Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn 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 areas or vent the engine exhaust fumesoutdoors. ...
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour Soudage A L...
Page 6 - b) radio and television transmitters and receivers
v v SAFETY Electromagnetic Compatibility (EMC) ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3 May1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility(89/336/EEC). It was manufactured in confo...
Page 7 - Methods of Reducing Emissions
vi vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply...
Page 8 - Thank You; Please Examine Carton and Equipment For Damage Immediately
vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this ma...
Page 9 - TABLE OF CONTENTS; PAGE
viii viii TABLE OF CONTENTS PAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION A TECHNICAL SPECIFICATIONS – IDEALARC DC-655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1...
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS – DC-655; See the OPERATION section; INPUT - THREE PHASE ONLY
A-1 DC-655 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – DC-655 Volts at Rated Amperes 44 44 Auxiliary Power See the OPERATION section for Auxiliary Power information by model Amps 650 815 Maximum Open Circuit Voltage 46 CV Mode 68 CC Mode Duty Cycle 100% Duty Cycle NEMA Class I (100)* 60% Duty Cycle ...
Page 11 - CE; NRTL
A-2 INSTALLATION DC-655 A-2 3 Phase transformer with rectified DC output INPUT POWER THREE PHASE Designates welder complies with National Electrical Manufacturers Association requirements EW 1 Class I with 100% duty cycle at 6 5 0 A m p s o u t p u t . ( D o m e s t i c , Canadian, and Export models...
Page 12 - SAFETY PRECAUTIONS; STACKING; ELECTRICAL INPUT CONNECTIONS; FUSE AND WIRE SIZES; Technical; GROUND CONNECTION; Technical Specifications; ELECTRIC SHOCK can kill.; FIGURE A.1 ELECTRICAL INPUT CONNECTIONS
A-3 INSTALLATION DC-655 A-3 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS SELECT SUITABLE LOCATION Place the welder where clean cooling air can freelycirculate in through the front louvers and out throughthe rear louvers. Dirt, dust or any foreign material thatcan ...
Page 13 - INPUT POWER SUPPLY CONNECTIONS; Follow all national and local electrical codes.; RECONNECT PROCEDURE; Electric Shock Can Kill; • Disconnect input power before perform-; CAUTION; FIGURE A.2 Dual Voltage Machine Reconnection Procedure
A-4 INSTALLATION DC-655 A-4 INPUT POWER SUPPLY CONNECTIONS A qualified electrician should connect the input powersupply leads. 1. Follow all national and local electrical codes. 2. Use a three-phase line. 3. Remove the input access door at upper rear of themachine. 4. Follow input supply connection ...
Page 14 - OUTPUT CONNECTIONS; ELECTRODE AND WORK CABLES; LOW INDUCTANCE TERMINAL; FIGURE A.3 Output Connections
A-5 INSTALLATION DC-655 A-5 OUTPUT CONNECTIONS ELECTRODE AND WORK CABLES Use the shortest possible cable lengths. See TableA.1 for recommended cable sizes based on length. The output terminals are located at the lower front ofthe welder behind a hinged door Refer to figure A.3.Route the welding cabl...
Page 15 - PIN; AUXILIARY POWER TABLE; 4 PIN MS TYPE RECEPTACLE
A-6 INSTALLATION DC-655 A-6 FIGURE A.4 FRONT VIEW OF 14-PIN CONNECTORRECEPTACLE PIN LEAD NO. FUNCTION A 32 115 VAC B GND Chassis Connection C 2 Trigger Circuit D 4 Trigger Circuit E 77 Output Control F 76 Output Control G 75 Output Control H 21 Work Sense Connection 2 I 41 42 VAC J 31 115 VAC 1. K 4...
Page 16 - TERMINAL STRIPS
A-7 INSTALLATION DC-655 A-7 TERMINAL STRIPS Terminal strips are available behind the cover panelon the lower case front to connect wire feeder controlcables that do not have a 14 Pin MS-type connector.Refer to figure A.3 for the location of this cover panel.These terminals supply the connections as ...
Page 17 - OPERATION; GENERAL DESCRIPTION; GENERAL WARNINGS
B-1 OPERATION B-1 GENERAL DESCRIPTION The DC-655 is an energy efficient constant voltage DC powersource that produces outstanding arc characteristics for multi-ple CV or CC welding processes Four models are available: Domestic - all 60 Hertz models except 230/460/575v. NEMA Class 1 rated Canadian - ...
Page 18 - DESIGN FEATURES AND ADVANTAGES; WELDING CAPABILITY
B-2 OPERATION B-2 DESIGN FEATURES AND ADVANTAGES • Separate output terminals for selecting high or low i n d u c t a n c e a s r e c o m m e n d e d f o r t h e w e l d i n gprocess. • Power on/off switch with pilot light and thermostat tripped indicator light. • Full range output voltage (CV mode) ...
Page 19 - Machine Shutdown section; CONTROLS AND SETTINGS; FIGURE B.1 CONTROL PANEL CONTROLS
B-3 OPERATION B-3 1. INPUT POWER ON/OFF SWITCH - This tog- gle switch turns the machine on or off. Putting thes w i t c h i n t h e O N p o s i t i o n e n e r g i z e s t h emachine’s input contactor applying input power tot h e m a c h i n e . S w i t c h i n g t h e s w i t c h t o t h eOFF posit...
