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Lincoln Electric 655/R manual

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Table of contents for the manual

  • Page 1

    PO WER W A VE 655/R SVM180-A January , 2008 For use with machines having Code Numbers: 10630, 10863, 1 1410 TM  SER VICE MANUAL Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info • Sales and Service through Subsidiaries and Distributors Worldwi[...]

  • Page 2

    SAFETY i i Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated ar[...]

  • Page 3

    SAFETY ii ii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases [...]

  • Page 4

    SAFETY iii iii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar ʻ95 FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the m[...]

  • Page 5

    SAFETY iv iv Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûre[...]

  • Page 6

    I I - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - POWER W A VE 655/R RETURN TO MAIN INDEX Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specifications[...]

  • Page 8

    INST ALLA TION A-2 A-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TECHNICAL SPECIFICA TIONS - POWER W A VE 655/R (K1519-1, K1519-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPE[...]

  • Page 9

    INST ALLA TION A-3 A-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC state fan control relay , located on the back of the Control PC board enclosure. LIFTING Lift the machine by the lift bail only . The li[...]

  • Page 10

    INST ALLA TION A-4 A-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power W ave. Connections should be made in accordanc[...]

  • Page 11

    INST ALLA TION A-5 A-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELDING WITH MUL TIPLE POWER W A VES Special care must be taken when more than one Power W ave is welding simultaneously on a single par[...]

  • Page 12

    INST ALLA TION A-6 A-6 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRODE AND WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length (Per T able 1) between the proper output terminal[...]

  • Page 13

    INST ALLA TION A-7 A-7 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE SENSING The best arc performance occurs when the Power W aves has accurate data about the arc conditions. Depending upon the p[...]

  • Page 14

    INST ALLA TION A-8 A-8 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE / POWER FEED WIRE FEEDER INTERCONNECTIONS Connect the control cable between the power source and wire feeder . The wire fee[...]

  • Page 15

    INST ALLA TION A-9 A-9 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with[...]

  • Page 16

    INST ALLA TION A-10 A-10 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DIP Switch Settings and Locations DIP switches on the P .C. Boa rds allow for custom con- figuration of the Power W ave. T o access th[...]

  • Page 17

    INST ALLA TION A-11 A-11 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Bank (S2) : switch Description 1 Devicenet Baud Rate 2( see table 4 ) T ABLE 4 Prior to S24958-6 software switch 1 switch 2 baud rate [...]

  • Page 18

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES A-12 A-12 POWER W A VE 655/R[...]

  • Page 19

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . .[...]

  • Page 20

    OPERA TION B-2 B-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless usin[...]

  • Page 21

    OPERA TION B-3 B-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT PO[...]

  • Page 22

    OPERA TION B-4 B-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECOMMENDED EQUIPMENT • Automatic Operation All welding programs and procedures are set through software for the robotic Power W aves. F A[...]

  • Page 23

    OPERA TION B-5 B-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Light Condition Steady Green Blinking Green Alternating Green and Red Steady Red Blinking Red Meaning S y s t e m O K . P o w e r s o u r c [...]

  • Page 24

    OPERA TION B-6 B-6 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELDING MODE DESCRIPTIONS CONST ANT VOL T AGE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine th[...]

  • Page 25

    OPERA TION B-7 B-7 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltag[...]

  • Page 26

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES B-8 B-8 POWER W A VE 655/R[...]

  • Page 27

    T ABLE OF CONTENTS - ACCESSORIES C-1 C-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Optional Equipment . . . . . . . . . . [...]

  • Page 28

    ACCESSORIES C-2 C-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONAL EQUIPMENT F ACTOR Y INST ALLED There are no factory installed options available for the Power W ave. FIELD INST ALLED Gas Guard Re[...]

  • Page 29

    T ABLE OF CONTENTS - MAINTENANCE D-1 D-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . [...]

  • Page 30

    MAINTENANCE D-2 D-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • T urn the input power OFF at [...]

  • Page 31

    MAINTENANCE D-3 D-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 1 7 7 7 7 7 7 3 3 4 4 5 5 2 2 6 6 2 2 2 2 1. CASE FRONT ASSEMBL Y 2. TRANSFORMER AND OUTPUT RECTIFIER ASSEMBL Y 3. INPUT ASSEMBL Y 4. CON[...]

