Embed Size (px)
Citation preview
IDEALARC ® DC655
Operator’s Manual
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM602-A | Issue D ate 11-Aug
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
10501; 10502; 10503; 10504; 10506; 10507; 10508; 10509; 10510; 11324
Register your machine: www.lincolnelectric.com/register
Authorized Service and Distributor Locator: www.lincolnelectric.com/locator
FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
____________________________________________________1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.
____________________________________________________1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND MAGNETIC FIELDSmay be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
iiSAFETYii
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 flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployerʼs safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.f. Also see item 1.b.
iiiSAFETYiii
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturerʼsrecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturerʼs recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.
Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:
Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de nʼimporte quellepartie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux durayonnement de lʼarc et des projections quand on soudeou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.
c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflamma-bles.
4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protectionlibres de lʼhuile, tels que les gants en cuir, chemise épaisse,pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au codede lʼélectricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du posteseront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼ interieur de poste, ladebrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
vv SAFETY
Electromagnetic Compatibility (EMC)
ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonizedstandard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
IntroductionAll electrical equipment generates small amounts of electromagnetic emission. Electrical emission may betransmitted through power lines or radiated through space, similar to a radio transmitter. When emissionsare received by other equipment, electrical interference may result. Electrical emissions may affect manykinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlledmachines, telephone systems, computers, etc. WARNING: This equipment is not intended for use in residential locations where the electrical power is pro-vided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnet-ic compatibility in those locations, due to conducted as well as radiated disturbances.
Installation and UseThe user is responsible for installing and using the welding equipment according to the manufacturer’sinstructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of thewelding equipment to resolve the situation with the technical assistance of the manufacturer. In some casesthis remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases itcould involve construction of an electromagnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbances must be reduced to the point wherethey are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons. Follow your local andnational standards for installation and use. Changing the earthing arrangements should onlybe authorized by a person who is competent to assess whether the changes will increase therisk of injury, e.g., by allowing parallel welding current return paths which may damage theearth circuits of other equipment.
Assessment of AreaBefore installing welding equipment the user shall make an assessment of potential electromagnetic prob-lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to thewelding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ensure that other equipment beingused in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
vivi 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
Public Supply SystemWelding equipment should be connected to the public supply system according to the manufacturer’s rec-ommendations. If interference occurs, it may be necessary to take additional precautions such as filtering ofthe public supply system. Consideration should be given to shielding the supply cable of permanentlyinstalled welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuousthroughout its length. The shielding should be connected to the welding power source so that good electricalcontact is maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding EquipmentThe welding equipment should be routinely maintained according to the manufacturer’s recommendations.All access and service doors and covers should be closed and properly fastened when the welding equip-ment is in operation. The welding equipment should not be modified in any way except for those changesand adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking andstabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding CablesThe welding cables should be kept as short as possible and should be positioned close together, running ator close to floor level.
Equipotential BondingBonding of all metallic components in the welding installation and adjacent to it should be considered.However, metallic components bonded to the work piece will increase the risk that the operator couldreceive a shock by touching these metallic components and the electrode at the same time. The operatorshould be insulated from all such bonded metallic components.
Earthing of the WorkpieceWhere the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its sizeand position, e.g., ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduceemissions in some, but not all instances. Care should be taken to prevent the earthing of the workpieceincreasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countrieswhere direct connection is not permitted, the bonding should be achieved by suitable capacitance, selectedaccording to national regulations.
Screening and ShieldingSelective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-lems of interference. Screening of the entire welding installation may be considered for special applica-
tions1.
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-uct standard for arc welding equipment.”
viivii
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.
CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric 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. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.
On-Line Product Registration- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Support” and then “RegisterYour Product”. Please complete the form and submit your registration.
viii viii
TABLE OF CONTENTS
PAGE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Graphic Symbols that appear on Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Fuses and Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Input Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Electrode and Work Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Auxiliary Power and Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Auxiliary Power Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6115Vac Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6230v Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-614 Pin MS Type Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
__________________________________________________________________________________________OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION B
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Design features and advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5Machine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .b-5Welding Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
__________________________________________________________________________________________ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION C
Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1__________________________________________________________________________________________MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
__________________________________________________________________________________________
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION EHow To Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1Machine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2P.C. Board Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9, E-10
__________________________________________________________________________________________DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION F__________________________________________________________________________________________PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-317 SERIES__________________________________________________________________________________________
A-1
DC-655
A-1 INSTALLATIONTECHNICAL SPECIFICATIONS – DC-655
Volts at Rated Amperes44
44
Auxiliary PowerSee the OPERATION section
for Auxiliary Power information by model
Amps650
815
Maximum Open Circuit Voltage46 CV Mode68 CC Mode
Duty Cycle100% Duty Cycle
NEMA Class I (100)*60% Duty Cycle
INPUT - THREE PHASE ONLY
OUTPUT
* European models meet IEC974-1 standards.
1Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
RECOMMENDED INPUT WIRE AND FUSE SIZES
StandardVolatge
230/460/60230/460/575/60
208/416/60460/60575/60
230/400/50/60*380/500/50/60
440/50/60200/400/50/60
415/50/60
CodeNumber
1050110502, 11324
1050310504105051050610507105081050910510
100% Duty Cycle
122/61122/61/49135/67.5
6149
122/7074/56
64140/70
68
60% Duty Cycle
150/75150/75/60
166/837560
150/8690/69
78172/86
83
Input Current at Rated Output
RATED OUTPUT
INPUTVOLTAGE /
FREQUENCY
208230416460575200230380400415440500
(SUPER LAG)OR BREAKERSIZE (AMPS)1
250 Amp225 Amp125 Amp110 Amp90 Amp250 Amp225 Amp125 Amp125 Amp110 Amp110 Amp110 Amp
CopperGROUND WIRE
IN CONDUITAWG(IEC-MM2) SIZES
4 (21)4 (21)6 (14)6 (14)8 (8.4)4 (21)4 (21)6 (14)6 (14)6 (14)6 (14)6 (14)
TYPE 80°CCOPPER WIRE
IN CONDUITAWG(IEC-MM2) SIZES40°C (104°F) Ambient
1 (43)1 (43)6 (14)6 (14)8 (8.4)1/0 (54)1 (43)4 (21)4 (21)6 (14)6 (14)6 (14)
INPUT AMPERERATING ON
NAMEPLATE
13512267.561491401227470686456
HERTZ
6060606060
50/6050/6050/6050/6050/6050/6050/60
PHYSICAL DIMENSIONSHEIGHT27.5 in
699 mm
WIDTH22.2 in
564 mm
DEPTH38.0 in
965 mm
WEIGHT720 lbs.326 kg.
Current Range
50-815
Voltage Range
13-44 DC
A-2INSTALLATION
DC-655
A-2
3 Phase transformer with rectified DC output
INPUT POWER
THREE PHASE
Designates welder complies withNational Electrical ManufacturersAssociation requirements EW 1Class I with 100% duty cycle at650Amps output. (Domestic,Canadian, and Export models)
Designates welder complies withboth Underwriters Laboratories(UL) standards and CanadianStandards Association (CSA)standards. (Canadian Model)
GMAW
FCAW
GRAPHIC SYMBOLS THAT APPEAR ONRATING PLATE (LOCATED ON CASE BACK)
Constant Voltage OutputCharacteristics
R
NEMA EW 1 (100%)
Designates welder complies withInternational ElectrotechnicalCommission requirements 974-1.(European Models)
IEC 974-1
Designates welder complies withlow voltage directive and withEMC directive. (European models)
CE
Designates welder can be usedin environments with increasedhazard of electric shock.(European models)
S
NRTL/C
Designates welder complies withUnderwriters Laboratories (UL)standards. (Domestic Models)
R
NRTL
SMAW
SAW
Constant Current OutputCharacteristics
Designates the degree of envi-ronmental protection provided bythe power sources enclosure.
IP-23
Open Circuit Output VoltageUo
Input Voltage Rating(s)U1
Input Current Rating(s)I1
Output Voltage Rating(s)U2
Output Duty Cycle Rating(s)X
Output Current Rating(s)I2
A-3INSTALLATION
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 be drawn into the welder should be kept at aminimum. Failure to observe these precautions canresult in excessive operating temperatures andnuisance shut-downs.
STACKING
The DC-655 may be stacked three-high provided thebottom machine is on a stable, hard, level surface. Besure that the two pins in the roof fit into the slots in thebase of the DC-655 above it.
TILTING
Do not place the machine on a surface that is inclinedenough to create a risk of the machine falling over.
ELECTROMAGNETIC COMPATIBILITY (EMC)
The EMC classification of the DC-655 is Industrial,Scientific and Medical (ISM) group 2, class A.
The DC-655 is for industrial use only. (See printsL10093-1, -2 safety pages in the Front of InstructionManual for further details).
