Lincoln Electric 10630 Operator's Manual
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Lincoln Electric 10630 Operator's Manual

Lincoln Electric 10630 Operator's Manual

Power wave 655r
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Operator's Manual

POWER WAVE

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Date Purchased
Code:
(ex: 10859)
Serial:
(ex: U1060512345)
IM713-C
| Issue D ate 12-Jan
© Lincoln Global, Inc. All Rights Reserved.
655R
®
For use with machines having Code Numbers:
10630, 10863, 11410, 11880
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric 10630

  • Page 1: Power Wave

    Operator’s Manual POWER WAVE 655R ® For use with machines having Code Numbers: 10630, 10863, 11410, 11880 Register your machine: Need Help? Call 1.888.935.3877 www.lincolnelectric.com/register to talk to a Service Representative Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon.

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
  • Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 6 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.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Page Installation .......................Section A Technical Specifications ..................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 ®...

  • Page 8: Installation

    CODE NUMBERS INPUT VOLTS OUTPUT IDLE POWER FACTOR EFFICIENCY CONDITIONS CURRENT POWER @ RATED OUT- @ RATED AMPS OUTPUT 10630 43/34 600A@44V.100% 460/575V - 60HZ. 53/42 10863 815A@44V. 60% 400 Watts 550A@44V.100% 400V - 50HZ. 675A@44V. 60% Max. .95 MIN.

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS If desired, the F.A.N. feature can be disabled (causing the fan to run whenever the power source is on). To disable Read this entire installation section before you F.A.N., connect leads 444 and X3A together at the output of start installation.

  • Page 10: Input Connection

    W / L3 V / L2 U / L1 THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. S24190 NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do so will result in damage to the machine.

  • Page 11: Welding With Multiple Power Waves

    INSTALLATION WELDING WITH MULTIPLE Power For the best results when pulse welding, set the wire size and wire feed speed the same for all the Power Waves ® Wave ® CAUTION When these parameters are identical, the pulsing fre- quency will be the same, helping to stabilize the arcs. Special care must be taken when more than one Power Wave ®...

  • Page 12: Electrode And Work Cable Connections

    INSTALLATION For long work piece lengths, a sliding ground should ELECTRODE AND WORK CABLE be considered to keep the total welding loop length CONNECTIONS less than 50ft.(15m). (See Figure A.4.) Connect a work lead of sufficient size and length (Per Table 1) between the proper output terminal on the FOR A DETAILED CONNECTION DIAGRAM USING power source and the work.

  • Page 13: Negative Electrode Polarity

    INSTALLATION NEGATIVE ELECTRODE POLARITY VOLTAGE SENSING When negative electrode polarity is required, such as The best arc performance occurs when the Power in some Innershield applications, reverse the output Waves ® has accurate data about the arc conditions. connections at the power source (electrode cable to Depending upon the process, inductance within the the negative (-) stud, and work cable to the positive electrode and work lead cables can influence the volt-...

  • Page 14: Power Wave / Power Feed Wire Feeder Interconnections

    INSTALLATION Work Voltage Sensing ® POWER WAVE / POWER FEED The Power Waves ® are shipped from the factory with WIRE FEEDER the work sense lead enabled. INTERCONNECTIONS For processes requiring work voltage sensing, con- Connect the control cable between the power source nect the (21) work voltage sense lead from the Power and wire feeder.

  • Page 15: External I/O Connector

    INSTALLATION EXTERNAL I/O CONNECTOR HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PC The Power Wave is equipped with a port for making board switch change. The Power Feed Wire Feeders ® ® simple input signal connections. The port is divided are shipped with both high speed and a low speed into three groups: Trigger group, Cold Inch Group and gears.

  • Page 16: Dip Switch Settings And Locations

    INSTALLATION DIP Switch Settings and Locations Feed Head Board DIP Switch: DIP switches on the P.C. Boards allow for custom Switch 1 = Object Instance LISE (see table 3) configuration of the Power Wave ® . To access the DIP Switch 2 = Object Instance msp (see table 3) switches: Switch 3 = Equipment Group 1 Select...

  • Page 17: Bank (S2

    A-10 A-10 INSTALLATION Bank (S2): SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3 SWITCH 8 Switch Description Devicenet Baud Rate (see table 4) TABLE 4 Prior to S24958-6 software Switch 1 switch 2 Baud rate Programmable value 125K 250K 500K S24958-6 and later software...

  • Page 18: Operation

    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.

