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Lincoln Electric DC-655 IM602-A User's Manual

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1. All e dus Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e18 9 9115215 R8 T THEA APIX e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HAUSHERMRELTTF eU 712 55578 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO LOS CONSUMIBLES 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 PRODU
2. 000 ae CABLE RECEPTACLE 14 SOCKET TO LN 7 WIRE FEEDERS K1485 1 Cable Hanger Bracket Mounts over stan dard lift bale of the DC 655 and provides a cable hanger on both sides of the power source each side capable of holding up to 100 ft of weld cable Installation instructions are included with the kit K1486 1 Air Filter Kit Removable metal filter easily slides in and out of a bracket which mounts to the front of the DC 655 Filter is designed to trap 80 of entering particles which are 5 microns or larger in size Installation instructions are included with the kit Cannot be used with K1528 1 Dual process switch DC 655 LINCOLN 5 2 ACCESSORIES K1528 1 Dual Process Switch Cannot be used with K1486 1 Air Filter Kit The Dual Process Switch mounts easily to the front of the machine and is designed to provide a selection between left and right side output terminals Each pair of output terminals can be switched to either the DC 655 high or low inductance terminals as desired Wire feed unit cables and air carbon arc cables can be connected to either or both sides of the box and with proper connection can provide polarity change with just a switch change Selecting one side only energizes those output studs and opens the other side Installation instructions are
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4. ASO SSE HUHNE SAA HAY HUF BPS LINCOLN ELECTRIC World s Leader in Welding and Cutting Products 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
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14. Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue corrente antes de fazer servi o N o toque as partes el tricas nuas 9 PRK VF hf Y2 TF e e KTH AHS e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas OSILDI ERUH L tt CRERTMRALARS BHR x e gdo yal HHS ye AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Chinese x Korean LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR EL TRHO RARE FEU E gt RMR PBN XA A OHRBEE lt BRA EFBRLTR SEL BA MO DD UN 3E EH SUS CHR BE AO EL R RE S
15. 6 79 TOHLNOO INdINO 22 3 LIN9HI9 399141 N 399141 z 9 NOILOANNOO SISSVHO GND 8 __ Nid NVHDVIG ONIHIM 21VIHdOHddV 339 03 HOA NI LN3S3dd 38 LON AVN AVN HOV3 ANY ATNO 30N3U3433H 031911 3HV SNOILONN 2 401 IWANVW 9NILVH3dO _ ONLLVH3dO 324005 H3MOd 335 lt sanis 114100 11VIHdOHddY JO IWALOV JOHNOS H3MOd SIHOLIMS 40 SONILI3S H3dOHd HOJ tr 1N3S3Hd3H ATH VSS3O3N LON 5300 NOILVULSNTI 3N 5 SI ALIHV10d 300810313 JHL A18IN3SSV YHOM OL lt H3JA3N3HM GADNVHO 38 LSNW NOILOANNOO 31870 ALIYW10d TVNIINH3LL A 108 JHL OL LOSNNOO dIHLS TVNIWH3L 430333 3149 3004193173 FHL OL Q3193NNOO 38 OL SI 1 731 Al ON 318Vv9 GSLOANNOO LON 03151 LON SNId 0N 30dnos TONSHdWV SATEVO ANY 300819313 3543134 JoN3HdAY vk 990 NYNL ALIYW10d 39NVHO 6 OL 3ALLISOd 300419713 SMOHS E N NOILVO I ddY 40 71949 ALNA ANY IN344N9 401 03215 38 ISNN 31870 9NIQTJM VN TI NYO 98 SIU BINS 10 991 5 pinoys suosJed payijend 10 e sued an 34238 210110000 43433 308105 H3MOd 810190 921105 8 00 1090009911 e 9 0 81 518102 910800 JOU 00 SNINIVM Ww i NId tI 394N0S YAMOd OL 01 1 HO 01 40 NOILO3NNOO DC 655
16. DH 10 LN 9 LN 10 LN 9 LN 7 GMA LN 23P LN 742 LN 25 LN 7 LN 8 AUTOMATIC WIRE FEEDERS 3 NA 5R 5 LT 7 Tractor European DC 655 models only provide 115VAC for these feeders at the terminal strip TS2 FIELD INSTALLED OPTIONS K1482 1 Digital Ammeter Voltmeter Kit Installs easily to the front control panel and provides digital display of actual welding voltage and amperage while welding Installation instructions are included with the kit K1483 1 Analog Ammeter Voltmeter Kit Installs easily to the front control panel and provides analog display of actual welding voltage and amperage while welding Installation instructions are included with the kit K1484 1 Dual Feeder Kit This kit replaces the 14 Pin MS receptacle panel on the lower case front of the DC 655 It provides two 14 Pin MS receptacles and a built in transfer circuit for connecting and operating NOTE A dirty air filter may cause the thermal protec tion of the DC 655 to prematurely activate Remove and blow out or wash and dry the filter every two months or less if in extremely dirty conditions Replace if necessary Undercarriage K817P K842 The DC 655 is designed for use with the Lincoln K817P or K842 Undercarriage Complete installation instructions are included with each undercarriage When any of the undercarriages are installed the DC 655 lift bail is no longer functional Do not attempt to
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18. DC 655 LINCOLN E 9 DIAGRAMS F 9 a a B SATOH OINILNNOW 3578 30 011 201 DC 655 LINCOLN ELECTRIC DIAGRAMS F 10 F 10 S310H 3578 30 011 201 DC 655 LINCOLN ELECTRIC Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel ropa moja d a Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se e terra e RRPORABA RBHKE 7 amp amp amp ATUSRELTFEL e BLBXSCR Sk eri Syza FY sE au ong e HIE O
19. RECONNECT PROCEDURE rre mx male eue der a fer RE Pe A A 4 OUTPUT CONNECTIONS 2 x kind o rare SEE Beto Aaa A 5 ELECTRODE AND WORK CABLES esse tases tb eae ek dada A 5 AUXILIARY POWER AND CONTROL CONNECTIONS A 6 AUXILIARY POWER TABLE set ee se e a a ee A 6 115VAC DUPLEX RECEPTACLE sa di ue eas ee dom were aE es A 6 290V RECEPTACLE Gratin Panes nhl dos ae dice A 6 14 PIN MS TYPE RECEPTACLE ea RR aa piano 2 A 6 TERMINAL STRIPS ba Pa e a Dl Rd Ue d A 7 OPERATION NETUS SECTION B SAFETY PR CAUTIONS dx se ten Canberra var ieee al phare B 1 GENERAL WARNINGS cu aie ad Salata B 1 GENERAL DESCRIPTION spisi cer is ca Rr x cete oh alata aide B 1 RECOMMENDED PROCESSES AND EQUIPMENT B 1 DESIGN FEATURES AND ADVANTAGES B 1 WELDING thie an cede Di ORA RA E seen B 2 CONTROLS AND SETTINGS ue ea a Beka ese e Roe ns E dure B 3 AUXILIARY POWER 2m ced et aa ha Ra ne LR B 5 MACHINE PROTECTI
20. This condition will be indicated by the illumination of the yellow Thermostatic Protection Light on the case front see figure B 1 The fan will continue to run to cool the power source No welding is possible until the machine is allowed to cool and the Thermostatic Protection Light goes out OVER CURRENT PROTECTION SHUTDOWN Average Current Shutdown To protect the SCR s the DC 655 will shut down to essentially no output if the output current averages over 900 amps for about 5 6 seconds and in less than 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 by opening the feeder gun trigger or switching the DC 655 Output Remote switch out of the on position Peak Current Shutdown To protect the SCR s the DC 655 will shut down immediately to essentially no output if the peak output current exceeds 2500 amps about 1800A average Control PC board LED4 shutdown light will turn on This peak current shut down can be reset by turning the DC 655 input power off then on REMOTE CONTROL LEADS FAULT PROTECTION SHUTDOWN The remote control leads from the 14 pin receptacle or terminal strip are protected against high voltage faults to the electrode circuit or auxiliary voltage sup plies If such a fault occurs the DC 655 will shut down the input primary voltage to the transformer to prevent the fau
