Common Devicenet+  
Devicenet H  
M
N
P
R
S
T
U
V
W
X
521  
522  
Devicenet L  
855A  
TABLE 6 EXTERNAL I/O S7  
Pin  
1
2
3
4
5
6
7
8
Lead #  
Function  
+15vdc for Trigger group  
Trigger input  
Dual procedure input  
4 Step input  
+15vdc for cold inch group  
cold inch forward  
cold inch reverse  
gas purge input  
+15vdc for shutdown group  
shutdown1 input  
shutdown2 input  
input B  
851  
852  
853  
854  
855  
856  
857  
858  
859  
860  
861  
862  
TABLE 2 WIRE FEEDER RECEPTACLE S1  
Pin  
A
B
C
D
Lead #  
53  
54  
67A  
52  
51  
Function  
Arclink L  
Arclink H  
Electrode Voltage Sense  
Ground(0v)  
9
E
+40vdc  
10  
11  
12  
TABLE 3 VOLTAGE SENSE RECEPTACLE S2  
Pin  
3
Lead #  
21A  
Function  
Work Voltage Sense  
POWER WAVE® 655/R  
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F-5  
F-5  
CONNECTION DIAGRAM  
Hard Automation and Electrode Positive  
Configuration  
TO SHIELDING GAS  
DEVICENET CABLE  
TO PLC/CONTROLLER  
ELECTRODE LEAD  
CONTROL CABLE K1795  
SHIELDING GAS  
COOLARC40POWER CORD  
WATER  
CONNECTIONS  
WORK  
SENSE  
LEAD  
WATERCOOLED  
TORCH  
K940  
POWER WAVE® 655/R  
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F-6  
F-6  
CONNECTION DIAGRAM  
Robotic Set Up, Electrode Positive, CV/Pulse  
Configuration  
CONTROL CABLE K1805-1  
K1804-1 CONTROL CABLE OR  
K1804-2 AND ANY K1795 CONTROL CABLE  
User supplied  
electrode lead  
POWERWAVE  
DEVICENET CABLE  
+
-
User supplied  
work lead  
K1796 COAXIAL WELD CABLE  
WORK SENSE LEAD K940  
POWER WAVE® 655/R  
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F-7  
F-7  
DIAGRAMS  
POWER WAVE® 655/R  
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NOTES  
POWER WAVE® 655/R  
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G Do not touch electrically live parts or  
electrode with skin or wet clothing.  
G Insulate yourself from work and  
ground.  
G Keep flammable materials away.  
G Wear eye, ear and body protection.  
WARNING  
Spanish  
G No toque las partes o los electrodos G Mantenga el material combustible  
G Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
G Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
G Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
G Gardez à l’écart de tout matériel  
inflammable.  
G Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
G Isolez-vous du travail et de la terre.  
German  
G Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
G Isolieren Sie sich von den  
G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
G Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
G Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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G Keep your head out of fumes.  
G Use ventilation or exhaust to  
remove fumes from breathing zone.  
G Turn power off before servicing.  
G Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
G Los humos fuera de la zona de res-  
piración.  
G Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
G Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
G No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux  
tien.  
G Gardez la tête à l’écart des fumées.  
G Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
G Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
G Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
G Vermeiden Sie das Einatmen von  
Schweibrauch!  
G Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
G Não opere com as tampas removidas.  
G Desligue a corrente antes de fazer  
serviço.  
G Mantenha-se afastado das partes  
moventes.  
G Não opere com os paineis abertos  
ou guardas removidas.  
G Mantenha seu rosto da fumaça.  
G Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
G Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• 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  
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