Locate the DC-655 away from radio controlledmachinery. The normal operation of the DC-655 mayadversely affect the operation of RF controlled equip-ment, which may result in bodily injury or damage tothe equipment.
ELECTRICAL INPUT CONNECTIONS
Before installing the machine check that the input sup-ply voltage, phase, and frequency are the same as thevoltage, phase, and frequency as specified on thewelder nameplate.
Use input wire sizes that meet local electrical codes orsee the Technical Specifications page in this manu-al.
Input power supply entry is through the hole in theCase Back Assembly. See Figure A.1 for the locationof the machineʼs input cable entry opening, InputContactor (CR1), and reconnect panel.
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses ordelay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machinebeing used. They are also called inverse time or ther-mal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a loweramp rating than recommended. This can result in“nuisance” tripping caused by inrush current evenwhen machine is not being used for welding at highoutput currents.
GROUND CONNECTION
Ground the frame of the machine. A ground terminal marked with the symbol ( ) is located insidethe case back of the machine near the input contactor.Access to the input box assembly is at the upper rearof the machine. See your local and national electricalcodes for proper grounding methods. Use groundingwire sizes that meet local electrical codes or see theTechnical Specifications page in this manual.
ELECTRIC SHOCK can kill.• Only qualified personnel should
perform this installation.• Turn the input power OFF at the discon-
nect switch or fuse box before working onthis equipment.
• Turn the Power switch on the DC-655“OFF” before connecting or disconnect-ing output cables, wire feeder or remoteconnections, or other equipment.
• Do not touch electrically hot parts.
• Always connect the Idealarc DC-655grounding terminal (located on the weldernear the reconnect panel) to a goodelectrical earth ground.
WARNINGINPUT POWER SUPPLYCABLE WITH BUSHINGOR BOX CONNECTOR
INPUTCONTACTOR (CR1)
RECONNECTPANEL ASSEMBLY
FIGURE A.1 ELECTRICAL INPUT CONNECTIONS
A-4INSTALLATION
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 diagram locatedon the inside the door. For multiple voltagemachines, follow the diagram for the voltage thatis within 10% of your actual input line voltage.
5. Connect the three-phase AC power supply leadsL1, L2, and L3 to the input contactorterminals in the input box assembly. See FigureA.1.
RECONNECT PROCEDURE
Electric Shock Can Kill• Disconnect input power before perform-
ing this procedure.
------------------------------------------------------------------------
Multiple voltage machines are shipped connected tothe highest input voltage listed on the machineʼs ratingplate. Before installing the machine, check that thereconnect panel in the input box assembly is connect-ed for the proper voltage.
Failure to follow these instructions can cause immedi-ate failure of components within the machine. Whenpowering welder from a generator be sure to turn offwelder first, before generator is shut down in order toprevent damage to welder. ------------------------------------------------------------------------To reconnect a multiple voltage machine to a differentvoltage, remove input power and refer to the inputconnection diagram located on the inside of case backinput access door. Follow the diagram for the voltagethat is within 10% of your actual input line voltage.
1. Figure A.2 shows a sample of the reconnectinstructions for a dual voltage machine.
CAUTION
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
H2GND 5. MOUNT THE LINKS IN THE POSITIONS SHOWN. CONNECT THE FLEX LEAD AS SHOWN;
LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.L1
LINES4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.
CODES.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS.
D-UF
INPUT 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 CONTROL TRANSFORMER
W CR1
V
L3
U
H3
CONTACTORL2L1
W
V
GND
CR1L3L2
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.
ALL OF THE HEX NUTS.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN; DOUBLE OR TRIPLE STACK THE LINKSIN THREE POSITIONS. LOOP THE FLEX LEAD IN THE POSITION SHOWN; POSITIONINGTHE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN
DUAL VOLTAGE MACHINEINPUT SUPPLY CONNECTION DIAGRAM
IMPORTANT: CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS.NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
Do not touch electrically live parts
Only qualified persons should install,use or service this equipment
Do not operate with coversremovedDisconnect input power before
LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
TRANSF.
CONTROL
TRANSF.
CONTROL
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 CONTROL TRANSFORMER
CONNECTION FOR HIGHEST RATING PLATE VOLTAGEservicing
M18225
INPUT
CONTACTOR
CONNECTION FOR LOWEST RATING PLATE VOLTAGE
H2H1
LINKS
LINES
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
LINKS
U
H1H3
WARNING
FIGURE A.2 Dual Voltage Machine Reconnection Procedure
A-5INSTALLATION
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 cables through the slotted strainreliefs of the base to the welding terminals.
LOW INDUCTANCE TERMINALOn the DC-655, the inside right Negative (-) outputterminal is lower choke inductance. This terminal ispresently only recommended for CV mode weldingwith NR203Ni 1% negative polarity procedures. Allother processes are to be welded using the outsideright Negative (-) output terminal with higher chokeinductance. CC mode processes must use highinductance.
For Positive Polarity:
1. Connect the work cable to the high inductance (-)terminal (marked " ").
2. Connect the electrode cable to the positive terminalmarked “+”.
3. Remove the terminal strip access cover panel onthe lower case front. Refer to figure A.3 for thelocation.
4. Work Sense lead #21 from the 14 Pin MS-recepta-cle must be connected to “-21”on the terminal strip.Note: This is how the DC-655 is shipped fromthe factory.
5. Replace the terminal strip access cover panel.
For Negative Polarity:
1. Connect the electrode cable to the appropriate highinductance (-) terminal (marked " ") orto the low inductance (-) terminal(marked " ") if using NR203Ni 1% elec-trode only.
2. Connect the work cable to the positive terminalmarked “+”.
3. Remove the terminal strip access cover panel onthe lower case front. Refer to figure A.3 for thelocation.
4. Work Sense lead #21 from the 14 Pin MS-recepta-cle must be connected to “+21”on the terminal strip.
5. Replace the terminal strip access cover panel.
TABLE A.1Cable Sizes for Combined Lengths of Copper
Electrode and Work Cable
Cable Lengthft. (m)
Parallel Cables Cable Size
0 (0) to 100 (30.4)100 (30.4) to 200 (60.8)200 (60.8) to 250 (76.2)
222
2/0 ( 70mm2)3/0 ( 95mm2)4/0 (120mm2)
POSITIVEOUTPUT TERMINAL
LOW INDUCTANCENEGATIVE OUTPUTTERMINAL
HIGH INDUCTANCENEGATIVE OUTPUTTERMINALTERMINAL STRIP
COVER PANEL
14 PIN MS RECEPTACLE
FIGURE A.3 Output Connections
A-6INSTALLATION
DC-655
A-6
FIGURE A.4 FRONT VIEW OF 14-PIN CONNECTORRECEPTACLE
PIN LEAD NO. FUNCTION
A 32 115 VACB GND Chassis ConnectionC 2 Trigger CircuitD 4 Trigger CircuitE 77 Output ControlF 76 Output ControlG 75 Output Control
H 21 Work Sense Connection2
I 41 42 VAC
J 31 115 VAC1.
K 42 42 VACL --- ---M --- ---N --- ---
F=76
G=75
H=21
I=41
J=31K=42
A=32
B=GND
C=2
D=4
E=77
L N
M
1.115VAC circuit is not present on IEC 974-1 European models.
2.As shipped from the factory Lead #21 from the 14 Pin connector isconnected to “-21” on the terminal strip. This is the configurationfor positive welding. If welding negative polarity, connect lead #21to the “+21” connection point on the terminal strip.
AUXILIARY POWER AND CONTROL CONNECTIONS
Located at the lower front of the welder behind ahinged door is a 115VAC duplex receptacle for auxil-iary power (Domestic and Canadian Models only) anda 14 Pin MS type receptacle for connection of auxil-iary equipment such as wire feeders. Also, terminalstrips with 115VAC and connections for auxiliaryequipment are located behind the access panel on thelower case of the welder. A 220VAC receptacle for awater cooler (European and Export Models only) islocated on the case back.
115VAC DUPLEX RECEPTACLE (DOMESTIC ANDCANADIAN MODELS ONLY)
The 115VAC duplex receptacle is protected by a cir-cuit breaker located below the receptacle (seeAuxiliary Power Table). Receptacle is a NEMA 5-20R(protected by a 20 amp breaker) on Domestic andCanadian Models, except Canadian Code 10502receptacle is a NEMA 5-15R, protected by a 15 ampbreaker.
220VAC RECEPTACLE (EUROPEAN AND EXPORTMODELS ONLY)
A Continental European receptacle is located on therear panel for supplying 220VAC to a water cooler.The receptacle has a protective cover to prevent inci-dently contact and is a Schuko type. The circuit is pro-tected by a 2 amp circuit breaker also located on therear panel. This circuit is electrically isolated from allother circuits, but on the European Models one line isconnected to chassis ground.