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22. 8 8 wires 205 206 32VAC P5 pins 5 amp 6 wires 207 208 3 If all voltages are present turn power off and plug P5 back into J5 Turn power back on If LED s 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 LED s 1 through 6 indicate gate signals are being sent to the main SCR s 1 through 6 respectively If LEDS is on CONTROL BOARD along with LED7 8 and 9 on firing PCB and LED s 1 through 6 are not on check to make 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 LED s 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 LED2 indicates that there is feedback voltage present in CV mode LED3 indicate an input shutdown Refer to Remote Control Leads Fault Protection Shutdown and Shorted Rectifier Fault Protection 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 LED5 Indicates Output Current should be present 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 supply 8 LED8 ind
23. LINCOLN E Sjeued y JO euo uo y splsul 1 n peised s epoo 1e norued e 10 5 eu SIU Aq paJeAoo 10 jou 3 89U918 91 10 S 5 41 8 20002 12 1 NOLLONMISNI 335 tdf NO SI HOLIMS O3ddlHS SY NIS 1V3H H3I3I11938 lndlno NO 0319201 i 0350 41 NDI1d0 0334 Q3 V dH 51 ONY SINIHOVN 15 NO 917 OLNE 50074 310143238 14 01 GUVONVIS 7 ONIONIM 7102 ABYONOJ3S NI 0312037 gt SH3I3A DOWNY HO3 NOIO3NNOO 3NI NI PI HO 24 7NIIOIG TWNOILdO 217 w3H113 309 AYITI Md NOILVOTISNI A009 1Sv33 1 30 AD5d OL AT31VHVd3S d 3dvl 53 2 ASHE H3AO 530 1 0 JINIS ONY 005 08 NO 1N3S3Ed LON 6 DMHl p SOv3 45913 Yad 5109 55 1V019123 T3 30 3018 LN3NOdAO2 O3NGIAY 3ON3 03S ONIN3SNTN N0123NNO2 1 000000 bo 8 25505255 0000500 8 T WS md 1 8 st ACTA a SIM siren sr 5 5 tr o 9 00000 a 1 aA Nous EE 1 an TWNOILdO 803 11 TNT NOLLISOd 292 NI_NMOHS H21IMS 3008 MS bye 5 h 268 mm A003 asnso 9 i i
24. Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing seh CYLINDER may explode E s if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a
25. THE LINKS o og 771 IN THREE POSITIONS LOOP THE FLEX LEAD IN THE POSITION SHOWN POSITIONING SE THE LUGS TO MAINTAIN MAXIMUM CLEARANCE THE LINKS INSTALL AND TIGHTEN TRANSF ALL OF THE HEX NUTS LINKS CONNECTION FOR LOWEST RATING PLATE VOLTAGE 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 2 DISCONNECT AND INSULATE THE LEAD TERMINAL WITH TAPE PROVIDE L3 ow LEAST 600 VOLT INSULATION INPUT 2 __ 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H2 CONTROL TRANSFORMER LINES CONTACTOR LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN L1 3 Su 4 CONNECT TERMINAL MARKED TO GROUND PER LOCAL NATIONAL ELECTRIC H1 GND H2 H3 e 5 MOUNT THE LINKS IN THE POSITIONS SHOWN CONNECT THE FLEX LEAD AS SHOWN o og POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS 5 5 INSTALL AND TIGHTEN ALL OF THE HEX NUTS LINKS D UF THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A M18225 FIGURE A 2 Dual Voltage Machine Reconnection Procedure DC 655 LINCOLN 5 5 OUTPUT CONNECTIONS ELECTRODE AND WORK CABLES Use the shortest possible cable lengths See Table A 1 for recommended cable sizes based on length TABLE A 1 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable Cable Length Parallel Cables Cable Size ft m 0 0 to 100 30 4 2 2 0 70mm 100 30 4 to 200 6
26. Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information LINCOLN 5 Jan 09 i SAFETY PRECAUTIONS DE SURETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pin
27. lift the machine with the undercarriage attached The undercarriage is designed for moving the machine by hand only Mechanized towing can lead to injury and or damage to the DC 655 REMOTE OUTPUT CONTROL K775 or K857 WITH K864 ADAPTER An optional remote output control is available This is the same remote control that is used on other Lincoln power sources K775 The K775 consists of a control box with 28 ft 8 5m of four conductor cable This con nects to terminals 75 76 and 77 on the terminal strip and the case grounding screw so marked with the sym bol 45 the machine These terminals are located behind the cover panel on the lower connection panel of the DC 655 This control will give the same control as the output control on the machine The K857 has a 6 pin MS style connector The K857 requires a K864 adapter cable which connects to the 14 pin connector on the DC 655 REMOTE CONTROL ADAPTER CABLE K864 na two like polarity wire feeders European DC 655 mod STRAIGHT PLUG 14 PIN E els can only use 42V feeders with this kit Installation instructions are included with the kit 000 CABLE RECEPTACLE 6 SOCKET TO K857 REMOTE CONTROL A cable 12 30m long to connect a 857 Remote 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 feeder connection is then not used
28. metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing 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 countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective 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 applications 1 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment 110093 3 1 96 LINCOLN vii vii for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing
29. sure the load on the receptacle troubleshooting assistance does not exceed the rating of the 115VAC breaker See wiring dia gram CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 5 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Thermal Protection Light comes ON j1 and fan does not run NOTE Fan is thermal controlled and 2 does not continuously run when machine is powered up PROBLEMS Check for obstructions that could prevent the fan from turning Check the fan control circuit See wiring diagram The fan motor may be faulty The Thermal Fan Snubber PC Fan runs continuously board may be faulty See PC board LED information The Thermal Fan Thermistor may be faulty See wiring diagram The Thermal Fan Snubber PC One or both Digital Meters not light ing board may be faulty See PC board LED information Contact your Local Lincoln Authorized The meters may not be receiving Field Service Facility for technical the voltages from the auxiliary troubleshooting assistance transformer Check plug P13 See wiring diagram The Digital meter PC board may Digital
30. 0 8 2 3 0 95mm 200 60 8 to 250 76 2 2 4 0 120mm The output terminals are located at the lower front of the welder behind a hinged door Refer to figure A 3 Route the welding cables through the slotted strain reliefs of the base to the welding terminals LOW INDUCTANCE TERMINAL On the DC 655 the inside right Negative output terminal is lower choke inductance This terminal is presently only recommended for CV mode welding with NR203Ni 196 negative polarity procedures All other processes are to be welded using the outside right Negative output terminal with higher choke inductance CC mode processes must use high inductance For Positive Polarity 1 Connect the work cable to the high inductance terminal marked _ AAA_ 7 INSTALLATION A 5 2 Connect the electrode cable to the positive terminal marked 3 Remove the terminal strip access cover panel on the lower case front Refer to figure A 3 for the location 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 from the factory 5 Replace the terminal strip access cover panel For Negative Polarity 1 Connect the electrode cable to the appropriate high inductance terminal marked or to the low inductance terminal marked f Na if using NR203Ni 1 elec trode only 2 Connect the work cable to the positive termina