  • Page 32

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES D-4 D-4 POWER W A VE 655/R[...]

  • Page 33

    T ABLE OF CONTENTS - THEOR Y OF OPERA TION E-1 E-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description . . . . . . . .[...]

  • Page 34

    THEOR Y OF OPERA TION E-2 E-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion GENERAL DESCRIPTION The Power Wave 655/R power source i[...]

  • Page 35

    THEOR Y OF OPERA TION E-3 E-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT VOL T AGE AND PRECHARGE The Power W ave 655/R can be connected for a variety of three-phase input voltages. Refer to Figure[...]

  • Page 36

    THEOR Y OF OPERA TION E-4 E-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion SWITCH BOARDS AND MAIN TRANSFORMER There are two switch[...]

  • Page 37

    THEOR Y OF OPERA TION E-5 E-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion DC BUS BOARD, POWER BOARD, FEED HEAD BOARD, GA TEW A Y [...]

  • Page 38

    THEOR Y OF OPERA TION E-6 E-6 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E.5 – POWER W A VE 655/R COMMUNICA TIONS A rc L in k A A r r c c L L i i n n k k D ev i ce N et D D e e v v i i c c e e [...]

  • Page 39

    THEOR Y OF OPERA TION E-7 E-7 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion CONTROL BOARD The Control Board performs the primary in[...]

  • Page 40

    THEOR Y OF OPERA TION E-8 E-8 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion OUTPUT RECTIFIER, OUTPUT CHOKE The output rectifier rec[...]

  • Page 41

    THEOR Y OF OPERA TION E-9 E-9 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL PROTECTION Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermo[...]

  • Page 42

    THEOR Y OF OPERA TION E-10 E-10 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INSULA TED GA TE BIPOLAR TRANSISTOR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited[...]

  • Page 43

    THEOR Y OF OPERA TION E-11 E-11 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION (PWM) is used to describe how much time is devoted to conduc- tion in [...]

  • Page 44

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES E-12 E-12 POWER W A VE 655/R[...]

  • Page 45

    T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR F-1 F-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide [...]

  • Page 46

    TROUBLESHOOTING & REP AIR F-2 F-2 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the thr[...]

  • Page 47

    TROUBLESHOOTING & REP AIR F-3 F-3 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electric[...]

  • Page 48

    TROUBLESHOOTING & REP AIR F-4 F-4 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power W ave / Power Feed are best diagnosed as a system. Each [...]

  • Page 49

    TROUBLESHOOTING & REP AIR F-5 F-5 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ERROR CODES FOR THE POWER W A VE The following is a list of possible error codes that the Power Wave 655 can output via t[...]

  • Page 50

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical trouble[...]

  • Page 51

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical trouble[...]

  • Page 52

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical trouble[...]

  • Page 53

    FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troub[...]

  • Page 54

    FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for a ny reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troub[...]

  • Page 55

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 56

    SWITCH BOARD CAP ACIT OR TERMINALS FIGURE F .1 – CAP ACITOR DISCHARGE PROCEDURE INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the left and right case sides. 3. Remove the two Hi gh V oltage Protection shields. Be careful not to touch the capacitor terminals th[...]

  • Page 57

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 58

    FIGURE F .2 – LEFT SIDE SWITCH BOARD TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case sides. 3. Perform the Capacitor Discharge Procedure. 4 Using the volt-ohmmeter , perform the resistance tests detailed in T able F .1. The readings should all be similar . One or more readings that [...]

  • Page 59

    (LEFT ) 11 NEG POS 13 12 NEG POS 14 (RIGHT ) 16 NEG POS 18 15 NEG POS 17 FIGURE F .3 – RIGHT SIDE AND TEST POINTS SWITCH BOARD TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-15 F-15 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retur[...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-16 F-16 POWER W A VE 655/R[...]

  • Page 61

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 62

    NEG (-) A B C INPUT RECTIFIER POS (+) FIGURE F .4 – INPUT RECTIFIER TEST INPUT RECTIFIER TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top and Input Panel. 3. Perform the Capacitor Discharge Procedure. 4. Locate the Input Rectifier and lead locations. Refer to Figure F .4. 5. Use [...]