AUXILIARY POWER TABLEVoltage and Circuit Breaker Ratings at Auxiliary Power
Connections for Various ModelsAuxiliary Domestic Canadian European ExportPower Models Model Models Models
Connections (60Hz) (230/460/575V/60 Hz) (50/60 Hz) (50/60 Hz)
(Code 10502) (Code 11300) At Duplex 115V 20A 115V 15A 115V 20A No Duplex No DuplexReceptacle
Terminal strip 115V 20A 115V 15A 115V 20A 115V 15A 115V 15Aterminals 31 & 32
MS-Receptacle 115V 20A 115V 15A 115V 20A Open Circuit 115V 15Apins A & J
MS-Receptacle 42V 10A 42V 10A 42V 10A 42V 10Apins I & K
At 220V No Receptacle No Receptacle 220V 2A 220V 2AReceptacle
14 PIN MS TYPE RECEPTACLE(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
Refer to the figure A.4 for the available circuits in the14 pin receptacle.
42 VAC is available at receptacle pins I and K.A 10 amp circuit breaker protects this circuit.
115 VAC is available at receptacle pins A and J(Domestic, Canadian and Export Models). This circuitis protected by a circuit breaker (see Auxiliary PowerTable). Note that the 42 VAC and 115 VAC circuitsare electrically isolated from each other. However, onthe European model one line of the 115VAC is con-nected to chassis ground.
A-7INSTALLATION
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 shown inthe following Terminal Strip charts. See AuxiliaryPower Table for rating of circuit breaker in 115VACcircuit. Remove a plug button from the terminal stripcover and install an appropriate strain relief clamp forthe cable being used. NOTE: There are two worksense lead connection points on the terminal strip.Connect both the work sense lead #21 from the 14 pinconnector and #21 lead of the control cable to “-21”when welding positive polarity or to “+21” when weld-ing negative polarity.
TERMINAL STRIP 1 (T.S.1)
TERMINAL STRIP 2 (T.S.2)
Lead No. Function
75 Output Control76 Output Control77 Output Control
1.115VAC circuit is also present on IEC 974-1 European models.
2.If connecting a feeder cable directly to the terminal strip, Lead #21from the cable is connected to “-21” on the terminal strip for posi-tive welding. If welding negative polarity, connect lead #21 to the“+21” connection point on the terminal strip.
Lead No. Function
+21 Work Connection -21 Work Connection2
41 42 VAC 4 Trigger Circuit 2 Trigger Circuit 31 115 VAC1
32 115 VAC1
B-1OPERATIONB-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 ratedCanadian - 230/460/575v 60 Hertz
NEMA Class 1 ratedEuropean - 50/60 Hertz models “CE” qualified andrated for IEC 974-1Export - 50/60 Hertz models NEMA Class 1 rated
RECOMMENDED PROCESSES ANDEQUIPMENT
The DC-655 is designed for CV or CC processes.
CV processes include: GMAW (MIG) and FCAW (flux-cored) welding, plus the capability of CV submergedarc welding and air carbon arc gouging. It producesoutstanding welding performance with a single rangefull output control knob.
CC processes include stick welding, CC submergedarc and superior air carbon arc gouging with up to 3/8”(10 mm) diameter carbons. The same single range fulloutput control knob is used and paralleling capabilityis provided.
The DC-655 is recommended for use with LincolnʼsDH-10 or LN-10 as well as the LN-7*, LN-7 GMA*,LN-15, LN-742, LN-8*, LN-9*, LN-9 GMA*, LN-23P andLN-25 semiautomatic wire feeders. It is also recom-mended for use with the NA-3, NA-5 and NA-5R auto-matic feeders. “Cold starting” for sub-arc or acrossarc “touch-sensing” can be used.
* The 14-pin MS receptacle on the European mod-els does not provide 115 VAC for these feeders; 115VAC must be obtained from terminal strip.
Two DC-655ʼs may be paralleled in a “master” and“slave” interconnection using the K1611-1 Parallelingkit.
DC-655
ELECTRIC SHOCKcan kill.
• Do not touch electrically live partsor electrode with skin or wetclothing.
• Insulate yourself from work andground.
• Always wear dry insulating gloves.
FUMES AND GASEScan be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust toremove fumes from breathingzone.
WELDING SPARKScan cause fire orexplosion
• Keep flammable material away.
• Do not weld on containers thathave held combustibles.
ARC RAYScan burn.
• Wear eye, ear and bodyprotection.
SAFETY PRECAUTIONS
Read and understand this entire section before oper-ating the machine.
GENERAL WARNINGS
Observe additional Safety Guidelines detailedthroughout this manual.
WARNING
B-2OPERATIONB-2
DESIGN FEATURES AND ADVANTAGES
• Separate output terminals for selecting high or lowinductance as recommended for the weldingprocess.
• Power on/off switch with pilot light and thermostattripped indicator light.
• Full range output voltage (CV mode) and current(CC mode) control for easy operation.
• Panel switches behind a latched front panel forremote or local output control, output on or remoteselection, and CC, CV Sub-arc or CV MIG modeselection.
• Panel knob settable CC arc force control with built-inadjustable “Hot Start”.
• High efficiency output, and selectable “sleep mode”idle mode timer which shuts down input power if notused for extra energy conservation.
• Fan as needed (F.A.N.). Solid state thermally con-trolled fan operates cooling fan only when required.Minimizes power consumption, operating noise anddust intake.
• Hinged cover to protect output terminals and auxil-iary connections.
• Electronic and thermostatic protection for currentoverload and excessive temperatures.
• 42 VAC, 10 amp auxiliary power available for thewire feeder; circuit breaker protected.
• 115 VAC, auxiliary power protected by a 20 ampbreaker available for the wire feeder. Canadian Code10502, European, and Export Models protected by15 amp breaker.
• 115 VAC duplex receptacle protected by 20 ampbreaker is available on Domestic and CanadianModels, except for Canadian Code 10502 receptaclethat is a NEMA 5-15R, protected by a 15 amp break-er.
• 220 VAC receptacle on European and Export mod-els for connecting to a water cooler. Protected by 2amp breaker.
• Single MS-type (14-pin) connection for wire feeder.
• Optional Field Installed Digital or AnalogVoltmeter/Ammeter kits are available.
• Optional dual feeder kit for like polarity connection oftwo wire feeders. Easy panel installation.
• Optional Dual Process Switch for two processes withpolarity change and electrical isolation.
WELDING CAPABILITY
The DC-655 has the following Output and Duty Cyclebased on operation for a 10 minute period:
650 Amps, 44 Volts at 100%815 Amps, 44 Volts at 60%
DC-655
B-3OPERATIONB-3
1. INPUT POWER ON/OFF SWITCH - This tog-gle switch turns the machine on or off. Putting theswitch in the ON posit ion energizes themachineʼs input contactor applying input power tothe machine. Switching the switch to theOFF position de-energizes the input contactor.This switch is also used to reset a machine shut-down. (See Machine Shutdown section)
2. PILOT LIGHT - When the power switch is in theON position the machineʼs white pilot light will illu-minate. If the input contactor de-energizes themachine in a shutdown situation the pilot will stillilluminate. In this situation it will be necessary toreset the machine by switching the power switch tothe OFF then ON posit ion. (See MachineShutdown section)
3. OUTPUT CONTROL - This control providescontinuous control of the machineʼs output fromminimum to maximum as it is rotated clockwise.The CV mode voltage range of control is 13 to 44V.The CC mode current range of control is 50 to815A.
4. OUTPUT TERMINALS ON/REMOTE - When thisswitch is in the REMOTE position, the DC-655ʼsoutput terminals will be electrically “cold” until a
remote device such as a wire feeder closes the #2and #4 circuit in the MS-receptacle or terminal strip.When this switch is in the ON posit ion themachineʼs output terminals will be electrically ener-gized all the time.
5. LOCAL/REMOTE CONTROL SWITCH - When thisswitch is set to the LOCAL position, control ofthe output voltage is via the output control on theDC-655ʼs control panel. When this switch is set tothe REMOTE position, control is through aremote source such as a wire feeder via the #75,#76, and #77 leads in the MS-receptacle or terminalstrip.
6. CC STICK/CV SUBARC/CV MIG MODE SWITCH -This switch selects the proper welding characteris-tics for the process being used:
CC Stick provides a constant current outputcharacteristic through the 50 to 815 amp range.The current is adjusted within this range by theOutput Control dial. The open circuit (no load)voltage will be about 68 volts in this mode.
DC-655
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the DC-655. Refer to Figures B.1, and B.2and corresponding explanations.
FIGURE B.1 CONTROL PANEL CONTROLS
DC-655
54
8
1
923
67
B-4OPERATIONB-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 toWelding Performance Section.
CV MIG provides a constant voltage outputcharacteristic through the 13 to 44 volt range.The voltage is adjusted within this range by theOutput Control dial.