31. 1105 leMod y jeeu pue F Ieuluuel 0 amod y dujs anos amod y jeeu LINN 0334 3HIM OL euiu8 ewe 34 ol pee ejqeo 0002 10euuo 318 0 33081033 s 12 peaj J uoroeuuoo 9104 dn N 1 34 0 10118 Sppe 1 uonoeuuoo 9U JOU S SIU JEU aloN AIS y uo 1z euius 0 pue peeu zou Soop 10 peal UA ejqeije eq oj peroedxe eq ueo Suonoeuuoo pue 199 GZ ULY sse 410 5 51 21429 YOM Duipjow jo au ji eu 0 padez eq pinoys peo 0 SIU eoueiueAuoo 104 uoipeuuoo HIOM aux jo juepuedepur 82810 YOM 0U 0 3i 129 02 esodind siy 10 eq peaj ejouel HL9N3 98991S UY ay 10 SIENS jeois ud 19612 10 DMV p L4 Buisn ajoeydeoes uld p WO 10 5103990009 dis euluuel ui 482 0002 WO peel 04002 N7 4y peddinbe si N11I g N E CL LEE LD L L 8R 3A LISOd AALLYOAN DC 655 LINCOLN DIAGRAMS 892 5 1900101 10 enuey 1 1995
32. 5A 115V 20A No Duplex No Duplex At Duplex Receptacle erminal strip 115 20 115V 15A 115V 20A 115V 15 115V 15A erminals 31 amp 32 MS Receptacle 115V 20 115V 15A 115V 20A Open Circuit 115V 15A pins A amp J MS Receptacle 42V 10 42V 10 42V 10 42V 10 pins amp K At 220V No Receptacle No Receptacle 220V 2A 220V 2A Receptacle 115VAC DUPLEX RECEPTACLE DOMESTIC AND CANADIAN MODELS ONLY The 115VAC duplex receptacle is protected by a cir cuit breaker located below the receptacle see Auxiliary Power Table Receptacle is a NEMA 5 20R protected by a 20 amp breaker on Domestic and Canadian Models except Canadian Code 10502 receptacle is a NEMA 5 15R protected by a 15 amp breaker 220VAC RECEPTACLE EUROPEAN AND EXPORT MODELS ONLY A Continental European receptacle is located on the rear 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 the rear panel This circuit is electrically isolated from all other circuits but on the European Models one line is connected to chassis ground 14 PIN MS TYPE RECEPTACLE For MS3106A 20 27PX Plug L E C Part 512020 32 Refer to the figure A 4 for the available circuits in the 14 pin receptacle 42 VAC is available at receptacle pins and K A 10 amp circuit breaker protects this circuit 115 VAC is avail
33. EMOTE position control is through a remote source such as a wire feeder via the 75 76 and 77 leads in the MS receptacle or terminal strip 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 output characteristic through the 50 to 815 amp range The current is adjusted within this range by the Output Control dial The open circuit no load voltage will be about 68 volts in this mode LINCOLN 5 This mode is used for stick welding SMAW and CC air carbon arc gouging and employs a Hot Start feature and an Arc Force Control CC mode may also be used for CC submerged arc with appropriate arc sensing CC VV wire feed ers if arc force is set high enough Refer to Welding Performance Section MIG provides a constant voltage output characteristic through the 13 to 44 volt range The voltage is adjusted within this range by the Output Control dial The dynamic characteristics of this mode are ideal for open arc processes including MIG MAG GMAW Innershield and other cored wire FCAW processes Faster travel submerged arc processes and CV air carbon arc gouging may also use this mode Refer to the Welding Performance Section CV Sub Arc provides the same constant voltage output control range as CV MIG but the dynam ic characteristics of this mode make possible improved CV constant wire speed sub
34. F before connecting or disconnect ing output cables wire feeder or remote connections or other equipment Do not touch electrically hot parts Always connect the Idealarc DC 655 grounding terminal located on the welder near the reconnect panel to a good electrical earth ground SELECT SUITABLE LOCATION Place the welder where clean cooling air can freely circulate in through the front louvers and out through the rear louvers Dirt dust or any foreign material that can be drawn into the welder should be kept at a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shut downs STACKING The DC 655 may be stacked three high provided the bottom machine is on a stable hard level surface Be sure that the two pins in the roof fit into the slots in the base of the DC 655 above it TILTING Do not place the machine on a surface that is inclined enough 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 prints L10093 1 2 safety pages in the Front of Instruction Manual for further details Locate the DC 655 away from radio controlled machinery The normal operation of the DC 655 may adversely affect the operation of RF controlled equip ment which may result in bodily injury or damage to the equip
35. IM602 A DC 655 For use with machine Code Number 10501 thru 10510 11324 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful 77 MOM 2 OPERATOR S MANUAL ISO 9001 Designed and Manufactured Under Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI NCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products 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 A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Diesel Engines The Above Fo
36. ITS A ETRE 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria eta Lb55 451 T CRACVHEL TIMELTFEL CTPA ER o EHRE e FR REK HF 802 e 897158 S EXACE E 25748 HHSHP 9184 7 5471214 E878 ASSHAIR e Turn power off before servicing Desconectar el cable de ali de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien
37. LdO 99508 79 TYNOUdO pee gt siz Hee Her oz 9 Li0z 4 140 202 2 ST do A FROM T AUX WINDINGS SUSLaW SOTWNY WNOILdO gt zzz 692 012 tsis A oz sodz es 102 9 3 gt 108 202 1 0 N 8 HOLIMS OH LNO9 indino RT HANHOASNVEL Quvog 1odlNoo H3WHOJSNVHL NIV LL gee SEE HaNHOJSNVHL TOHINOO ZL zx x TT HYHOVIQ NOLLOINNOD zy 0 Aer vot VZELL 20501 S3009 ANIHOVIN HOS NO NMOHS SV ALVINSNI HO LO3NNOO os Eis 1000 sve A000 zsy00 vesz 4 uo19v1NO9 193NNOO3H 082 Q3103NNO9 NMOHS SLS09y0ez a009 CB AWNOLWN OL DC 655 LINCOLN E DIAGRAMS peised s epoo ened 5 eu SIU Aq 10 eq jou ACW 1 8v 9 ATNO SHAGTAM
38. NDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Machine will not weld is less The machine may be in a over than 1 volt load condition Refer to Machine Protection in the operation sec tion See the PC board LED informa tion The wire feeder will not come on Either the 42VAC or the 115VAC circuit breakers may be tripped Reset if necessary Check for the presence of the required voltage to operate the wire feeder The control cable or wire feeder may be faulty Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Poor arc characteristics 1 The negative welding cable may be connected to the wrong induc tance tap Make sure the mode switch is in the proper position for the process The control board may be faulty See PC board LED information 115VAC receptacle not working Check the 115VAC circuit break Contact your Local Lincoln Authorized er Reset if necessary Make Field Service Facility for technical
39. ON xeu usage RES EIER ER eS a Red eia ces B 5 WELDING PERFORMANCE Rex amp nae a eae ux E UR B 6 ACCESSORIES ein ne ne S XN aud FN SECTION C FIELD INSTALLED OPTIONS isis roms Gaede doe Gee en donde oa d c C 1 MAINTENANCE eee oe dn SECTION D SAFETY PRECAUTIONS asena a prn See t send D 1 GENERAL MAINTENANCE eer Sone de gaie ste UR RE use dada D 1 TROUBLESHOOTING 23 peg dew eRe o d galette de diet ei dansant SECTION HOW USE TROUBLESHOOTING GUIDE 1 E 1 MACHINE TROUBLESHOOTING 1 E 2 P C BOARD TROUBLESHOOTING Saas teo cune a veda E 9 E 10 DIAGRAMS iex uox ri ea aa ERR I bg EE XR ERG KE Em eir eens SECTION F PARTS LISTS 2 DATOS dU EUR RR ns e RR P 317 SERIES 1 INSTALLATION TECHNICAL SPECIFICATIONS DC 655 INPUT THREE PHASE ONLY Input Current at Rated Output 100 Duty Cycle Standard Volatge 60 Duty Cycle 122 61 122 61 49 135 67 5 150 75 150 75 60 230 460 60 230 460 575 60 208 416 60 460 60 575 60 230 400 50 60 380 500 50 60 440 50 60 200 400 50 60 415 50 60 RATED OUTPUT Amps 650 Duty Cycle 100 Duty Cy