Page 20 - Welding Performance Section; T H E R M A L P R O T E C T I O N L I G H T -; I f t h e; 15VAC DUPLEX RECEPTACLE (Domestic and; This receptacle provides up to; FIGURE B.2 LOWER CASE FRONT CONTROLS & CONNECTIONS
B-4 OPERATION B-4 This mode is used for stick welding (SMAW) andCC air carbon-arc gouging, and employs a “HotStart” feature and an Arc Force Control. CCmode may also be used for CC submerged arcwith appropriate arc-sensing CC(VV) wire feed-ers if arc force is set high enough. Refer to Welding Perfor...
Page 21 - MS Type Receptacle; CASE BACK CONNECTIONS; 2 0 VA C A U X I L I A RY R E C E P TA C L E; AUXILIARY POWER; MACHINE PROTECTION; THERMAL FAN CONTROL
B-5 OPERATION B-5 DC-655 3. 42VAC 10 AMP CIRCUIT BREAKER - This breaker protects the 42VAC auxiliary circuits locat-ed in the terminal strip and MS-receptacle. 4. 14 PIN MS-RECEPTACLE - This connector pro- vides easy connection for a wire feeder controlcable. It provides connections for auxiliary po...
Page 22 - THERMAL SHUTDOWN; Average Current Shutdown; IDLE SHUT DOWN TIMER; WELDING PERFORMANCE
B-6 OPERATION B-6 DC-655 THERMAL SHUTDOWN This welder has thermostatic protection from exces-sive duty cycles, overloads, loss of cooling, and highambient temperature. When the welder is subjected toan overload or loss of cooling, a thermostat will open.This condition will be indicated by the illumi...
Page 23 - CV MODE CURRENT-LIMITING; Machine Protection; CC MODE ARC FORCE; DC-655 Control PC Board
B-7 OPERATION B-7 CV MODE CURRENT-LIMITING CV MIG and CV Sub-Arc modes employ electroniccurrent limiting to limit excessive short circuit outputcurrent which can result in undesirable arc character-istics or nuisance over current protection shutdown(see Machine Protection section). As shipped, the D...
Page 24 - ACCESSORIES; SEMI-AUTOMATIC WIRE FEEDERS
C-1 ACCESSORIES C-1 The DC-655 can be used to power any ofthe following Lincoln Wire feeders: SEMI-AUTOMATIC WIRE FEEDERS • LN-15 • DH-10 • LN-9* • LN-10 • LN-9 GMA* • LN-7 GMA* • LN-23P • LN-742 • LN-25 • LN-7* • LN-8* AUTOMATIC WIRE FEEDERS* • NA-3 • NA-5R • NA-5 LT-7 Tractor * European DC-655 mod...
Page 25 - Provides interconnection of
C-2 ACCESSORIES C-2 K1528-1 Dual Process Switch - (Cannot be used with K1486-1 Air Filter Kit) The Dual-Process Switchm o u n t s e a s i l y t o t h e f r o n t o f t h e m a c h i n e a n d i sdesigned to provide a selection between left and rightside output terminals. Each pair of output terminal...
Page 26 - MAINTENANCE; GENERAL MAINTENANCE; The fan motor has sealed bearings which require
D-1 MAINTENANCE D-1 DC-655 SAFETY PRECAUTIONS GENERAL MAINTENANCE 1. The fan motor has sealed bearings which require no service. 2. In extremely dusty locations, dirt may restrict the cooling air causing the welder to run hot with pre-mature tripping of thermal protection. Blow out thewelder with lo...
Page 27 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 DC-655 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. CAUTION This Troubleshooting Guide i...
Page 28 - PROBLEMS; Local Lincoln Authorized
E-2 TROUBLESHOOTING E-2 DC-655 Observe all Safety Guidelines detailed throughout this manual 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 assis...
Page 31 - Machine
E-5 TROUBLESHOOTING E-5 DC-655 Observe all Safety Guidelines detailed throughout this manual 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 assis...
Page 35 - Remote Control Leads Fault Protection Shutdown
E-9 TROUBLESHOOTING E-9 DC-655 Observe all Safety Guidelines detailed throughout this manual 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 assis...
Page 36 - Observe all Safety Guidelines detailed throughout this manual; BOARD; Fan will run for minimum of 5 minutes once fan turns on.
E-10 TROUBLESHOOTING E-10 DC-655 Observe all Safety Guidelines detailed throughout this manual 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 ass...
Page 37 - DIAGRAMS; OR
F-1 DIAGRAMS DC-655 F-1 N.C. T ape up bolted connection if lead # 21 is extended . N.D. C onnect the control cable ground lead to the frame terminal marked near the power source terminal strip . T he power source grounding terminal (marked and located near the power source input power connections) m...
Page 42 - particular code is pasted
F-6 DIAGRAMS F-6 DC-655 WIRING DIAGRAM FOR CODES 10501,10503, 10504, 10505 This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
Page 43 - particular code is pasted inside
F-7 DIAGRAMS F-7 DC-655 This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.