  • Page 19: Graphic Symbols That Appear On This Machine Or In This Manual

    OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SMAW INPUT POWER GMAW FCAW HIGH TEMPERATURE GTAW OPEN CIRCUIT MACHINE STATUS VOLTAGE CIRCUIT BREAKER INPUT VOLTAGE WIRE FEEDER OUTPUT VOLTAGE POSITIVE OUTPUT INPUT CURRENT NEGATIVE OUTPUT OUTPUT CURRENT PROTECTIVE 3 PHASE INVERTER GROUND...

  • Page 20: General Description

    OPERATION GENERAL DESCRIPTION RECOMMENDED EQUIPMENT • Automatic Operation The Power Wave ® power source is designed to be a All welding programs and procedures are set through part of a modular, multi-process welding system. software for the robotic Power Wave ®...

  • Page 21: Case Front Controls

    OPERATION CASE FRONT CONTROLS 3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temper- All operator controls and adjustments are located on ature situation occurs. Output is disabled until the the case front of the Power Wave ®...

  • Page 22: Constant Voltage Welding

    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 ®...

  • Page 23: Pulse Welding

    OPERATION PULSE WELDING The Power Wave ® utilizes "adaptive control" to com- pensate for changes in electrical stick-out while weld- Pulse welding procedures are set by controlling an ing. (Electrical stick-out is the distance from the con- overall "arc length" variable. When pulse welding, the tact tip to the work piece.) The Power Wave ®...

  • Page 24: Accessories

    ACCESSORIES OPTIONAL EQUIPMENT * Water Flow Sensor (K1536-1) Water cooled guns can be damaged very quickly if FACTORY INSTALLED they are used even momentarily without water flow- ing. Recommend practice is to install a water flow There are no factory installed options available for the sensor such as on the water return line of the torch.

  • Page 25: Maintenance

    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.

  • Page 26: 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.
  • Page 27 Blinking Red Not applicable. 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...
  • Page 28 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...
  • Page 29 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...
  • Page 30 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...
  • Page 31 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PROBLEMS 1. Check for fault signals from the The PowerWave is triggered to weld, but there is no output. I/O connector. Possible faults are lack of water flow/ water flow turned off.

  • Page 32: Troubleshooting The Power Wave / Power Feed System Using The Status Led

    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 Power Wave / Power Feed System Using the Status LED").
  • Page 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Error Code # Indication 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 ®...

  • Page 34: Diagrams

    DIAGRAMS Enhanced Diagram POWER WAVE ® 655/R...
  • Page 35 DIAGRAMS Enhanced Diagram POWER WAVE ® 655/R...
  • Page 36 DIAGRAMS Enhanced Diagram POWER WAVE ® 655/R...
  • Page 37 PIN, LEAD CONNECTOR DIAGRAMS TABLE 4 RS232 CONNECTOR S3 TABLE 1 INTERFACE CONNECTOR S6 Lead # Function Lead # Function RS232 Receive +15vdc Tach voltage RS232 Transmit Tach common Tach 1A differential signal S3 Pin5 Tach 1B differential signal S3 Pin4 S3 Pin20 Tach 2A differential signal Tach 2B differential signal...

  • Page 38: Connection Diagram

    CONNECTION DIAGRAM Hard Automation and Electrode Positive Configuration TO SHIELDING GAS DEVICENET CABLE DEVICENET CABLE TO PLC/CONTROLLER TO PLC/CONTROLLER ELECTRODE LEAD ELECTRODE LEAD CONTROL CABLE K1795 CONTROL CABLE K1795 SHIELDING GAS WATER COOLER COOL ARC 40 POWER CORD POWER CO NNECT ION WATER CONNECTIONS WORK...
  • Page 39 CONNECTION DIAGRAM Robotic Set Up, Electrode Positive, CV/Pulse Configuration CONTROL CABLE K1805-1 CONTROL CABLE K1805-1 K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE User supplied User supplied electrode lead electrode lead POWERWAVE DEVICENET CABLE User supplied User supplied work lead work lead K1796 COAXIAL WELD CABLE...
  • Page 40 DIAGRAMS POWER WAVE ® 655/R...
  • Page 41 NOTES POWER WAVE ® 655/R...
  • Page 42 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. • • • WARNING electrode with skin or wet clothing. Insulate yourself from work and • ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el •...
  • Page 43 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or • • • WARNING Use ventilation or exhaust to guards off. • remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- •...
  • Page 44 • 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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