40. ON position energizes the machine s input contactor applying input power to the machine Switching the switch to the position de energizes the input contactor This switch is also used to reset a machine shut down See Machine Shutdown section PILOT LIGHT When the power switch is in the ON position the machine s white pilot light will illu minate lf the input contactor de energizes the machine in a shutdown situation the pilot will still illuminate In this situation it will be necessary to reset the machine by switching the power switch to the OFF then ON position See Machine Shutdown section OUTPUT CONTROL This control provides continuous control of the machine s output from minimum 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 to 815A OUTPUT TERMINALS ON REMOTE When this switch is in the position the DC 655 s output terminals will be electrically cold until a DC 655 remote device such as a wire feeder closes the 2 and 4 circuit in the MS receptacle or terminal strip When this switch is in the ON position the machine s output terminals will be electrically ener gized all the time LOCAL REMOTE CONTROL SWITCH When this switch is set to the LOCAL position control of the output voltage is via the output control on the DC 655 s control panel When this switch is set to the R
41. Voltmeter not working proper ly or erratic display be faulty Meter may not be receiving auxil iary or sensing voltages Make sure plug P12 amp P13 are securely plugged into the Digital meter PC board and also plug P3 is securely plugged into the control board The may be an open in the volt age feedback circuit See wiring diagram 3 The Digital meter PC board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 8 TROUBLESHOOTING E 8 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Digital Ammeter not working properly 1 The meter PC board may not be or erratic display receiving the auxiliary or sensing voltages Check plug P3 and plugs P12 amp P13 See wiring diagram The current feedback circuit may be faulty From the shunt to the control board See wiring dia gram The Digital meter PC board may be faulty Analog Meters not reading or not The meters may not be receiving reading correctly voltage or current feedback sig nals Make sure plug P3 is securely plugged in the control board and plug J14 in line con nector is securely seated in the plug assembly from t
42. able at receptacle pins A and J Domestic Canadian and Export Models This circuit is protected by a circuit breaker see Auxiliary Power Table Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other However on the European model one line of the 115VAC is con nected to chassis ground FIGURE A 4 FRONT VIEW OF 14 PIN CONNECTOR RECEPTACLE LEAD NO FUNCTION 32 115 VAC GND Chassis Connection Trigger Circuit Trigger Circuit Output Control Output Control Output Control Work Sense Connection 42 VAC 115 42 VAC A B C D E F G H L M N 415VAC circuit is not present on IEC 974 1 European models As shipped from the factory Lead 21 from the 14 Pin connector is connected to 21 on the terminal strip This is the configuration for positive welding If welding negative polarity connect lead 21 to the 21 connection point on the terminal strip DC 655 LINCOLN 5 7 INSTALLATION TERMINAL STRIPS Terminal strips are available behind the cover panel on the lower case front to connect wire feeder control cables 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 in the following Terminal Strip charts See Auxiliary Power Table for rating of circuit breaker in 115VAC circuit Remove a plug button from the terminal strip cover and install an app
43. and to the input contactor terminals in the input box assembly See Figure 1 Figure 2 shows a sample of the reconnect instructions for a dual voltage machine RECONNECT PROCEDURE A WARNING 9 Electric Shock Can Kill Disconnect input power before perform ing this procedure AMNIS HIGH VOLTAGE KILL DUAL VOLTAGE MACHINE Do not operate with covers Do not touch electrically live parts INPUT SUPPLY CONNECTION DIAGRAM removet e Disconnect input power before Only qualified persons should install IMPORTANT CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS servicing use or service this equipment NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS CONNECTION FOR HIGHEST RATING PLATE VOLTAGE 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 INPUT 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H3 CONTROL TRANSFORMER LINES L2 LEADS TO THE INPUT SIDE OF CONTACTOR AS SHOWN L1 0 9 4 CONNEC ERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC GND LL H H2 e 5 MOUNT THE LINKS IN THE POSITIONS SHOWN DOUBLE OR TRIPLE STACK
44. ce de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risq
45. cle NEMA Class 100 60 Duty Cycle 815 OUTPUT Voltage Range Current Range 46 CV Mode 13 44 DC 50 815 68 CC Mode Maximum Open Circuit Voltage Code Number 10501 10502 11324 10503 10504 10505 10506 10507 10508 10509 10510 Volts at Rated Amperes 44 44 Auxiliary Power See the OPERATION section for Auxiliary Power information by model RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT AMPERE 80 C Copper RATING ON COPPER WIRE GROUND WIRE NAMEPLATE IN CONDUIT IN CONDUIT SIZES AWG IEC MMP SIZES 40 C 104 F Ambient INPUT VOLTAGE FREQUENCY SUPER LAG OR BREAKER SIZE AMPS OO eee e Hw TE k ND ND po O eee WEIGHT 720 lbs 326 kg HEIGHT 27 5 in 699 mm European models meet IEC974 1 standards 1Also called inverse time thermal magnetic circuit breakers circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases DC 655 LINCOLN 5 2 DD 3 NEMA EW 1 100 IEC 974 1 IP 23 INSTALLATION GRAPHIC SYMBOLS THAT APPEAR ON RATING PLATE LOCATED ON CASE BACK 3 Phase transformer with rectified DC output INPUT POWER THREE PHASE Designates welder complies with National Electrical Manufacturers Associatio
46. coln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Machine has output but no control 1 Check the Local Remote output switch SW3 and associated leads See wiring diagram Make sure the remote control leads 75 76 and or 77 are NOT grounded to either welding output Make sure control cable to feeder if used is connected properly The output control potentiometer may be faulty Control board transformer may be faulty faulty Machine does not have maximum Make sure the correct three Contact your Local Lincoln Authorized output phase input is applied to the DC Field Service Facility for technical 655 machine troubleshooting assistance The output control potentiometer may be faulty The control or firing board may Poor arc striking with semiautomatic 1 Make sure the mode switch is in or automatic wire feeders the proper position for the process Make sure the welding cables and connections are secure Check for correct welding proce dures CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for techn
47. d Canadian Models This receptacle provides up to 20 amps of 115 VAC auxiliary power on the Domestic and Canadian Models except Canadian Model Code 10502 is 15 amps 115 VAC DC 655 2 115VAC CIRCUIT BREAKER 6 This breaker protects the 115 VAC auxiliary circuits located in the duplex receptacle terminal strip and MS recep tacle Breaker is rated 20 amps on Domestic and Canadian Models except Canadian Model Code 10502 and all other models are 15 amps LINCOLN 5 5 OPERATION B 5 3 42VAC 10 AMP CIRCUIT BREAKER This breaker protects the 42VAC auxiliary circuits locat ed in the terminal strip and MS receptacle 4 14 PIN MS RECEPTACLE This connector pro vides easy connection for a wire feeder control cable It provides connections for auxiliary power output switching remote output control wire feeder voltmeter sense lead and ground Refer to 14 Pin MS Type Receptacle in the Installation Section of this manual for information about the circuits made available at this receptacle 5 TERMINAL STRIP COVER PANEL Remove this panel to gain access to the circuits made available at the terminal strip and the 4 pin receptacle for the optional paralleling kit This terminal strip contains the same circuits as the 14 pin MS receptacle The cover also provides for installation of cable strain relief clamps 9 POSITIVE OUTPUT TERMINAL This output ter minal is for connecting a welding cable To change we