The dynamic characteristics of this mode areideal for open arc processes including,MIG/MAG (GMAW), Innershield®, and othercored wire (FCAW) processes. Faster travelsubmerged arc processes and CV air carbon-arc gouging may also use this mode. Refer tothe Welding Performance Section.
CV Sub-Arc provides the same constant voltageoutput control range as CV MIG, but the dynam-ic characteristics of this mode make possibleimproved CV (constant wire speed) submergedarc welding. This improved process is mostnoticeable on high deposition slow travel speedwelds. Fast travel, narrow bead subarc weldswill have better performance in CV MIG mode.
7. ARC FORCE CONTROL - This control is only func-tional in CC Stick mode. It prevents “stubbing” ofthe electrode by providing the extra weld currentthat linearly increases as the welding voltagedecreases below a level determined by the settingof the constant current control.
The Arc Force control knob, located behind thelatched cover, adjusts arc force from “Min” (no cur-rent increase) to “Max” (higher short circuit current).“Mid” position (#5) is recommended for most CCwelding. Refer to the Welding PerformanceSection.
8. OPTIONAL VOLTMETER & AMMETER - Digitalor analog meter kits are available as field installedoptions. Refer to the Accessories Section of thismanual.
9. THERMAL PROTECTION LIGHT - If themachine overheats due to lack of proper air flowthrough the machine or due to exceeding themachineʼs duty cycle, thermostats will disable thewelding output and this light will illuminate. Inputpower is still applied to the machine and the coolingfan will continue to run. When the machine coolsthe welding output will resume.
DC-655
1. 115VAC DUPLEX RECEPTACLE (Domestic andCanadian Models) This receptacle provides up to20 amps of 115 VAC auxil iary power on theDomestic and Canadian Models, except CanadianModel (Code 10502) is 15 amps 115 VAC.
2. 115VAC CIRCUIT BREAKER - This breakerprotects the 115 VAC auxiliary circuits located inthe duplex receptacle, terminal strip and MS- recep-tacle. Breaker is rated 20 amps on Domestic andCanadian Models, except Canadian Model (Code10502) and all other models are 15 amps.
FIGURE B.2 LOWER CASE FRONT CONTROLS & CONNECTIONS
76 5
431 2
B-5OPERATIONB-5
DC-655
3. 42VAC 10 AMP CIRCUIT BREAKER - Thisbreaker 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 power,output switching, remote output control, wire feedervoltmeter sense lead and ground. Refer to 14 PinMS Type Receptacle in the Installation Section ofthis manual for information about the circuits madeavailable at this receptacle.
5. TERMINAL STRIP COVER PANEL - Remove thispanel to gain access to the circuits made availableat the terminal strip and the 4-pin receptacle for theoptional paralleling kit. This terminal strip containsthe same circuits as the 14 pin MS-receptacle. Thecover also provides for installation of cable strainrelief clamps.
6. POSITIVE OUTPUT TERMINAL - This output ter-minal is for connecting a welding cable. To changewelding polarity and for proper welding cable sizerefer to Electrode and Work Cables in theInstallation Section of this manual.
7. NEGATIVE OUTPUT TERMINALS - These outputterminals are for connecting a welding cable toeither the High Inductance or Low InductanceTerminal for desired arc characteristics. (Low induc-tance is recommended only for NR203Ni 1%). Tochange welding polarity and for proper weldingcable size refer to Electrode and Work Cables inthe Installation Section of this manual.
CASE BACK CONNECTIONS
220VAC AUXILIARY RECEPTACLE(European and Export Models)This receptacle provides up to 2 amps of 220VACauxiliary power for a water cooler.
220VAC 2 AMP CIRCUIT BREAKER(European and Export Models)This breaker protects the 220VAC auxiliary circuitlocated in the 220VAC receptacle.
AUXILIARY POWER
42 volt AC auxiliary power, as required for some wirefeeders, is available through the wire feeder recepta-cle. A 10 amp circuit breaker protects the 42 volt cir-cuit from overloads.
DC-655 machines can also supply 115 volt AC auxil-iary power through the wire feeder receptacle. A 20amp circuit breaker on the Domestic and Canadianmodels, except for a 15 amp on Canadian Code10502 and Export models protects the 115 volt circuitfrom overloads. 115VAC is not available in the MS-receptacle on the European models.
Note that some types of equipment, especially pumpsand large motors, have starting currents which aresignificantly higher than their running current. Thesehigher starting currents may cause the circuit breakerto open. If this situation occurs, the user should refrainfrom using the DC-655 auxiliary power for that equip-ment.___________________________________________
MACHINE PROTECTION
THERMAL FAN CONTROL
The machineʼs cooling fan remains off when the tem-perature of the rectifiers and windings inside themachine are below that requiring air flow cooling, asdetermined by electronic monitoring of several thermalsensors and the welding current of the machine. Thefan may remain off until welding begins, but once thefan is activated, it will remain on for at least 5 minutesto assure proper cooling. This feature saves energyand also minimizes the amount of dirt and other airborne particles being drawn into the machine.
FAN MOTOR FUSE (EUROPEAN MODEL)
A 10 amp slow blow fuse protects the fan motor cir-cuit. This fuse is located inside the DC-655 mountedon the fan motor bracket.
MACHINE SHUTDOWN
The DC-655 provides shutdown modes for thermalover-heating, excessive load currents and faults. Italso provides an idle timer shutdown feature for addi-tional operating economy.
CAUTION
B-6OPERATIONB-6
DC-655
THERMAL SHUTDOWNThis 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 illumination ofthe yellow Thermostatic Protection Light on the casefront (see figure B.1). The fan will continue to run tocool the power source. No welding is possible until themachine is allowed to cool and the ThermostaticProtection Light goes out.
OVER CURRENT PROTECTIONSHUTDOWN
Average Current ShutdownTo protect the SCRʼs , the DC-655 will shut down toessentially no output if the output current averagesover 900 amps for about 5-6 seconds, and in lessthan 0.3 seconds if averaging over 1200 amps (short-er time for higher current). Control PC board LED4,shutdown light, will turn on.
This average current shut down can only be reset byopening the feeder gun trigger, or switching the DC-655 Output/Remote switch out of the “on” position.
Peak Current ShutdownTo protect the SCR;s, the DC-655 will shut downimmediately to essentially no output if the peak outputcurrent exceeds 2500 amps (about 1800A average).Control PC board LED4, shutdown light, will turn on.
This peak current shut down can be reset by turningthe DC-655 input power off, then on.
REMOTE CONTROL LEADS FAULT PROTECTION SHUTDOWNThe remote control leads from the 14-pin receptacleor terminal strip are protected against high voltagefaults to the electrode circuit or auxiliary voltage sup-plies. If such a fault occurs the DC-655 will shut downthe input primary voltage to the transformer to preventthe fault output. Control PC board LED3, input shut-down light, turns on.
If this input shutdown occurs the input power pilot light remains lit, since the power switch is ON and controlpower is still present. Welding output or auxiliary sup-ply output will not be present
This input shut down is reset by turning the DC-655input power off, then on. If the fault is not correctedhowever, the shutdown will re-occur when turning onthe input power.
SHORTED RECTIFIER FAULT PROTECTIONIf a short occurs across one of the silicon controlledrectifiers of the DC-655, a potentially hazardous ACvoltage could appear across the welding output termi-nals, even in idle mode when no output should be pre-sent. If such a fault occurs the DC-655 will shut downthe input primary voltage to the transformer to preventthe fault output. Control PC board LED3, input shut-down light, turns on.
If this input shutdown occurs the input power pilot light remains lit, since the power switch is ON and controlpower is still present. Welding output or auxiliary sup-ply output will not be present
This input shut down is reset by turning the DC-655input power off, then on. If the fault is not correctedhowever, the shutdown will re-occur when turning onthe input power.
IDLE SHUT DOWN TIMERFor additional operating economy, the DC-655 can beset up to automatically shut off the primary inputpower to the main transformer after a selectable time(1/2 or 2 hr.) has expired without welding. The unex-pired timer is reset with each weld.
The idle mode timer is activated by setting Switch #1(left most) of the DIP Switch located on the lower-cen-ter of the DC-655 Control PC board. from the down(Off) position to the up (On) position. Setting Switch#2 of the DIP switch to up (On) sets the shutdowntime to 2 hours. Setting Switch #2 of the DIP switch todown (Off) sets the shutdown time to 1/2 hour. Shutdown is reset by turning the DC-655 input power off,then on.
WELDING PERFORMANCE
LOW INDUCTANCE TERMINALThe inside right Negative (-) terminal is lower chokeinductance and presently is only recommended forwelding with NR203Ni 1% procedures. All otherprocesses are to be welded using the outside rightNegative (-) terminal with higher choke inductance.