  • Page 63

    T ABLE F .2 – INPUT RECTIFIER TEST POINTS AND ACCEPT ABLE READINGS INPUT RECTIFIER TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-19 F-19 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PO[...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-20 F-20 POWER W A VE 655/R[...]

  • Page 65

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 66

    INPUT CONT ACTOR 601 X4 FIGURE F .5 – INPUT CONT ACTOR COIL INPUT CONT ACTOR TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the input access panel and case top. 3. Locate, mark, and remove the two leads (601, X4) that are connected to the input contactor coil. Refer to Figure F .5. 4. Use a[...]

  • Page 67

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 68

    A1 C13 L1 C15 R12 R9 R10 R11 R25 D1 D2 DZ4 C6 R4 R5 R7 R8 R19 X1 X2 C2 C3 C5 C7 C8 C9 C10 C11 MOV1 LED1 R3 R13 R14 R20 R21 R22 R23 DZ5 DZ6 R15 R16 D3 J47 J46 C14 C16 C17 D4 D5 MOV2 R26 R27 R28 R29 C1 LED J47 J46 1 2 1 2 3 4 5 6 7 8 3 4 C3 Power Bd. Rectier FIGURE F .6 – DC BUS PC BOARD DC BUS BOARD TEST PROCEDURE (CONTINUED) TROUB L ESHOOTING [...]

  • Page 69

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 70

    PO WER PC BO ARD CAP ACITOR C3 P ower Bd. Rectier 6 5 4 4 3 12 11 10 9 8 7 3 2 1 2 1 6 5 4 3 2 1 FIGURE F .7 – POWER BOARD TEST POWER BOARD TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top. 3. Locate the Power Board and plugs J42 and J43. Do n o t r em o v e p l u g s o r l ea[...]

  • Page 71

    T ABLE F .4 – POWER BOARD VOL T AGE CHECKS POWER BOARD TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-27 F-27 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC P O W E R B O A R D C O N N E C T O[...]

  • Page 72

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-28 F-28 POWER W A VE 655/R[...]

  • Page 73

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 74

    FIGURE F .8 – INPUT BOARD AND CONT ACTOR INPUT BOARD TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top. 3. Remove lead X4 from the coil terminal of main input contactor CR1. Insulate lead X4. Refer to Figure F .8. 4. Carefully apply input power to the POWER W A VE 655/R. EL ECTRIC[...]

  • Page 75

    T ABLE F .5 – INPUT BOARD VOL T AGE CHECKS INPUT BOARD TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-31 F-31 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST POINTS PLUG J61 PIN 8 (H1D) TO[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-32 F-32 POWER W A VE 655/R[...]

  • Page 77

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 78

    FIGURE F .9 – CURRENT TRANSDUCER TEST CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect the input power to the POWER W A VE 655/R. 2. Remove the case top and the control box cover . 3. Locate the current transducer leads at Control Board plug J8. See Figure F .9. 4. Carefully apply input power to the POWER W A VE 655/R. EL ECT[...]

  • Page 79

    FIGURE F .10 – RS 232 port CURRENT TRANSDUCER TEST PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-35 F-35 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .6 - CURRENT FEEDBACK CHART OUTPUT [...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-36 F-36 POWER W A VE 655/R[...]

  • Page 81

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 82

    NEGA TIVE (-) OUTPUT TERMINALS POSITIVE (+) OUTPUT TERMINALS R1 FIGURE F .1 1 – OUTPUT RECTIFIER TEST OUTPUT RECTIFIER TEST PROCEDURE (CONTINUED) PROCEDURE 1. Remove main input supply power to the POWER W A VE 655/R. 2. Remove the case sides and perform the Input Filter Capacitor Discharge procedure. 3. Remove any output cables that may be con- n[...]

  • Page 83

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 84

    INPUT CONT ACTOR 601 X4 POWER BOARD RECTIFIER BRIDGE X1 X2 + - X3 X5 AUXILIAR Y TRANSFORMER #1 WHITE RED F AN MOTOR WINDING F AN RELA Y 444 X3A FIGURE F .12 – AUXILIAR Y TRANSFORMER NO. 1 TEST AUXILIAR Y TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED) PROCEDURE 1. Remove the main input power to the POWER W A VE 655/R machine. 2. Remove the case top [...]