48. dental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and
49. detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Input contactor CR1 chatters 1 Faulty input contactor CR1 2 Low line voltage Machine input contactor does not If Power Pilot light is off operate 1 Make sure the proper three phase input power is applied to the DC 655 machine The power switch SW1 may be faulty The pilot transformer may be faulty f Power Pilot light is on The input contactor may be faulty Input shutdown may be activated LED3 on on Control Board See Shorted Rectifier Fault Contact your Local Lincoln Authorized Protection in Operation Section Field Service Facility for technical troubleshooting assistance Machine input contactor operates Electrode or work cables may be but no output when trying to weld loose or broken Firing P C board is not connected or is faulty See PC board LED information Trigger circuit may not be working Place Output Terminals Switch to the ON position or place a jumper wire across 2 and 4 on the ter minal strip If output is enabled then check control cable to feeder if connected If the thermal protection light is ON the machine is overheated Make sure the fan is operating and remove the cause of the overheating problem CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lin
50. elding current exceeds a level proportional to the voltage set ting then falls off linearly at about 10 volts per 100 amps to a limited short circuit current Lo current limiting provides the same short circuit current but the arc voltage begins to linearly fall off at lower current at about 5 volts per 100 amps is recommended for all CV processes especially for CV subarc and CV arc gouging but Lo tends to soften the arc more when welding NR203Ni 1 on the Low Inductance terminal If Lo is desired switch 4 right most of the DIP switch located on the lower center of the DC 655 Control PC board needs to be switched from up Hi position to down Lo posi tion VOLTS 4 High lt Setting EM HI Current Limit Lo Current Limit Ew 5 Low Setting s AMPS CV OUTPUT CC MODE ARC FORCE Arc Force provides extra weld current which linearly increases as the welding voltage decreases below a level determined by the constant current setting The Arc Force control knob located behind the latched cover adjust Arc Force from Min no current increase to Max about 9A V increase VOLTS 4 m 1 r Hot Start 1 1 Low Hi Setting CC OUTPUT A general guideline for CC welding is to set Arc Force to Mid position 5 and increase typically no more than
51. euuoo 00 dn 1919 1 0 19 0 10118 Sppe j esneoeq 3y JOU 51 SIU JEU 3ALLISOd 3ALLVO3N JON AUIS euluuel 34 uo 1z euluuel ol aq ued pue pepuejxe eq oi peeu JOU PES ejqeo uay 8lqellel 01 pejoedxe eq ueo pue oys 811010 peaj HIOM Jo 6ual 0U peaj eu 0 pede eq pjnous 24 slut eoueiueAuoo DC 655 LINCOLN E 104 Uonoeuuoo pue peaj YOM Hulpjam ay uio 91018095 jjeoujoeje 1 Buide y 29a1d yom adl o1 Adap 11 990009 asodund SIU 10 eq pee 00U01 19 311 989915 uv uonejjeisur ay 10 ejqeuns Ajeorsfud pejejnsul 10 DMV p L4 Duisn ejoejdeoe 10 0145 euluuel ejqeo WO 2 peaj pueyX3 HN DIAGRAMS suoneoidde ann pue 10 ejo o pue uauno y 10 190010 snw sejqeo 6ulple WN SHOLOANNOO GVA 41815 HLIM YOOHS 31870 1OHLNOO 404 sped A B0111080 2101 jou 0 e YOLOANNOOD 9014 910 90 921105 9 0 1090009810 e 3dAL SN HILIM 519102 9121900 100 00 ONINYVM wW 318
52. 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 shutdown time to 2 hours Setting Switch 2 of the DIP switch to down Off sets the shutdown time to 1 2 hour Shut down is reset by turning the DC 655 input power off then on Switch 1 Timer On Off UP ON Down OFF 2 mm Ci DIP Switch Switch 2 Time selection UP 2 hours Down 1 2 hour Note See Weld Performance section for use of switch 3 and 4 WELDING PERFORMANCE LOW INDUCTANCE TERMINAL The inside right Negative terminal is lower choke inductance and presently is only recommended for welding with NR203Ni 1 procedures All other processes are to be welded using the outside right Negative terminal with higher choke inductance DC 655 LINCOLN 7 OPERATION B 7 CV MODE CURRENT LIMITING CV MIG and CV Sub Arc modes employ electronic current limiting to limit excessive short circuit output current 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 w
53. he control board Contact your Local Lincoln Authorized Check the current feedback and Field Service Facility for technical voltage feedback circuits See troubleshooting assistance wiring diagram The meter s may be defective 220VAC receptacle not working Check the circuit breaker Reset 50 60 Hz Europe and Export mod if necessary els only Check for broken or loose con nections in the 220VAC circuit See wiring diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 5 9 TROUBLESHOOTING E 9 Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE FIRING P C BOARD 1 All 10 LED s must be ON when the POWER SOURCE is turned ON and the wire feeder s trigger is closed or a jumper is placed between 2 amp 4 or the OUTPUT TERMINALS SWITCH is in the ON position 2 LED s 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 5 from the firing board the machine back on and check the fol lowing voltages Light that was off Check AC voltage between Voltage should be approximately 7 P5 pins 15 amp 16 wires 230 204 32VAC P5 pins
54. ical troubleshooting assistance before you proceed DC 655 LINCOLN E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Variable or sluggish welding arc 1 Make sure the mode switch is in the proper position for the process Make sure the welding cables are sized correctly and the connec tions are tight Make sure the welding proce dures are correct Output Control Pot not functioning in 1 Check the Local Remote control Local control only switch and associated leads See wiring diagram The machine output control potentiometer may be faulty Also check associated leads See wiring diagram Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance No output control in Remote control 1 Output Control Switch in wrong only position Faulty Output Control Switch Faulty Remote Control Pot Leads or connections open in con trol circuit 75 76 77 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 5 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMME
55. icates the Control PC Board is signalling the Firing PC Board to fire the SCRs 9 LED9 10V power supply 10 LED10 indicates that 42V input is present to the Control PC Board 11 LED11 indicates that there is feedback voltage present in CC mode on CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 10 TROUBLESHOOTING E 10 Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE THERMAL FAN SNUBBER P C BOARD NOTE Fan will run for minimum of 5 minutes once fan turns on T 2 3 LED1 when ON indicates fan should be running If ON and machine is cold replace PCB LED2 when ON indicates welding current greater than 50 amps If ON and not drawing more than 40 amps replace PCB LED3 when ON indicates Main SCR S need cooling and turns fan ON If ON and machine is cold replace PCB 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 LED5 when ON indicates an open thermostat Thermal Protection light should also be ON If Thermal Protection light is not ON and LEDS is ON replace PCB LED6 when ON indicates fan sho