1 2 3 4
Switch #2 Time selection(UP=2 hours, Down=1/2 hour)
Switch #1 Timer On/Off(UP=ON, Down=OFF)
DIP Switch
See Weld Performance section for use of switch #3 and #4.
Note:
B-7OPERATIONB-7
CV MODE CURRENT-LIMITINGCV 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 DC-655 is set for “Hi” current limiting,which maintains constant voltage until the weldingcurrent exceeds a level proportional to the voltage set-ting, then falls off linearly at about 10 volts per 100amps to a limited short circuit current. “Lo” currentlimiting provides the same short circuit current, but thearc voltage begins to linearly fall off at lower current,at about 5 volts per 100 amps.
“Hi” is recommended for all CV processes, especiallyfor CV subarc and CV arc gouging, but “Lo” tends to“soften” the arc more when welding NR203Ni 1% onthe Low Inductance (-) terminal. If “Lo” is desired,switch #4(right-most) of the DIP switch located on thelower-center of the DC-655 Control PC board needsto be switched from up (Hi) position to down (Lo) posi-tion.
CC MODE ARC FORCEArc Force provides extra weld current which linearlyincreases as the welding voltage decreases below alevel determined by the constant current setting. TheArc Force control knob, located behind the latchedcover, adjust Arc Force from “Min” (no currentincrease) to “Max” (about 9A/V increase).
A general guideline for CC welding is to set Arc Forceto “Mid” position (#5) and increase (typically no morethan to #7) as necessary to prevent “stubbing” or“pop-outs” while welding. This higher Arc Force is rec-commended especially for low end 6010 stick welding.
CC MODE HOT STARTHot start is built-in for CC mode stick and carbon arcstarting. Hot Start provides an extra weld current“boost” at the arc strike which increases with highercurrent settings. This Hot Start level exponentiallydecays to the weld current setting in a few seconds.
Adjustment of the Hot Start shouldnʼt be necessary,but an unsealed trimmer (R81) is provided on the DC-655 Control PC Board to adjust hot start. Full counter-clockwise adjustment will reduce Hot Start to zero
CC MODE ARC GOUGING
The DC-655 is rated for air carbon arc gouging withup to 3/8” (10mm) diameter carbons. CC mode goug-ing is often preferred over CV mode for cutting control,but some Arc Force may be required to avoid carbonstubbing.
DC-655
VOLTS
AMPSCV OUTPUT
"HI" Current Limit
"Lo" Current Limit
HighSetting
LowSetting
VOLTS
AMPS
CC OUTPUT
Min. Arc Force
Hot Start
OCV
LowSetting
HiSetting
Max. Arc Force
1 2 3 4
Switch #4 "Hi"CV Current Limit (as shown)
Switch #3 is for testpurposes and is to be downDIP Switch
See Machine Shutdown section for use of switch #1 and #2.
Note:
CC Hot StartTrimmer
DC-655 Control PC Board
C-1ACCESSORIESC-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 models only provide 115VAC for these feeders at theterminal strip (TS2)
FIELD INSTALLED OPTIONS
K1482-1 Digital Ammeter/Voltmeter Kit - Installseasily to the front control panel and provides digitaldisplay of actual welding voltage and amperage whilewelding. (Installation instructions are included with thekit).
K1483-1 Analog Ammeter/Voltmeter Kit - Installseasily to the front control panel and provides analogdisplay of actual welding voltage and amperage whilewelding. (Installation instructions are included with thekit).
K1484-1 Dual Feeder Kit - This kit replaces the 14Pin MS-receptacle panel on the lower case front of theDC-655. It provides two 14 Pin MS-receptacles and abuilt in transfer circuit for connecting and operatingtwo like-polarity wire feeders. European DC-655 mod-els can only use 42V feeders with this kit. (Installationinstructions are included with the kit).
K1485-1 Cable Hanger Bracket - Mounts over stan-dard lift bale of the DC-655 and provides a cablehanger on both sides of the power source, each sidecapable of holding up to 100 ft. of weld cable.(Installation instructions are included with the kit).
K1486-1 Air Filter Kit - Removable metal filter easilyslides in and out of a bracket which mounts to thefront of the DC-655. Filter is designed to trap 80% ofentering particles which are 5 microns, or larger, insize. (Installation instructions are included with thekit). Cannot be used with K1528-1 Dual processswitch.
NOTE: A dirty air filter may cause the thermal protec-tion of the DC-655 to prematurely activate. Removeand blow out, or wash and dry, the filter every twomonths, or less if in extremely dirty conditions.Replace if necessary.
Undercarriage (K817P, K842) - The DC-655 isdesigned for use with the Lincoln K817P or K842Undercarriage. Complete installation instructions areincluded with each undercarriage. When any of theundercarriages are installed, the DC-655 lift bail is nolonger functional. Do not attempt to lift the machinewith the undercarriage attached. The undercarriage isdesigned for moving the machine by hand only.Mechanized towing can lead to injury and /or damageto the DC-655.
REMOTE OUTPUT CONTROL(K775 or K857 WITH K864 ADAPTER)
An optional “remote output control” is available. This isthe same remote control that is used on other Lincolnpower sources (K775). The K775 consists of a controlbox with 28 ft (8.5m) of four conductor cable. This con-nects to terminals 75, 76, and 77 on the terminal stripand the case grounding screw so marked with the sym-bol on the machine. These terminals are locatedbehind the cover panel on the lower connection panel ofthe DC-655. This control will give the same control asthe output control on the machine.
The K857 has a 6-pin MS-style connector. The K857requires a K864 adapter cable which connects to the14-pin connector on the DC-655.
REMOTE CONTROL ADAPTER CABLE (K864)
A “V” cable 12” (.30m) long to connect a K857Remote Control (6 pin connector) with a wire-feeder(14-pin connector) and the machine (14-pin connec-tor). If a remote control is used alone the wire-feederconnection is then not used.
DC-655
STRA IGHT PLUG (14 P IN )TO POWER SOURCE
CABLE RECEPTACLE (6 SOCKET )
CABLE RECEPTACLE (14 SOCKET )
TO : K857 REMOTE CONTROL
TO: LN-7 WIRE FEEDERS
C-2ACCESSORIESC-2
K1528-1 Dual Process Switch - (Cannot be usedwith K1486-1 Air Filter Kit) The Dual-Process Switchmounts easily to the front of the machine and isdesigned to provide a selection between left and rightside output terminals. Each pair of output terminalscan be switched to either the DC-655, high or lowinductance terminals as desired. Wire feed unit cablesand air carbon arc cables can be connected to eitheror both sides of the box and with proper connectioncan provide polarity change with just a switch change.Selecting one side only energizes those output studsand opens the other side. Installation instructions areincluded with the switch.)
K1611-1 Paralleling Kit - Provides interconnection oftwo DC-655 machines in parallel for doubling the cur-rent capacity of one machine. This “master” and“slave” connection configuration allows the “master” tocontrol the balanced output of both machines.Individual protection circuits of both machines functionnormally. (Installation instructions are included withthe switch.)
DC-655
D-1MAINTENANCED-1
DC-655
SAFETY PRECAUTIONS
GENERAL MAINTENANCE
1. The fan motor has sealed bearings which requireno service.
2. In extremely dusty locations, dirt may restrict thecooling air causing the welder to run hot with pre-mature tripping of thermal protection. Blow out thewelder with low pressure air at regular intervals toeliminate excessive dirt and dust build-up on inter-nal parts.
3. Periodically check the welding cables. Inspect forany slits or punctures. Also make sure that all con-nections are tight.
ELECTRIC SHOCK can kill.
• Only qualified personnel shouldperform this maintenance.
• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on thisequipment.
• Do not touch electrically hot parts.
WARNING
E-1TROUBLESHOOTINGE-1
DC-655
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WARNING
E-2TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Input contactor (CR1) chatters.
Machine input contactor does notoperate.
Machine input contactor operates,but no output when trying to weld.
1. Faulty input contactor (CR1).
2. Low line voltage.
If Power Pilot light is off:1. Make sure the proper three-
phase input power is applied tothe DC-655 machine.
2. The power switch (SW1) may befaulty.
3. The pilot transformer may befaulty.
If Power Pilot light is on:1. The input contactor may be
faulty.
2. Input shutdown may be activated(LED3 on on Control Board). SeeShorted Rectifier FaultProtection in Operation Section.
1. Electrode or work cables may beloose or broken.
2. Firing P.C. board is not connectedor is faulty. See PC board LEDinformation.
3. Trigger circuit may not be working.Place Output Terminals Switch tothe ON position, or place a jumperwire across #2 and #4 on the ter-minal strip. If output is enabledthen check control cable to feederif connected.
4. If the thermal protection light isON the machine is overheated.Make sure the fan is operatingand remove the cause of theoverheating problem.
Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.
E-3TROUBLESHOOTINGE-3
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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Machine has output, but no control.
Machine does not have maximumoutput.