  • Page 85

    AUXILIAR Y TRANSFORMER NO. 1 TEST PROCEDURE (CONTINUED) TROUB L ESHOOTING & REP A IR F-41 F-41 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .7 – SECONDAR Y VOL T AGES 7. Carefully apply the[...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-42 F-42 POWER W A VE 655/R[...]

  • Page 87

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 88

    1 2 5 3 4 3 2 1 5 2 6 3 6 4 4 1 35 0 (W HITE ) 35 2 (BL ACK ) 3 3 (R ED ) 32 (W HITE ) 3 52A (BL AC K) H6 33 A (RE D) H1 T o W A TER COOLER RECEPT ACLE (S8) T o S4, CB2 & A UX. F AN T o AUX.ILIAR Y TRANSFORMER #2 PRIMARY (P50) FIGURE F .13 – AUXILIAR Y TRANSFORMER NO. 2 TEST AUXILIAR Y TRANSFORMER NO. 2 TEST PROCEDURE (CONTINUED) PROCEDURE 1.[...]

  • Page 89

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 90

    NEG (-) A B C INPUT RECTIFIER POS (+) FIGURE F .14 – INPUT RECTIFIER REMOV AL AND REPLACEMENT INPUT RECTIFIER REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R. 2. Remove the case top, sides, and input access panel. 3. Perform the Capacitor Discharge procedure. 4. Remove the RTV seal[...]

  • Page 91

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 92

    INPUT CONT ACTOR 601 X4 FIGURE F .15 – INPUT CONT ACTOR REMOV AL AND REPLACEMENT INPUT CONT ACTOR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R. 2. Remove the case top, sides and input access panel. 3. Perform the Capacitor Discharge procedure 4. Locate the input contactor . Labe[...]

  • Page 93

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 94

    INPUT CONT ACTOR 601 X4 POWER BOARD RECTIFIER BRIDGE X1 X2 + - X3 X5 AUXILIARY TRANSFORMER #1 WHITE RED F AN MOTOR WINDING F AN RELA Y 444 X3A FIGURE F .16 – AUXILIAR Y TRANSFORMER NO. 1 REMOV AL AND REPLACEMENT AUXILIAR Y TRANSFORMER NO. 1 REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE[...]

  • Page 95

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 96

    1 2 5 3 4 3 2 1 5 2 6 3 6 4 4 1 35 0 (W HIT E) 35 2 (BL AC K) 3 3 (R ED ) 32 (W HITE ) 3 52A (BL AC K) H6 33 A (RE D) H1 T o W A TER COOLER RECEPT ACLE (S8) T o S4, CB2 & A UX. F AN T o AUX.ILIAR Y TRANSFORMER #2 PRIMARY (P50) FIGURE F .17 – AUXILIAR Y TRANSFORMER NO. 2 REMOV AL AND REPLACEMENT AUXILIAR Y TRANSFORMER NO. 2 REMOV AL AND REPLAC[...]

  • Page 97

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 98

    C ONTROL BOARD FEED HEAD BO ARD A UXILIARY DRIVER BD . VOL T AGE SENSE BD . Step 6 Removal Step 6 Removal FIGURE F .18 – CONTROL OR FEED HEAD BOARD REMOV AL AND REPLACEMENT CONTROL, FEED HEAD, VOL T AGE SENSE OR AUXILIAR Y DRIVER BOARD REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/[...]

  • Page 99

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 100

    Suppor t the P anel Ethernet/ Gateway PC Board FIGURE F .19 – GA TEW A Y BOARD REMOV AL AND REPLACEMENT ETHERNET/GA TEW A Y PC BOARD REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R. 2. Using a phillips head screw driver , remove the six screws from the case front cover . Tilt the c[...]

  • Page 101

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 102

    CURRENT TRANSDUCER + THIS SIDE F ACES REAR FIGURE F .20 – POWER W A VE CURRENT TRANSDUCER REMOV AL AND REPLACEMENT PROCEDURE CURRENT TRANSDUCER REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE 1. Remove input power to the POWER W A VE 655/R. 2. Remove the case sides. 3. Perform the Capacitor Discharge procedure . 4. Remove the 1/[...]