56. included with the switch K1611 1 Paralleling Kit Provides interconnection of two DC 655 machines in parallel for doubling the cur rent capacity of one machine This master and slave connection configuration allows the master to control the balanced output of both machines Individual protection circuits of both machines function normally Installation instructions are included with the switch DC 655 LINCOLN 5 D 1 MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts GENERAL MAINTENANCE 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may restrict the cooling air causing the welder to run hot with pre mature tripping of thermal protection Blow out the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on inter nal parts 3 Periodically check the welding cables Inspect for any slits or punctures Also make sure that all con nections are tight DC 655 LINCOLN D 1 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this e
57. ion is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found 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 you have recorded above The code number is especially important when identifying the correct replacement parts 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 packet accompanying 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 Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to
58. l marked 3 Remove the terminal strip access cover panel on the lower case front Refer to figure A 3 for the location 4 Work Sense lead 21 from the 14 Pin MS recepta cle must be connected to 21 the terminal strip 5 Replace the terminal strip access cover panel 14 PIN MS RECEPTACLE pon POSITIVE OUTPUT TERMINAL TERMINAL STRIP COVER PANEL LOW INDUGTANCE HIGH INDUCTANCE NEGATIVE OUTPUT NEGATIVE OUTPUT TERMINAL TERMINAL FIGURE A 3 Output Connections DC 655 LINCOLN 6 INSTALLATION A 6 AUXILIARY POWER AND CONTROL CONNECTIONS Located at the lower front of the welder behind a hinged door is a 115VAC duplex receptacle for auxil iary power Domestic and Canadian Models only and a 14 Pin MS type receptacle for connection of auxil iary equipment such as wire feeders Also terminal strips with 115VAC and connections for auxiliary equipment are located behind the access panel on the lower case of the welder A 220VAC receptacle for a water cooler European and Export Models only is located on the case back AUXILIARY POWER TABLE Voltage and Circuit Breaker Ratings at Auxiliary Power Connections for Various Models Auxillary Domestic anaaian uropean Xport Power Models Model Models Models Connections 60Hz 230 460 575V 60 Hz 50 60 Hz 50 60 Hz Code 10502 Code 11300 115V 20A 115V 1
59. lding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section of this manual 7 NEGATIVE OUTPUT TERMINALS These output terminals are for connecting a welding cable to either the High Inductance or Low Inductance Terminal for desired arc characteristics Low induc tance is recommended only for NR203Ni 196 To change welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section of this manual CASE BACK CONNECTIONS 220VAC AUXILIARY RECEPTACLE European and Export Models This receptacle provides up to 2 amps of 220VAC auxiliary power for a water cooler 220VAC 2 AMP CIRCUIT BREAKER European and Export Models This breaker protects the 220VAC auxiliary circuit located in the 220VAC receptacle AUXILIARY POWER 42 volt AC auxiliary power as required for some wire feeders 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 20 amp circuit breaker on the Domestic and Canadian models except for a 15 amp on Canadian Code 10502 and Export models protects the 115 volt circuit from overloads 115VAC is not available in the MS receptacle on the European models CAUTION Note that some types of equipment especially pumps and large motors have starting cur
60. le turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 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 you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS lt r may 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welder
61. lt output Control PC board LEDS 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 control power is still present Welding output or auxiliary sup ply output will not be present This input shut down is reset by turning the DC 655 input power off then on If the fault is not corrected however the shutdown will re occur when turning on the input power SHORTED RECTIFIER FAULT PROTECTION If a short occurs across one of the silicon controlled rectifiers of the DC 655 a potentially hazardous AC voltage 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 down the input primary voltage to the transformer to prevent the 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 control power is still present Welding output or auxiliary sup ply output will not be present This input shut down is reset by turning the DC 655 input power off then on If the fault is not corrected however the shutdown will re occur when turning on the input power IDLE SHUT DOWN TIMER For additional operating economy the DC 655 can be set up to automatically shut off the primary input power to the main transformer after a selectable time 1 2 or 2 hr
62. ment INPUT CONTACTOR CR1 INPUT POWER SUPPLY CABLE WITH BUSHING OR BOX CONNECTOR RECONNECT PANEL ASSEMBLY FIGURE A 1 ELECTRICAL INPUT CONNECTIONS ELECTRICAL INPUT CONNECTIONS Before installing the machine check that the input sup ply voltage phase and frequency are the same as the voltage phase and frequency as specified on the welder nameplate Use input wire sizes that meet local electrical codes or see the Technical Specifications page in this manu al Input power supply entry is through the hole in the Case Back Assembly See Figure A 1 for the location of the machine s input cable entry opening Input Contactor CR1 and reconnect panel FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Technical Specifications page of this manual for the machine being used They are also called inverse time or ther mal magnetic circuit breakers DO NOT use fuses or circuit breakers with a lower amp rating than recommended This can result in nuisance tripping caused by inrush current even when machine is not being used for welding at high output currents GROUND CONNECTION Ground the frame of the machine A ground terminal marked with the symbol is located inside the case back of the machine near the input contactor Access to the input box assembly is at the upper rear of the machine See your local and national electrical codes fo
63. merged arc welding This improved process is most noticeable on high deposition slow travel speed welds Fast travel narrow bead subarc welds will have better performance in CV MIG mode OPERATION B 4 7 ARC FORCE CONTROL This control is only func tional in CC Stick mode It prevents stubbing of the electrode by providing the extra weld current that linearly increases as the welding voltage decreases below a level determined by the setting of the constant current control The Arc Force control knob located behind the latched cover adjusts arc force from Min no cur rent increase to Max higher short circuit current Mid position 5 is recommended for most CC welding Refer to the Welding Performance Section 8 OPTIONAL VOLTMETER amp AMMETER Digital or analog meter kits are available as field installed options Refer to the Accessories Section of this manual THERMAL PROTECTION LIGHT E If the machine overheats due to lack of proper air flow through the machine or due to exceeding the machine s duty cycle thermostats will disable the welding output and this light will illuminate Input power is still applied to the machine and the cooling fan will continue to run When the machine cools the welding output will resume FIGURE B 2 LOWER CASE FRONT CONTROLS amp CONNECTIONS 1 115VAC DUPLEX RECEPTACLE Domestic an