Poor arc striking with semiautomaticor automatic wire feeders.
1. Check the Local/Remote outputswitch (SW3) and associatedleads. See wiring diagram.
2. Make sure the remote controlleads #75, #76 and /or #77 areNOT grounded to either weldingoutput.
3. Make sure control cable to feeder(if used) is connected properly.
4. The output control potentiometermay be faulty.
5. Control board transformer may befaulty
6. The control or firing board maybe faulty.
1. Make sure the correct three-phase input is applied to the DC-655 machine.
2. The output control potentiometermay be faulty.
3. The control or firing board maybe faulty.
1. Make sure the mode switch is inthe proper position for theprocess.
2. Make sure the welding cablesand connections are secure.
3. Check for correct welding proce-dures.
Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.
E-4TROUBLESHOOTINGE-4
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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Variable or sluggish welding arc.
Output Control Pot not functioning in“Local” control only.
No output control in “Remote” controlonly.
1. Make sure the mode switch is inthe proper position for theprocess.
2. Make sure the welding cables aresized correctly and the connec-tions are tight.
3. Make sure the welding proce-dures are correct.
1. Check the Local/Remote control switch and associated leads.See wiring diagram.
2. The machine output controlpotentiometer may be faulty.Also check associated leads.See wiring diagram.
1. Output Control Switch in wrongposition.
2. Faulty Output Control Switch.
3. Faulty Remote Control Pot.
4. Leads or connections open in con-trol circuit. (#75, #76, #77)
Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.
E-5TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Machine will not weld. OCV is lessthan 1 volt.
The wire feeder will not come on.
1. The machine may be in a over-load condition. Refer to MachineProtection in the operation sec-tion.
2. See the PC board LED informa-tion.
1. Either the 42VAC or the 115VACcircuit breakers may be tripped.Reset if necessary.
2. Check for the presence of therequired voltage to operate thewire feeder.
3. The control cable or wire feedermay be faulty.
Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.
E-6TROUBLESHOOTINGE-6
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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Poor arc characteristics.
115VAC receptacle not working.
1. The negative welding cable maybe connected to the wrong induc-tance tap.
2. Make sure the mode switch is inthe proper position for theprocess.
3. The control board may be faulty.See PC board LED information.
1. Check the 115VAC circuit break-er. Reset if necessary. Makesure the load on the receptacledoes not exceed the rating of the115VAC breaker. See wiring dia-gram.
Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.
E-7TROUBLESHOOTINGE-7
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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Thermal Protection Light comes ONand fan does not run.
NOTE: Fan is thermal controlled anddoes not continuously run whenmachine is powered up.
Fan runs continuously.
One or both Digital Meters not light-ing.
Digital Voltmeter not working proper-ly or erratic display.
1. Check for obstructions that couldprevent the fan from turning.
2. Check the fan control circuit. Seewiring diagram.
3. The fan motor may be faulty.
4. The Thermal Fan/Snubber PCboard may be faulty. See PCboard LED information.
1. The Thermal Fan Thermistor maybe faulty. See wiring diagram.
2. The Thermal Fan/Snubber PCboard may be faulty. See PCboard LED information.
1. The meters may not be receivingthe voltages from the auxiliarytransformer. Check plug P13.See wiring diagram.
2. The Digital meter PC board maybe faulty.
1. Meter may not be receiving auxil-iary or sensing voltages. Makesure plug P12 & P13 are securelyplugged into the Digital meter PCboard and also plug P3 is securelyplugged into the control board.
2. The may be an open in the volt-age feedback circuit. See wiringdiagram.
3. The Digital meter PC board maybe faulty.
Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.
E-8TROUBLESHOOTINGE-8
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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Digital Ammeter not working properlyor erratic display.
Analog Meters not reading, or notreading correctly.
220VAC receptacle not working. (50/60 Hz Europe and Export mod-els only)
1. The meter PC board may not bereceiving the auxiliary or sensingvoltages. Check plug P3 andplugs P12 & P13. See wiringdiagram.
2. The current feedback circuit maybe faulty. From the shunt to thecontrol board. See wiring dia-gram.
3. The Digital meter PC board maybe faulty.
1. The meters may not be receivingvoltage or current feedback sig-nals. Make sure plug P3 issecurely plugged in the controlboard and plug J14 (in-line con-nector) is securely seated in theplug assembly from the controlboard.
2. Check the current feedback andvoltage feedback circuits. Seewiring diagram.
3. The meter(s) may be defective.
1. Check the circuit breaker. Resetif necessary.
2. Check for broken or loose con-nections in the 220VAC circuit.See wiring diagram.
Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.
E-9TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PC BOARD TROUBLESHOOTING GUIDE - FIRING P.C. BOARD1. All 10 LEDʼs must be ON when the POWER SOURCE is turned ON and the wire feederʼs trigger is closed, or
a jumper is placed between 2 & 4, or the “OUTPUT TERMINALS SWITCH” is in the ON position.2. LEDʼs 7, 8, and 9 indicate AC power being supplied to the P.C. board from auxiliary windings (T1). If a light is
not on, turn the machine off and unplug P5 from the firing board. Turn the machine back on and check the fol-lowing voltages:
Light that was off Check AC voltage between Voltage should be approximately7 P5 pins 15 & 16 (wires 230,204) 32VAC8 P5 pins 7 & 8 (wires 205,206) 32VAC9 P5 pins 5 & 6 (wires 207,208) 32VAC
3. If all voltages are present, turn power off, and plug P5 back into J5. Turn power back on. If LEDʼs are still out,replace firing PCB.
4. If voltages were not present then check the wiring back to the auxiliary windings for a possible open.5. LEDʼs 1 through 6 indicate gate signals are being sent to the main SCRʼs 1 through 6 respectively If LED5 is
on (CONTROL BOARD), along with LED7, 8, and 9 on firing PCB, and LEDʼs 1 through 6 are not on, check tomake sure lead 231 between control board and firing board is not broken.
6. If any one of LED 1 through 6 are not on and LEDʼs 7,8, and 9 are on, replace the firing PCB.
PC BOARD TROUBLESHOOTING GUIDE - CONTROL P.C. BOARD
1. LED1 indicates that the CC mode switch is closed. When the CC mode switch closed LED6 should also illu-minate. See LED6.
2. LED2 indicates that there is feedback voltage present in CV mode.3. LED3 indicate an input shutdown. Refer to Remote Control Leads Fault Protection Shutdown and
Shorted Rectifier Fault Protection or Idle Shut Down Timer in the Operation section.4. LED4 indicates an over current fault shutdown. Refer to Overcurrent Protection Shutdown in the
Operation Section.5. LED5 Indicates Output Current should be present.6. LED6 indicates that the machine is in CC mode. This LED should light whenever LED1 lights. If not the
Control PC Board may be faulty.7. LED7 +16V power supply8. LED8 indicates the Control PC Board is signalling the Firing PC Board to fire the SCRs.9. LED9 -10V power supply10. LED10 indicates that 42V input is present to the Control PC Board11. LED11 indicates that there is feedback voltage present in CC mode.
E-10TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PC BOARD TROUBLESHOOTING GUIDE - THERMAL FAN/ SNUBBER P.C.BOARD
NOTE: Fan will run for minimum of 5 minutes once fan turns on.
1. LED1 when ON indicates fan should be running. If ON and machine is cold, replace PCB.2. LED2 when ON indicates welding current greater than 50 amps. If ON and not drawing more than 40 amps,
replace PCB. 3. LED3 when ON indicates Main SCRʼS need cooling and turns fan ON. If ON and machine is cold, replace
PCB.4. LED4 when ON indicates an open Thermal Fan Thermistor, or open connection to PCB. Fan will run constant-
ly. Check Thermal Fan Thermistor for an open. If open replace. If not open Replace PCB.5. LED5 when ON indicates an open thermostat. Thermal Protection light should also be ON. If Thermal
Protection light is not ON, and LED5 is ON, replace PCB.6. LED6 when ON indicates fan should be running. LED6 will be ON whenever LEDʼs 2, 3 4 or 5 is ON. If LEDʼs
2, 3, 4, or 5 are not ON when LED6 is ON, replace PCB.
F-1DIAGRAMS
DC-655
F-1
N.C
. Ta
pe u
p bo
lted
conn
ectio
n if
lead
#21
is e
xten
ded.
N.D
. Co
nnec
t the
con
trol c
able
gro
und
lead
to th
e fra
me
term
inal
mar
ked
nea
r the
pow
er s
ourc
e te
rmin
al s
trip.
The
pow
er
s
ourc
e gr
ound
ing
term
inal
(mar
ked
and
loca
ted
near
the
pow
er
s
ourc
e in
put p
ower
con
nect
ions
) mus
t be
prop
erly
conn
ecte
d to
ele
ctric
al g
roun
d pe
r the
pow
er s
ourc
e op
erat
ing
man
ual.
