Cutting torches, attachments and handles for welding / cutting / heating (33 pages)
Summary of Contents for Lincoln Electric POWERWAVE 655/R
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RETURN TO MAIN MENU POWERWAVE 655/R 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 thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT...
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C C A A N N B B E E H H A A Z Z A A R R D D O O U U S S . .
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------------------------------------------------------------- ------------------------------------------------------------- POWER WAVE 655/R...
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INPUT SUPPLY CONNECTION DIAGRAM THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. ------------------------------------------------------------- Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Disconnect input power before inspecting or servicing machine. Do not operate with covers removed.
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POWERWAVE Electrode Lead POWERWAVE Travel Direction Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 655/R Electrode Lead Connect All Work Sense Leads at the End of the Joint...
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FIGURE A.3 POWER WAVE POWER WAVE K1796 COAXIAL CABLE MEASURE FROM END OF OUTER JACKET OF CABLE WORK POWER WAVE 655/R FIGURE A.4 WORK SLIDING GROUND...
GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT POWER WAVE 655/R SMAW GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE...
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WARNING • 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. POWER WAVE 655/R...
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POWER WAVE 655/R CAP. V/F FEEDBACK INPUT RECTIFIER HARMONIC FILTER CAP. V/F FEEDBACK INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD 40 VDC RECONNECT 115 VAC RELAY 380- 115 VAC 440- 550- 65 VDC 52 VAC BUS BOARD RECTIFIER BOARD...
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POWER WAVE 655/R FEEDBACK INPUT RECTIFIER HARMONIC FILTER FEEDBACK INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RECONNECT 115 VAC RELAY 380- 115 VAC 440- 65 VDC 550- 52 VAC BUS BOARD RECTIFIER 230 VAC WATER COOLER Auxiliary...
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r r c c L L i i n n k k rc Link PF 10R PW 655R D D e e v v i i c c e e N N e e t t Device Net Robot Controller POWER WAVE 655/R...
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POWER WAVE 655/R CAP. V/F FEEDBACK INPUT RECTIFIER HARMONIC FILTER CAP. V/F FEEDBACK INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD 40 VDC RECONNECT 115 VAC RELAY 380- 115 VAC 440- 65 VDC 550- 52 VAC BUS BOARD RECTIFIER BOARD...
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POWER WAVE 655/R CAP. V/F FEEDBACK INPUT RECTIFIER HARMONIC FILTER FEEDBACK INPUT BOARD CONTACTOR AND PRECHARGE CONTROL SIGNALS FROM CONTROL BOARD FROM CONTROL BOARD RECONNECT 115 VAC RELAY 380- 115 VAC 440- 65 VDC 550- 52 VAC BUS BOARD RECTIFIER 230 VAC WATER COOLER...
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GATE SOURCE BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER DRAIN A. PASSIVE POWER WAVE 655/R POSITIVE VOLTAGE APPLIED GATE SOURCE BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER DRAIN B. ACTIVE...
INPUT CONTACTOR TEST PROCEDURE FIGURE F.5 – INPUT CONTACTOR COIL PROCEDURE Ω POWER WAVE 655/R INPUT CONTACTOR F F I I G G U U R R E E F F . . 5 5 A A C C O O N N T T A A C C T T O O R R T T E E S S T T P P O O I I N N T T S S Ω...
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DC BUS BOARD TEST PROCEDURE POWER WAVE 655/R...
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DC BUS BOARD TEST PROCEDURE FIGURE F.6 – DC BUS PC BOARD WARNING POWER WAVE 655/R MOV1 Power Bd. Recti er...
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POWER BOARD TEST PROCEDURE POWER WAVE 655/R...
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POWER BOARD TEST PROCEDURE POWER PC BOARD CAPACITOR PROCEDURE WARNING FIGURE F.7 – POWER BOARD TEST 12 11 10 9 POWER WAVE 655/R Power Bd. Recti er...
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POWER BOARD TEST PROCEDURE TABLE F.4 – POWER BOARD VOLTAGE CHECKS POWER WAVE 655/R...
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CURRENT TRANSDUCER TEST PROCEDURE POWER WAVE 655/R...
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CURRENT TRANSDUCER TEST PROCEDURE FIGURE F.9 – CURRENT TRANSDUCER TEST CONTROL BOARD 211 212 213 1 2 3 4 CURRENT TRANSDUCER PROCEDURE WARNING POWER WAVE 655/R...
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CURRENT TRANSDUCER TEST PROCEDURE FIGURE F.10 – RS 232 port RS 232 PORT TABLE F.6 - CURRENT FEEDBACK CHART POWER WAVE 655/R...
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OUTPUT RECTIFIER TEST PROCEDURE POWER WAVE 655/R...
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OUTPUT RECTIFIER TEST PROCEDURE FIGURE F.11 – OUTPUT RECTIFIER TEST NEGATIVE (-) OUTPUT TERMINALS PROCEDURE POSITIVE (+) OUTPUT TERMINALS POWER WAVE 655/R...
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AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE POWER WAVE 655/R...
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AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE FIGURE F.12 – AUXILIARY TRANSFORMER NO. 1 TEST INPUT CONTACTOR WHITE FAN MOTOR WINDING PROCEDURE RECTIFIER BRIDGE AUXILIARY TRANSFORMER #1 POWER WAVE 655/R POWER BOARD FAN RELAY...