64. n requirements EW 1 Class with 100 duty cycle at 650Amps output Domestic Canadian and Export models Designates welder complies with International Electrotechnical Commission requirements 974 1 European Models Designates the degree of envi ronmental protection provided by the power sources enclosure Constant Current Output Characteristics SMAW SAW DC 655 LINCOLN 2 Constant Voltage Output Characteristics GMAW FCAW Designates welder can be used in environments with increased hazard of electric shock European models Designates welder complies with low voltage directive and with EMC directive European models Designates welder complies with both Underwriters Laboratories UL standards and Canadian Standards Association CSA standards Canadian Model Designates welder complies with Underwriters Laboratories UL standards Domestic Models Open Circuit Output Voltage Input Voltage Rating s Input Current Rating s Output Duty Cycle Rating s Output Voltage Rating s Output Current Rating s 3 INSTALLATION A 3 Read entire installation section before starting installation SAFETY PRECAUTIONS A WARNING 2 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 on this equipment Turn the Power switch on the DC 655 OF
65. ng for sub arc or across arc touch sensing can be used The 14 MS receptacle on the European mod els does not provide 115 VAC for these feeders 115 VAC must be obtained from terminal strip Two DC 655 s may be paralleled in a master and slave interconnection using the K1611 1 Paralleling kit DC 655 LINCOLN 2 OPERATION B 2 DESIGN FEATURES AND ADVANTAGES Separate output terminals for selecting high or low inductance as recommended for the welding process Power on off switch with pilot light and thermostat tripped indicator light Full range output voltage CV mode and current CC mode control for easy operation Panel switches behind a latched front panel for remote or local output control output on or remote selection and CC CV Sub arc or CV MIG mode selection Panel knob settable CC arc force control with built in adjustable Hot Start High efficiency output and selectable sleep mode idle mode timer which shuts down input power if not used 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 and dust intake Hinged cover to protect output terminals and auxil iary connections Electronic and thermostatic protection for current overload and excessive temperatures 42 10 amp auxiliar
66. praying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5 f LINCOLN 5 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Jan 09 SAFETY ii WELDING and CUTTING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Acci
67. quipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate 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 symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines
68. r Gasoline Engines PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 cm 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 before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine 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 and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 1 9 To prevent accidentally starting gasoline engines whi
69. r proper grounding methods Use grounding wire sizes that meet local electrical codes or see the Technical Specifications page in this manual DC 655 LINCOLN 5 4 INSTALLATION A 4 INPUT POWER SUPPLY CONNECTIONS A qualified electrician should connect the input power supply leads Multiple voltage machines are shipped connected to the highest input voltage listed on the machine s rating plate Before installing the machine check that the reconnect panel in the input box assembly is connect ed for the proper voltage CAUTION Failure to follow these instructions can cause immedi ate failure of components within the machine When powering welder from a generator be sure to turn off welder first before generator is shut down in order to prevent damage to welder 1 Follow all national and local electrical codes 2 Use a three phase line 3 Remove the input access door at upper rear of the machine 4 Follow input supply connection diagram located on the inside the door For multiple voltage machines follow the diagram for the voltage that is within 10 of your actual input line voltage To reconnect a multiple voltage machine to a different voltage remove input power and refer to the input connection diagram located on the inside of case back input access door Follow the diagram for the voltage that is within 10 of your actual input line voltage 5 Connect the three phase AC power supply leads L1 L2
70. recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The 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 changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding 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 could receive a shock by touching these
71. rents which are significantly higher than their running current These higher starting currents may cause the circuit breaker to open If this situation occurs the user should refrain from using the DC 655 auxiliary power for that equip ment MACHINE PROTECTION THERMAL FAN CONTROL The machine s cooling fan remains off when the tem perature of the rectifiers and windings inside the machine are below that requiring air flow cooling as determined by electronic monitoring of several thermal sensors and the welding current of the machine The fan may remain off until welding begins but once the fan is activated it will remain on for at least 5 minutes to assure proper cooling This feature saves energy and also minimizes the amount of dirt and other air borne 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 mounted on the fan motor bracket MACHINE SHUTDOWN The DC 655 provides shutdown modes for thermal over heating excessive load currents and faults It also provides an idle timer shutdown feature for addi tional operating economy DC 655 LINCOLN 6 OPERATION B 6 THERMAL SHUTDOWN This welder has thermostatic protection from exces sive duty cycles overloads loss of cooling and high ambient temperature When the welder is subjected to an overload or loss of cooling a thermostat will open
72. ropriate strain relief clamp for the cable being used NOTE There are two work sense lead connection points on the terminal strip Connect both the work sense lead 21 from the 14 pin connector 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 Output Control Output Control Output Control Work Connection Work Connection 42 VAC Trigger Circuit Trigger Circuit 115 115 415VAC circuit is also present on IEC 974 1 European models if connecting a feeder cable directly to the terminal strip Lead 21 from 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 DC 655 LINCOLN 1 OPERATION 1 SAFETY PRECAUTIONS Read and understand this entire section before oper ating the machine GENERAL WARNINGS A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS DE can cause fire or explosion Keep flammable material away not weld on containers