N.E
. If
an o
ptio
nal r
emot
e vo
ltage
con
trol i
s us
ed, c
onne
ct it
to
this
term
inal s
trip.
N.
A. W
eldi
ng c
able
s m
ust b
e of
pro
per c
apac
ity fo
r the
cur
rent
and
du
ty c
ycle
of i
mm
edia
te a
nd fu
ture
app
licat
ions
. Se
e LN
-7
Ope
ratin
g M
anua
l for
pro
per s
izes.
N.
B. I
f LN-
7 is
equi
pped
with
a m
eter
kit,
ext
end
LN-7
con
trol c
able
su
itabl
e fo
r the
inst
alla
tion.
An
S165
86-[L
ENG
TH] r
emot
e
volta
ge s
ensin
g w
ork
lead
may
be
orde
red
for t
his
purp
ose.
Co
nnec
t it d
irect
ly to
the
wor
k pi
ece
inde
pend
ent o
f the
wel
ding
w
ork
cabl
e co
nnec
tion.
For
con
veni
ence
, thi
s ex
tend
ed #
21 le
ad
shou
ld b
e ta
ped
to th
e w
eldi
ng w
ork
lead
. (If
the
leng
th o
f
wel
ding
wor
k ca
ble
is sh
ort,
less
than
25
feet
, and
con
nect
ions
ca
n be
exp
ecte
d to
be
relia
ble,
then
con
trol c
able
lead
#21
doe
s
not n
eed
to b
e ex
tend
ed a
nd c
an b
e di
rect
ly co
nnec
ted
to
term
inal
#21
on
the
term
inal
stri
p. N
ote
that
this
is no
t the
pr
efer
red
conn
ectio
n be
caus
e it
adds
erro
r to
the
LN-7
vol
tmet
er
Abo
ve d
iagra
m sh
ows e
lectro
de co
nnec
ted p
ositiv
e. T
o ch
ange
pola
rity,
turn
pow
er o
ff, re
verse
the e
lectro
de an
d wo
rk lea
ds at
the p
ower
414
231
3275
7677
NEG
ATIV
EPO
SITI
VE
32 31 2 4 GND 21
N.A.
N.D.
ELEC
TRO
DE
CAB
LETO
WIR
E FE
ED U
NIT
TO W
OR
K
POW
ER S
OU
RC
E
N.E.
N.F
.
re
adin
g.)
N.F
. If
lead
#21
is to
be
conn
ecte
d to
the
term
inal s
trip,
con
nect
to th
e #2
1 te
rmina
l tha
t mat
ches
work
pol
arity
. Th
is c
onne
ctio
n m
ust b
e ch
ange
d wh
enev
er th
e ele
ctro
de p
olar
ity is
ch
ange
d.
Only
quali
fied p
erson
s sho
uld in
stall,
use o
rse
rvice
this
mach
ine.
Do no
t ope
rate w
ith co
vers
remov
ed.
Disco
nnec
t pow
er so
urce b
efore
servi
cing.
Do no
t tou
ch el
ectric
ally l
ive pa
rts.
LN-7
TO
INPU
T C
ABLE
PLU
G
LN-7
CO
NTR
OL
CAB
LE
21-
21
FOR
CONT
ROL
CABL
EW
ITH
14 P
INM
S-TY
PEPL
UG C
ONN
ECTO
R
OR
FOR
CONT
ROL
CABL
EW
ITH
TERM
INAL
STR
IPLE
AD C
ONN
ECTO
RS
CO
NTRO
L CA
BLE
S
2297
6
sour
ce an
d po
sition
the s
witch
on w
ire fe
eder
(if eq
uippe
d )
to p
rope
r pola
rity.
Also
refer
to no
te N.
F.
N.B.
& N
.C.
14-P
INRE
CEPT
ACLE
lead
#21
from
con
trol c
able
with
term
inal
stri
p co
nnec
tors
or f
rom
14-
pin
rece
ptac
le u
sing
#14
AWG
or l
arge
r ins
ulat
ed w
ire p
hysic
ally
21+
REM
OTE
VO
LTAG
E SE
NSI
NG
LEA
D
10-3
0-98
F
N.G
.
N.G
. Illu
stra
tion
does
not
nec
essa
rily
repr
esen
t act
ual p
ositi
on o
f
fo
r mor
e inf
orm
atio
n.
CO
NN
EC
TIO
N O
F L
N-7
TO
TH
E C
V-6
55
, D
C-6
55
OR
DC
-60
0 P
OW
ER
SO
UR
CE
ap
prop
riate
out
put s
tuds
. Ref
er to
pow
er s
ourc
e op
erat
ing m
anua
l
For p
rope
r set
ting
of s
witc
hes
on p
ower
sou
rce,
see
pow
er s
ourc
e op
erat
ing
man
ual.
F-2DIAGRAMSF-2
DC-655
N.C
. Ta
pe u
p bo
lted
conn
ectio
n if
lead
#21
is e
xten
ded.
N.D
. Co
nnec
t the
con
trol c
able
gro
und
lead
to th
e fra
me
term
inal
mar
ked
near
the
pow
er s
ourc
e te
rmin
al s
trip.
The
pow
er
s
ourc
e gr
ound
ing
term
inal
(mar
ked
and
loca
ted
near
the
pow
er
s
ourc
e in
put p
ower
con
nect
ions
) mus
t be
prop
erly
conn
ecte
d to
ele
ctric
al g
roun
d pe
r the
pow
er s
ourc
e op
erat
ing
man
ual.
N.
A. W
eldi
ng c
able
s m
ust b
e of
pro
per c
apac
ity fo
r the
cur
rent
and
Abo
ve d
iagra
m sh
ows e
lectro
de co
nnec
ted p
ositiv
e. T
o ch
ange
pola
rity,
turn
pow
er o
ff, re
verse
the e
lectro
de an
d wo
rk lea
ds at
the p
ower
NEG
ATIV
EPO
SITI
VE
32 31 2 4 GND 21
N.A.
N.D.
ELEC
TRO
DE
CAB
LETO
WIR
E FE
ED U
NIT
TO W
OR
K
POW
ER S
OU
RC
E
N.E.
Only
quali
fied p
erson
s sho
uld in
stall,
use o
rse
rvice
this
mach
ine.
Do no
t ope
rate w
ith co
vers
remov
ed.
Disco
nnec
t pow
er so
urce b
efore
servi
cing.
Do no
t tou
ch el
ectric
ally l
ive pa
rts.
CAB
LE
21
FOR
CONT
ROL
CABL
EW
ITH
14 P
INM
S-TY
PEPL
UG C
ONN
ECTO
R
OR
FOR
CONT
ROL
CABL
EW
ITH
TERM
INAL
STR
IPLE
AD C
ONN
ECTO
RS
CO
NTRO
L CA
BLE
S
2297
7
sour
ce an
d po
sition
the s
witch
on w
ire fe
eder
(if eq
uippe
d )
to p
rope
r pola
rity.
Also
refer
to no
te N.
F.
N.B.
& N
.C.
14-P
INRE
CEPT
ACLE
ABC
N.E
. If
usin
g an
old
er L
N-8
cont
rol c
able
: con
nect
lead
#75
to #
75 o
nte
rmin
al s
trip,
con
nect
lead
#76
to #
76 o
n te
rmin
al s
trip,
con
nect
lead
#77
to #
77 o
n th
e te
rmin
al s
trip.
the
#21
term
inal t
hat m
atch
es w
ork
polar
ity. T
his c
onne
ctio
n m
ust b
e c
hang
ed w
hene
ver t
he e
lectro
de p
olar
ity is
cha
nged
.
N.G
. If
lead
#21
is to
be
conn
ecte
d to
the
term
inal s
trip,
con
nect
to
N.F.
The
LN-
9 vo
ltage
con
trol j
umpe
rs m
ust b
e co
nnec
ted
as fo
llow
s(re
fer t
o LN
-9 O
pera
ting
Man
ual):
Whi
te ju
mpe
r on
volta
ge b
oard
to p
in "S
" .Bl
ue ju
mpe
r on
volta
ge b
oard
(lat
er u
nits
onl
y),
or o
n st
art b
oard
(ear
lier u
nits
), to
pin
"B".
rem
ote
volta
ge s
ensin
g w
ork
lead
may
be
orde
red
for t
his
purp
ose.
N.B.
Ext
end
lead
#21
from
con
trol c
able
with
term
inal
stri
p co
nnec
tors
or
fro
m 1
4-pi
n re
cept
acle
usin
g #1
4 AW
G o
r lar
ger i
nsul
ated
wire
du
ty c
ycle
of i
mm
edia
te a
nd fu
ture
app
licat
ions
.
