Lincoln Electric 655/R

INSTALLATION

A-8 A-8

POWER WAVE 655/R

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POWER WAVE / POWER FEED

WIRE FEEDER

INTERCONNECTIONS

Connect the control cable between the power source

and wire feeder. The wire feeder connection on the

robotic Power Waves is located under the spring

loaded output cover, near the bottom of the case front.

The control cable is keyed and polarized to prevent

improper connect.

For convenience, the electrode and control cables can

be routed behind the left or right strain reliefs (under

the spring loaded output cover), and along the chan-

nels formed into the base of the Power Wave, out the

back of the channels, and then to the wire feeder.

Output connections on some Power Waves are made

via 1/2-13 threaded output studs located beneath the

spring loaded output cover at the bottom of the case

front. On machines which carry the CE mark, output

connections are made via Twist-Mate receptacles,

which also located beneath the spring loaded output

cover at the bottom of the case front.

A work lead must be run from the power source output

stud to the work piece. The work piece connection

must be firm and secure, especially if pulse welding is

planned.

Excessive voltage drops at the work piece connec-

tion often result in unsatisfactory pulse welding

performance.

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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.

The use of non-standard cables, especially in

lengths greater than 25 ft(7.6m), can lead to com-

munication problems (system shutdowns), poor

motor acceleration (poor arc starting) and low wire

driving force (wire feeding problems).

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Lincoln control cables are copper 22 conductor cable

in a SO-type rubber jacket.

Work Voltage Sensing

The Power Waves are shipped from the factory with

the work sense lead enabled.

For processes requiring work voltage sensing, connect

the (21) work voltage sense lead from the Power Wave

to the work. Attach the sense lead to the work as close

to the weld as practical. Enable the work voltage sens-

ing in the Power Wave as follows:

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrodes with your skin or wet

clothing.

• Insulate yourself from the work and

ground.

• Always wear dry insulating gloves.

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1. Turn off power to the power source at the disconnect

switch.

2. Remove the front cover from the power source.

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.

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.

5. Replace the cover and screws. The PC

board will “read” the switch at power up, and config-

ure the work voltage sense lead appropriately.

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.

WARNING

N1 2 3 4 5 6 7 8

CAUTION