Lincoln Electric DC-655 Operator's Manual
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Lincoln Electric DC-655 Operator's Manual

Lincoln Electric DC-655 Operator's Manual

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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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
RETURN TO MAIN INDEX
DC-655
For use with machine Code Number 10501 thru 10510
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
IM602
July, 2002

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Summary of Contents for Lincoln Electric DC-655

  • Page 1 RETURN TO MAIN INDEX IM602 DC-655 July, 2002 For use with machine Code Number 10501 thru 10510 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 ...

  • Page 2: California Proposition 65 Warnings

    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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
  • Page 6 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 this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.

  • Page 7: Table Of Contents

    TECHNICAL SPECIFICATIONS – IDEALARC DC-655 ........A-1...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – DC-655 INPUT - THREE PHASE ONLY Input Current at Rated Output Standard Code 100% Duty Cycle 60% Duty Cycle Volatge Number 122/61 150/75 230/460/60 10501 122/61/49 150/75/60 230/460/575/60 10502 135/67.5 166/83 208/416/60 10503 460/60 10504 575/60...

  • Page 9: Graphic Symbols That Appear On Rating Plate

    Designates welder complies with Constant Current Output Underwriters Laboratories (UL) Characteristics standards. (Domestic Models) NRTL SMAW 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) DC-655...

  • Page 10: Safety Precautions

    • 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 “OFF” before connecting or disconnect- ing output cables, wire feeder or remote connections, or other equipment.

  • Page 11: Input Power Supply Connections

    I N S T A L L A N D T I G H T E N A L L O F T H E H E X N U T S . TRANSF. D - U F LINKS M18225 THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. FIGURE A.2 Dual Voltage Machine Reconnection Procedure DC-655...

  • Page 12: Output Connections

    4. Work Sense lead #21 from the 14 Pin MS-recepta- TABLE A.1 cle must be connected to “-21”on the terminal strip. Cable Sizes for Combined Lengths of Copper Note: This is how the DC-655 is shipped from Electrode and Work Cable the factory. Cable Length...

  • Page 13: Auxiliary Power And Control Connections

    “-21” on the terminal strip. This is the configuration other circuits, but on the European Models one line is for positive welding. If welding negative polarity, connect lead #21 connected to chassis ground. to the “+21” connection point on the terminal strip. DC-655...

  • Page 14: Terminal Strips

    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...

  • Page 15: Operation

    OPERATION SAFETY PRECAUTIONS GENERAL DESCRIPTION Read and understand this entire section before oper- The DC-655 is an energy efficient constant voltage DC power ating the machine. source that produces outstanding arc characteristics for multi- ple CV or CC welding processes...

  • Page 16: Design Features And Advantages

    WELDING CAPABILITY tripped indicator light. • Full range output voltage (CV mode) and current The DC-655 has the following Output and Duty Cycle (CC mode) control for easy operation. based on operation for a 10 minute period: • Panel switches behind a latched front panel for...

  • Page 17: Controls And Settings

    OPERATION 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. DC-655 FIGURE B.1 CONTROL PANEL CONTROLS 1. INPUT POWER ON/OFF SWITCH - This tog- remote device such as a wire feeder closes the #2 gle switch turns the machine on or off.
  • Page 18 20 amps of 115 VAC auxiliary power on the the duplex receptacle, terminal strip and MS- recep- Domestic Models and up to 15 amps on the tacle. Breaker is rated 20 amps on Domestic Canandian Model. Models and 15 amps on all other models. DC-655...

  • Page 19: Auxiliary Power

    OPERATION 3. 42VAC 10 AMP CIRCUIT BREAKER - This DC-655 machines can also supply 115 volt AC auxil- breaker protects the 42VAC auxiliary circuits locat- iary power through the wire feeder receptacle. A 20 ed in the terminal strip and MS-receptacle.

  • Page 20: Welding Performance

    If such a fault occurs the DC-655 will shut down ambient temperature. When the welder is subjected to the input primary voltage to the transformer to prevent an overload or loss of cooling, a thermostat will open.
  • Page 21 (see Machine Protection section). “pop-outs” while welding. This higher Arc Force is rec- commended espicially for low end 6010 stick welding. As shipped, the DC-655 is set for “Hi” current limiting, which maintains constant voltage until the welding CC MODE HOT START...

  • Page 22: Accessories

    Mechanized towing can lead to injury and /or damage • NA-5 LT-7 Tractor to the DC-655. * European DC-655 models only provide 115VAC for these feeders at the REMOTE OUTPUT CONTROL terminal strip (TS2) (K775 or K857 WITH K864 ADAPTER) FIELD INSTALLED OPTIONS An optional “remote output control”...
  • Page 23 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.

  • Page 24: Maintenance

    3. Periodically check the welding cables. Inspect for any slits or punctures. Also make sure that all con- nections are tight. DC-655...

  • Page 25: Troubleshooting

    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. 2. The power switch (SW1) may be faulty. 3. The pilot transformer may be faulty.
  • Page 26 3. Check for correct welding porce- 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 technical troubleshooting assistance before you proceed. DC-655...
  • Page 27 (#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...
  • Page 28 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...
  • Page 29 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...
  • Page 30 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...
  • Page 31 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...
  • Page 32 11. LED11 indicates that there is feedback voltage present in CC mode. 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...
  • Page 33 2, 3, 4, or 5 are not 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...

  • Page 34: Diagrams

    DIAGRAMS DC-655...
  • Page 35 DIAGRAMS DC-655...
  • Page 36 DIAGRAMS DC-655...
  • Page 37 DIAGRAMS DC-655...
  • Page 38 DIAGRAMS DC-655...
  • Page 39 DIAGRAMS FROM T1 AUX. WINDINGS DC-655...
  • Page 40 DIAGRAMS FROM T1 AUX. WINDINGS CV-655...
  • Page 41 DIAGRAMS FROM T1 AUX. WINDINGS CV-655...
  • Page 42 DIAGRAMS DC-655...
  • Page 43 F-10 F-10 DIAGRAMS DC-655...
  • Page 44 NOTES...
  • Page 45 NOTES...
  • Page 46 NOTES...
  • Page 47 Year AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or,...
  • Page 48 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 49 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 50 • 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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