Con
nect
it d
irect
ly to
the
wor
k pi
ece
keep
ing
it el
ectri
cally
con
veni
ence
, thi
s ex
tend
ed #
21 le
ad s
houl
d be
tape
d to
the
wel
ding
wor
k le
ad.
(If th
e le
ngth
of w
ork
lead
circ
uit i
s
s
hort,
and
con
nect
ions
can
be
expe
cted
to b
e re
liabl
e, th
en
c
ontro
l cab
le le
ad #
21 d
oes
not n
eed
to b
e ex
tend
ed a
nd c
an b
e
d
irect
ly co
nnec
ted
to te
rmin
al #
21 o
n th
e te
rmin
al s
trip.
Not
e
t
hat t
his
is no
t the
pre
ferre
d co
nnec
tion
beca
use
it ad
ds e
rror
sep
arat
e fro
m th
e w
eldi
ng w
ork
lead
circ
uit a
nd c
onne
ctio
n. F
or
to
the
wire
feed
er v
oltm
eter
read
ing.
)
phy
sical
ly su
itabl
e fo
r the
inst
alla
tion.
An
S165
86-[L
ENG
TH]
TO L
N-8
OR
LN
-9
CO
NTR
OL
N.F
.IN
PUT
CAB
LE P
LUG
414
231
3275
7677
N.E.
N.G
.21-21+
REM
OTE
VO
LTAG
E SE
NSI
NG
LEA
D
10-3
0-98
F
N.H
. Ill
ustr
atio
n do
es n
ot n
eces
saril
y re
pres
ent a
ctua
l pos
ition
of a
ppro
pria
te
out
put s
tuds
. Ref
er to
pow
er s
ourc
e in
stru
ctio
n m
anua
l for
mor
e in
fo.
N.H.
CO
NN
EC
TIO
N O
F L
N-8
OR
LN
-9 T
O T
HE
CV
-65
5,
DC
-65
5 O
R D
C-6
00
PO
WE
R S
OU
RC
E
For p
rope
r set
ting
of s
witc
hes
on p
ower
sou
rce,
see
pow
er s
ourc
e op
erat
ing
man
ual.
F-3DIAGRAMSF-3
DC-655
F-4DIAGRAMSF-4
DC-655
F-5DIAGRAMSF-5
DC-655
S
2298
0
ELEC
TRO
DE
CAB
LE
-+
14 P
INAM
PHEN
OL
POW
ER S
OU
RC
E TO W
OR
K
AND
14-
PIN
CAB
LE P
LUG
, R
EAR
VIE
WAN
D 1
4-PI
N C
ABLE
PLU
G,
FRO
NT
VIEW
K=4
2
I=41 H
=21
D=4
C=2
PIN B C D E F
75767742
LEAD
42V
AC42
V AC
TRIG
GER
CIR
CU
IT
(SEE
APP
RO
PRIA
TE W
IRIN
G D
IAG
RAM
)
FUN
CTI
ON
FUN
CTI
ON
S AR
E LI
STED
FO
R R
EFER
ENC
EO
NLY
AN
D E
ACH
MAY
OR
MAY
NO
T B
EPR
ESEN
T IN
YO
UR
EQ
UIP
MEN
T.
14-S
OC
KET
BO
X R
ECEP
TAC
LE,
FRO
NT
VIEW
14-S
OC
KET
BO
X R
ECEP
TAC
LE,
REA
R V
IEW
N.C
. PI
NS
NO
T LI
STED
AR
E N
OT
CO
NN
ECTE
D
ON
CAB
LE.
N.A
. W
ELD
ING
CAB
LE M
UST
BE
SIZE
D F
OR
CU
RR
ENT
A
ND
DU
TY C
YCLE
OF
APPL
ICAT
ION
.
G21
H41
I42
J
MF=
76E=
77
G=7
5NL
A
B=G
ND
K=4
2
I=41
H=2
1
D=4C
=2
J
MF=
76E=
77G
=75
NL
A
B=G
ND
9 PI
NAM
PHEN
OL
K
GN
DC
HAS
SIS
CO
NN
ECTI
ON
WO
RK
OU
TPU
T C
ON
TRO
LO
UTP
UT
CO
NTR
OL
OU
TPU
T C
ON
TRO
L
TRIG
GER
CIR
CU
IT
Only
quali
fied p
erson
s sho
uld in
stall,
use o
rse
rvice
this
mach
ine.
Do no
t ope
rate w
ith co
vers
remov
ed.
Disco
nnec
t pow
er so
urce b
efore
servi
cing.
Do no
t tou
ch el
ectric
ally l
ive pa
rts.
N.D
. IF
LEA
D #
21 IS
TO
BE
CO
NN
ECTE
D T
O T
HE
T
ERM
INAL
STR
IP, C
ON
NEC
T TO
TH
E #2
1
TER
MIN
AL T
HAT
MAT
CH
ES W
OR
K P
OLA
RIT
Y.
TH
IS C
ON
NEC
TIO
N M
UST
BE
CH
ANG
ED W
HEN
EVER
T
HE
ELEC
TRO
DE
POLA
RIT
Y IS
CH
ANG
ED.
10-3
0-98
F
N.E
.
N.E
. ILL
UST
RAT
ION
DO
ES N
OT
NEC
ESSA
RIL
Y R
EPR
ESEN
TAC
TUAL
PO
SITI
ON
OF
APPR
OPR
IATE
OU
TPU
T ST
UD
S.
MO
RE
INFO
RM
ATIO
N.
CO
NN
EC
TIO
N O
F D
H-1
0 O
R L
N-1
0 T
O P
OW
ER
SO
UR
CE
WIT
H 1
4 P
IN A
MP
HE
NO
L
REF
ER T
O P
OW
ER S
OU
RC
E O
PER
ATIN
G M
ANU
AL F
OR
LIN
CO
LN
WIR
EFE
EDER
WIR
E FE
EDER
IN
PUT
CAB
LEAS
SEM
BLY
N.B
. D
IAG
RAM
SH
OW
S EL
ECTR
OD
E PO
SITI
VE.
TO
CH
ANG
E PO
LAR
ITY,
TU
RN
PO
WER
"O
FF",
R
EVER
SE E
LEC
TRO
DE
AND
WO
RK
CAB
LES
AT
PO
WER
SO
UR
CE.
FOR
PR
OPE
R S
ETTI
NG
S O
F SW
ITC
HES
ON
PO
WER
SO
UR
CE,
SEE
POW
ER S
OU
RC
E O
PER
ATIN
G M
ANU
AL.
F-6DIAGRAMSF-6
DC-655
WIR
ING
DIAGRAM
FOR
CODES
105
01,105
03, 1
0504
, 105
05W
IRING
DIAGRAM
FOR
CODES
105
01,105
03, 1
0504
, 105
05
Thi
s di
agra
m is
for
refe
renc
e on
ly. I
t may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
F-7DIAGRAMSF-7
DC-655
Thi
s di
agra
m is
for
refe
renc
e on
ly. I
t may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
F-8DIAGRAMSF-8
DC-655
Thi
s di
agra
m is
for
refe
renc
e on
ly. I
t may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
din
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
F-9DIAGRAMSF-9
DC-655
F-10DIAGRAMSF-10
DC-655
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
� Keep your head out of fumes.� Use ventilation or exhaust to
remove fumes from breathing zone.
� Los humos fuera de la zona de res-piración.
� Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
� Gardez la tête à l’écart des fumées.� Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
� Vermeiden Sie das Einatmen vonSchweibrauch!
� Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
� Mantenha seu rosto da fumaça.� Use ventilação e exhaustão para
remover fumo da zona respiratória.
� Turn power off before servicing.
� Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
� Débranchez le courant avant l’entre-tien.
� Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
� Não opere com as tampas removidas.� Desligue a corrente antes de fazer
serviço.� Não toque as partes elétricas nuas.
� Do not operate with panel open orguards off.
� No operar con panel abierto oguardas quitadas.
� N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
� Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
� Mantenha-se afastado das partesmoventes.
� Não opere com os paineis abertosou guardas removidas.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
� Do not touch electrically live parts orelectrode with skin or wet clothing.
� Insulate yourself from work andground.
� No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
� Aislese del trabajo y de la tierra.
� Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
� Isolez-vous du travail et de la terre.
� Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
� Isolieren Sie sich von denElektroden und dem Erdboden!
� Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
� Isole-se da peça e terra.
� Keep flammable materials away.
� Mantenga el material combustiblefuera del área de trabajo.
� Gardez à l’écart de tout matérielinflammable.
� Entfernen Sie brennbarres Material!
� Mantenha inflamáveis bem guarda-dos.
� Wear eye, ear and body protection.
� Protéjase los ojos, los oídos y elcuerpo.
� Protégez vos yeux, vos oreilles etvotre corps.
� Tragen Sie Augen-, Ohren- und Kör-perschutz!
� Use proteção para a vista, ouvido ecorpo.
• 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
• World's Leader in Welding and Cutting Products •