73. rrent return paths which may damage the earth circuits of other equipment Assessment of Area Before 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 the welding equipment radio and television transmitters and receivers c computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures the time of day that welding or other activities are to be carried out 110093 3 1 96 LINCOLN SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s
74. rsonnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or s
75. s should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them 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 and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Mar 95 LINCOLN ELECTRIC SHOCK kill 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 bare skin 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 full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Cons
76. siy 10 eq peaj Buisues a6e 0A HL9N3 98991S Uy uonejjeisur 0U 10 ejqeains Ajjeoiskyd JeDje 10 SMW p 4t Suisn ajoeydeoes 10 S10 98UU09 dus ui slqeo 04002 1z peaj g N pue pue ay 126062 190010 Jo aq 151 sejqeo WN SHOLOANNOO 0751 41819 TVNIINH3I 31879 1081 09 803 318 0 TOHINO9 Gute SIU 901095 10 SN pjnous 505190 pallenb 10 e H Q 4189 LAdNI DIAGRAMS ed 3 19 5 YS S VN OL syed e uono 10000 e HOLOINNOO 9118 0 3dALSW Nid PL TTT 1 810190 921105 18 00 990000810 11870 10H1NO9 parowa 8121800 10000 e ONINIVM wW 31870 1081 0 3040065 310V1d3038 394N0S 009 240 HO SS9 9d SS9 AD IHL OL YS S VN 40 NOILO3NNOO DC 655 LINCOLN E LO 086225 386 08 01 OV cV OV tr MIIA 1 ON1d 3199 Nid L ANY MJA ond 318 0 Nid vl XHOM 12 H MJA 319V143934 143905271 MJA 1 310V1d3903H 13H90S 1I JOHINOO INdLNO 1173 N 9 4 9 73 N TOHINOD 1ndinO 92 4
77. t mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard 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 Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through po
78. tant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby pe
79. that have held combustibles ARC RAYS can burn Wear eye ear and body protection Observe additional Safety Guidelines detailed throughout this manual GENERAL DESCRIPTION The 655 is an energy efficient constant voltage DC power source that produces outstanding arc characteristics for multi ple CV or CC welding processes Four models are available Domestic all 60 Hertz models except 230 460 575v NEMA Class 1 rated Canadian 230 460 575v 60 Hertz NEMA Class 1 rated European 50 60 Hertz models CE qualified and rated for IEC 974 1 Export 50 60 Hertz models NEMA Class 1 rated RECOMMENDED PROCESSES AND EQUIPMENT The 655 is designed for CV CC processes CV processes include GMAW MIG and FCAW flux cored welding plus the capability of CV submerged arc welding and air carbon arc gouging It produces outstanding welding performance with a single range full output control knob CC processes include stick welding CC submerged arc and superior air carbon arc gouging with up to 3 8 10 mm diameter carbons The same single range full output control knob is used and paralleling capability is provided The DC 655 is recommended for use with Lincoln s DH 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 and LN 25 semiautomatic wire feeders It is also recom mended for use with the NA 3 NA 5 and NA 5R auto matic feeders Cold starti
80. this product to you CUSTOMER ASSISTANCE POLICY The 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 Lincoln Electric 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 customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty 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 control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This informat
81. to 7 as necessary to prevent stubbing or pop outs while welding This higher Arc Force is commended especially for low end 6010 stick welding CC MODE HOT START Hot start is built in for CC mode stick and carbon arc starting Hot Start provides an extra weld current boost at the arc strike which increases with higher current settings This Hot Start level exponentially decays to the weld current setting in a few seconds Adjustment of the Hot Start shouldn t 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 Switch 3 is for test purposes and is to DIP Switch be down CC Hot Start 21 4 Trimmer ra 0 e Switch 4 Hi CV Current Limit as shown Note See Machine Shutdown section for use of switch 1 and 2 DC 655 Control PC Board The DC 655 is rated for air carbon arc gouging with up 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 carbon stubbing DC 655 LINCOLN 5 C1 ACCESSORIES 1 DC 655 can be used to power of the following Lincoln Wire feeders SEMI AUTOMATIC WIRE FEEDERS LN 15
82. ues d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion son
83. uld be running LED6 will be ON whenever LED s 2 3 4 or 5 is ON If LED s 2 3 4 or 5 are ON when LED6 is ON replace PCB CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed DC 655 LINCOLN 5 y 916005 480 0670 901105 amod 995 192105 amod uo seuojiws Buras 190010 104 101 01 10 10 J N 9100 0 13491 osy Auejod 1900 0 0 jenuew 921105 Jamod 01 5115 110410 91211101006 peddinba ji 19098 UO YOIIMS ay uoriisod pue 821105 jo uonisod jenjoe jueseide lueSsaoeu zou seop 9 au speoj YOM pue 34 951948 410 amod pofueup Quejod aniisod pejoeuuoo smoys eAoqy si Auejod eu Jeneueuw ed 8 SEIN SONS siu Auejod YOM YU 1z eui 0 1090109 LS 0 081290102 eq o1 S 28 peal Ji jeuiuue Sty OL W 0 1 10euuoo pesn si 1 ue 92105 18mod 01 pejoeuuoo eq 1snui 50010290102 Jewod 1ndui 92
84. use this equipment Save this manual and keep it handy 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii viii TABLE OF CONTENTS PAGE INSTALLATION Sis ari ag a Gratin SECTION A TECHNICAL SPECIFICATIONS IDEALARC DC 655 A 1 GRAPHIC SYMBOLS THAT APPEAR ON RATING PLATE A 2 SAFETY PRECAUTIONS rh tons Waa Bd bie times Tide ee ea A 3 SELECT SUITABLE LOCATION sas ct ouate date tea nage demo A 3 STACKING ass hac Re A 3 TENUNG ses Sa ud A 3 ELECTROMAGNETIC COMPATIBILITY 1 A 3 ELECTRICAL INPUT CONNECTIONS A 3 FUSE AND WIRE SIZES st So baie cae Goan dade awa eee A 3 GROUND CONNECTION ick caw ted ebb be ge de de out A 3 INPUT POWER SUPPLY CONNECTIONS 1 A 4
85. wer lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is compe tent to access whether the changes will increase the risk of injury e g by allowing parallel welding cu
86. y power available for the wire feeder circuit breaker protected 115 VAC auxiliary power protected by a 20 amp breaker available for the wire feeder Canadian Code 10502 European and Export Models protected by 15 amp breaker 115 VAC duplex receptacle protected by 20 amp breaker is available on Domestic and Canadian Models except for Canadian Code 10502 receptacle that is a NEMA 5 15R protected by a 15 amp break er 220 VAC receptacle on European and Export els for connecting to a water cooler Protected by 2 amp breaker Single MS type 14 pin connection for wire feeder Optional Field Installed Digital Voltmeter Ammeter kits are available or Analog Optional dual feeder kit for like polarity connection of two wire feeders Easy panel installation Optional Dual Process Switch for two processes with polarity change and electrical isolation WELDING CAPABILITY The DC 655 has the following Output and Duty Cycle based on operation for a 10 minute period 650 Amps 44 Volts at 100 815 Amps 44 Volts at 60 DC 655 LINCOLN 3 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 2 and corresponding explanations OPERATION B 3 FIGURE B 1 CONTROL PANEL CONTROLS INPUT POWER ON OFF SWITCH This tog gle switch turns the machine on or off Putting the switch in the

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