  • Page 103

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 104

    J 60 J48 J40/50 Output Choke Connection F an Relay Fr ont Horizontal Divider Panel Rear Horizontal Divider Panel F ront P anel Screws P ower Switch FIGURE F .21 – ACCESSING THE RECTIFIER MODULE OUTPUT RECTIFIER MODULE REPLACEMENT PROCEDURE (CONTINUED) ACCESSING THE RECTIFIER MODULE 1. Remove input power to the POWER W A VE 655/R. 2. Remove the ca[...]

  • Page 105

    FIGURE F .22 – RECTIFIER MODULE REPLACEMENT OUTPUT RECTIFIER AND RECTIFIER MODULE REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) RECTIFIER MODULE TESTING 1. Remove the leads and copper plate from one of the Diode Module pairs. (See Figure F .22). NOTE: Observe the placement and the mounting sequence of the leads and hardware so they can be put ba[...]

  • Page 106

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-62 F-62 POWER W A VE 655/R[...]

  • Page 107

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 108

    SWITCH BOARD CAP ACIT OR TERMINALS FIGURE F .23 – SWITCH BOARD AND FIL TER CAP ACITOR REMOV AL AND REPLACEMENT SWITCH BOARD AND FIL TER CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) REMOV AL PROCEDURE Observe all static electricity precau- tions . Lead and plug references below use a slash (/) to indicate machine right side/left side[...]

  • Page 109

    SWITCH BOARD AND FIL TER CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-65 F-65 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC REPLACEMENT PROCEDURE NOTE : Any in[...]

  • Page 110

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-66 F-66 POWER W A VE 655/R[...]

  • Page 111

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For you r safety and to avoid electrical shock, please observe all safety notes and precautions detailed th[...]

  • Page 112

    CALIBRA TION PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-68 F-68 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .24 – CALIBRA TION SCREEN Calibration T ab Machine output can be turned ?[...]

  • Page 113

    CALIBRA TION PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-69 F-69 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CALIBRA TION PROCEDURE 1. Once in the “Calibration” screen, make sure that the m[...]

  • Page 114

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-70 F-70 POWER W A VE 655/R[...]

  • Page 115

    RETEST AFTER REP AIR TROUBLESHOOTING & REP AIR F-71 F-71 POWER W A VE 655/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T EST PROCEDURE 1. Be certain that the machine is properly connected for the input voltage being a[...]

  • Page 116

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F-72 F-72 POWER W A VE 655/R[...]

  • Page 117

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER W A VE 655/R Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram for Code 10630 (G3498)) . [...]

  • Page 118

    ELECTRICAL DIAGRAMS G-2 WIRING DIAGRAM - CODE 10630 EN-170 G3498 INVERTER WELDERS WIRING DIAGRAM NO NE G3792 lw imb ley K.J U STI CE EAE UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± . 02 ON 3 P LA CE DEC IMA LS IS ± .002 O N ALL A NGLE S I S ± . 5 O F A DEGREE WI T H PUBL IS HE D[...]

  • Page 119

    ELECTRICAL DIAGRAMS G-3 WIRING DIAGRAM - CODE 10863 EN-170 G349 8- 1 INVERTER WELDERS WIRING DIAGRAM NO NE G3498 lw imb ley K.J U STI CE - UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± . 02 ON 3 P LA CE DEC IMA LS IS ± .002 O N ALL A NGLE S I S ± . 5 O F A DEGREE WI T H PUBL IS HE[...]

  • Page 120

    ELECTRICAL DIAGRAMS G-4 WIRING DIAGRAM - CODE 1 1410 EN-170 S O L ID E D G E G349 8- 2 PO WE R W AVE 65 5/R W IRI N G DIA GRAM NONE G3498- 1 DO NO T SC AL E T HIS DR A WING EQ UIP M ENT TYPE: SUBJECT: SCA L E: UF CRM38675 1 PAGE ___ OF ___ 1 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT URE R: No THIS DOCUMENT CONTAINS PROPRIETAR Y INFORMATION OWNED [...]

  • Page 121

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 COMPLETE MACHINE SCHEMA TIC - CODE 10630 EN-170 G3611 INVERTER WELDERS PW575/STT 208-575 MACHINE SCHE MATIC NO NE G4009 lw imb ley TK TK UNLESS OTHERWISE [...]