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AUXILIARY TRANSFORMER NO. 1 TEST PROCEDURE WARNING TABLE F.7 – SECONDARY VOLTAGES POWER WAVE 655/R...
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT INPUT CONTACTOR WHITE FAN MOTOR WINDING REMOVAL PROCEDURE POWER BOARD RECTIFIER BRIDGE FAN RELAY AUXILIARY TRANSFORMER #1 REPLACEMENT PROCEDURE POWER WAVE 655/R...
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE POWER WAVE 655/R...
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AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT REMOVAL PROCEDURE REPLACEMENT PROCEDURE POWER WAVE 655/R To WATER COOLER RECEPTACLE (S8) To AUX.ILIARY TRANSFORMER #2 PRIMARY (P50) To S4, CB2 & AUX. FAN...
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CONTROL, FEED HEAD, VOLTAGE SENSE, OR AUXILIARY DRIVER BOARD REMOVAL AND REPLACEMENT Ω POWER WAVE 655/R...
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CONTROL, FEED HEAD, VOLTAGE SENSE OR AUXILIARY DRIVER BOARD REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.18 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT CONTROL BOARD FEED HEAD BOARD Removal Removal Step 6 Step 6 VOLTAGE AUXILIARY SENSE BD. DRIVER BD. REMOVAL PROCEDURE REPLACEMENT PROCEDURE POWER WAVE 655/R...
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ETHERNET/GATEWAY PC BOARD REMOVAL AND REPLACEMENT PROCEDURE Ω POWER WAVE 655/R...
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ETHERNET/GATEWAY PC BOARD REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.19 – GATEWAY BOARD REMOVAL AND REPLACEMENT Ethernet/ Gateway PC Board Support the Panel REMOVAL PROCEDURE REPLACEMENT PROCEDURE POWER WAVE 655/R...
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CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE POWER WAVE 655/R...
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CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.20 – POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE THIS SIDE FACES REAR CURRENT TRANSDUCER REMOVAL PROCEDURE REPLACEMENT PROCEDURE POWER WAVE 655/R...
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OUTPUT RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE POWER WAVE 655/R...
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OUTPUT RECTIFIER MODULE REPLACEMENT PROCEDURE FIGURE F.21 – ACCESSING THE RECTIFIER MODULE Fan Relay Front Horizontal Power Divider Panel Switch Rear Horizontal Divider Panel J40/50 Output Choke Connection Front Panel Screws ACCESSING THE RECTIFIER MODULE POWER WAVE 655/R...
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OUTPUT RECTIFIER AND RECTIFIER MODULE REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.22 – RECTIFIER MODULE REPLACEMENT Copper Plate Original Modules may have 1/4-20 bolts in place of studs RECTIFIER MODULE TESTING RECTIFIER MODULE REPLACEMENT POWER WAVE 655/R...
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G3498 CHANGE DETAIL: RELEASED FROM X A.02 ENGINEERING CONTROLLED MANUFACTURER: TO J9 CONTROL BOARD 202A DEVICE NET TO R1 FEED HEAD GATEWAY BOARD BOARD .05/600V WORK J2VS WIRE FEEDER RECEPTACLE VOLTAGE SENSE RECEPTACLE 3 CONDUCTOR TWISTED/SHIELDED SHIELD GROUND TO CASE J1AD RS232 CONNECTOR...
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G3498-1 ADDED NOTE N.E. ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: TO J9 ETHERNET BOARD CONTROL BOARD 202A TO R1 FEED HEAD BOARD .05/600V WORK J2VS WIRE FEEDER RECEPTACLE N.E. VOLTAGE SENSE RECEPTACLE 3 CONDUCTOR TWISTED/SHIELDED SHIELD GROUND TO CASE J1AD RS232 CONNECTOR 222A 10A CIRCUIT...
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: POWERWAVE 655/R PAGE ___ OF ___ NONE DRAWN BY: DOCUMENT IF PRINTED...
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G3611 RELEASED FROM X A.02 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: INPUT RECTIFIER HARMONIC FILTER N.A. FEED HD BD 3J83 SOLENOID +40VDC 4J83 SOLENOID INPUT MOTOR "+" 1J83 2J83 MOTOR "-" 1J84 +15VDC TACH 2J84 TACH 1A DIFF. INPUT N.A. 3J84 TACH 1B DIFF.
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE REFERENCE: POWERWAVE 655/R DESIGN INFORMATION EQUIPMENT TYPE: MANUFACTURING TOLERANCE PER E2056 PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ±...
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE REFERENCE: INVERTER WELDER DESIGN INFORMATION EQUIPMENT TYPE: MANUFACTURING TOLERANCE PER E2056 PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ±...
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE REFERENCE: INVERTER WELDER DESIGN INFORMATION EQUIPMENT TYPE: MANUFACTURING TOLERANCE PER E2056 PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ±...
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE REFERENCE: INVERTER WELDER DESIGN INFORMATION EQUIPMENT TYPE: MANUFACTURING TOLERANCE PER E2056 PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ±...
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE REFERENCE: INVERTER WELDER DESIGN INFORMATION EQUIPMENT TYPE: MANUFACTURING TOLERANCE PER E2056 PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ±...
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NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. UNLESS OTHERWISE SPECIFIED TOLERANCE "X"...
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
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This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.