  • Page 122

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 COMPLETE MACHINE SCHEMA TIC - CODE 10863 EN-170 S O L ID ED G E G361 1- 1 INVER TER WELDERS PW655 /R MACHI NE SCHEMAT IC NO NE G4009 jb arto TK - UNLESS O[...]

  • Page 123

    ELECTRICAL DIAGRAMS G-7 COMPLETE MACHINE SCHEMA TIC - CODE 1 1410 EN-170 S O L ID ED G E G361 1- 2 POWERWAVE 65 5/R MACHI NE SCHEMATI C NO NE G3611-1 RAS PW - UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± . 02 ON 3 P LA CE DEC IMA LS IS ± .002 O N ALL A NGLE S I S ± . 5 O F A DEGR[...]

  • Page 124

    ELECTRICAL DIAGRAMS G-8 SCHEMA TIC - DEVICENET/GA TEW A Y PC BOARD (SHEET 1) G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to M[...]

  • Page 125

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-9 SCHEMA TIC - DEVICENET/GA TEW A Y PC BOARD (SHEET 2) G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by thi[...]

  • Page 126

    ELECTRICAL DIAGRAMS G-10 SCHEMA TIC - ETHERNET/GA TEW A Y PC BOARD (SHEET 1) G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to [...]

  • Page 127

    ELECTRICAL DIAGRAMS G-11 SCHEMA TIC - ETHERENET/GA TEW A Y PC BOARD (SHEET 2) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to[...]

  • Page 128

    ELECTRICAL DIAGRAMS G-12 SCHEMA TIC ETHERNET/GA TEW A Y PC BOARD (SHEET 3) G-12 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma[...]

  • Page 129

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-13 SCHEMA TIC - CONTROL PC BOARD (SHEET 1) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI . UNLESS OTHER[...]

  • Page 130

    ELECTRICAL DIAGRAMS G-14 SCHEMA TIC - CONTROL PC BOARD (SHEET 2) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI . UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± . 02 ON 3 P LA CE DEC IMA LS IS ± .002 O N ALL A NGLE S I S ± . 5 O F[...]

  • Page 131

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-15 SCHEMA TIC - CONTROL PC BOARD (SHEET 3) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI . UNLESS OTHER[...]

  • Page 132

    ELECTRICAL DIAGRAMS G-16 SCHEMA TIC - CONTROL PC BOARD (SHEET 4) EN-170 S O L ID ED G E G378 9- 2 FO INVERTER WELDER SCHEMATIC DIGITAL CONTROL NO NE G3789-1 E2 FEI . UNLESS OTHERWISE SPECI FIED TOLERANCE M ANUF ACTURING TO L ER ANC E P ER E 2056 O N 2 P LAC E DE CIM AL S I S ± . 02 ON 3 P LA CE DEC IMA LS IS ± .002 O N ALL A NGLE S I S ± . 5 O F[...]

  • Page 133

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-17 SCHEMA TIC - DIGIT AL POWER SUPPL Y PC BOARD .1 C 53 Vfb2 Vref 1 100K R29 CNY17-3 OCI2 4 2 1 6 5 .5 W 2 7V D Z2 VFB CS CO MP RT/CT V CC OUT VR EF GND X4 [...]

  • Page 134

    ELECTRICAL DIAGRAMS G-18 SCHEMA TIC - FEED HEAD PC BOARD (SHEET 1) G-18 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 135

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-19 SCHEMA TIC - FEED HEAD PC BOARD (SHEET 2) G-19 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

  • Page 136

    ELECTRICAL DIAGRAMS G-20 SCHEMA TIC - FEED HEAD PC BOARD (SHEET 3) G-20 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 137

    ELECTRICAL DIAGRAMS G-21 SCHEMA TIC - INPUT PC BOARD G-21 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 138

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 139

    ELECTRICAL DIAGRAMS G-23 SCHEMA TIC - SWITCH PC BOARD G-23 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 140

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 141

    ELECTRICAL DIAGRAMS G-25 SCHEMA TIC - VOL T AGE SENSE PC BOARD G-25 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 142

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 143

    ELECTRICAL DIAGRAMS G-27 SCHEMA TIC - 40VDC BUS PC BOARD G-27 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 144

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 145

    ELECTRICAL DIAGRAMS G-29 SCHEMA TIC - AUXILIAR Y DRIVER PC BOARD G-29 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 146

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]