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Lincoln Electric CV-655 Operator's Manual

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IM570
CV-655
May, 2005
For use with machine Code Number 10120 thru 10129.
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.
IP23
OPERATOR'S MANUAL
Copyright © 2005 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

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  • Page 1 IM570 CV-655 May, 2005 For use with machine Code Number 10120 thru 10129. 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.

  • 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 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.

  • Page 7: Table Of Contents

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

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – CV-655 INPUT - THREE PHASE ONLY Input Current at Rated Output Standard Code 100% Duty Cycle 60% Duty Cycle Voltage Number 94/47 116/58 230/460/60 10120 94/47/38 116/58/47 230/460/575/60 10121 104/52 128/64 208/416/60 10122 460/60 10123 575/60...

  • Page 9: Graphic Symbols That Appear On Rating Plate

    International Electrotechnical IEC 974-1 Commission requirements 974-1. (European Models) Designates welder complies with both Underwriters Laboratories (UL) standards and Canadian Standards Association (CSA) NRTL/C standards. (Canadian Model) Designates welder complies with Underwriters Laboratories (UL) standards. (Domestic Models) NRTL CV-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 CV-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 CV-655...

  • Page 12: Output Connections

    4. Work Sense lead #21 from the 14 Pin MS-recepta- A.1 for recommended cable sizes based on length. cle must be connected to “-21”on the terminal strip. Note: This is how the CV-655 is shipped from TABLE A.1 the factory.

  • 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. CV-655...

  • Page 14: Terminal Strips

    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. CV-655...

  • Page 15: Operation

    OPERATION SAFETY PRECAUTIONS GENERAL DESCRIPTION Read and understand this entire section before oper- The CV-655 is an energy efficient constant voltage DC power ating the machine. source that produces outstanding arc characteristics. Four models are available: GENERAL WARNINGS Domestic - all 60 Hertz models except 230/460/575v.

  • Page 16: Welding Capability

    Protected by 2 amp breaker. WELDING CAPABILITY The CV-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%...

  • Page 17: Controls And Settings

    OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the CV-655. Refer to Figures B.1, and B.2 and corresponding explanations. CV-655 FIGURE B.1 CONTROL PANEL CONTROLS 1. INPUT POWER ON/OFF SWITCH - This tog- machine’s output terminals will be electrically ener-...
  • Page 18 This terminal strip contains the same circuits as the 14 pin MS-receptacle. The cover also provides for installation of cable strain relief clamps. 6. NEGATIVE OUTPUT TERMINAL - This output ter- minal is for connecting a welding cable. To change CV-655...

  • Page 19: Auxiliary Power

    CAUTION OVERLOAD PROTECTION When using a CV-655 with wire feeders, there will be This welder has thermostatic protection from exces- a small spark if the electrode contacts the work or sive duty cycles, overloads, loss of cooling, and high ground with several seconds after releasing the trig- ambient temperatures.

  • Page 20: Accessories

    Mechanized towing can lead to injury and /or damage • NA-5 to the CV-655. * European CV-655 models only provide 115VAC for these feeders at the REMOTE OUTPUT CONTROL terminal strip (TS2) (K775 or K857 WITH K864 ADAPTER) “Cold starting for sub-arc cannot be used. (It must be jumpered out. See Auto Feeder manual) An optional “remote output control”...

  • Page 21: Maintenance

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

  • Page 22: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician 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.

  • Page 23: Troubleshooting

    See PC board LED information. 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. CV-655...
  • Page 24 2. 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. CV-655...
  • Page 25 (#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. CV-655...
  • Page 26 See PC board LED information. 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. CV-655...
  • Page 27 20A). 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. CV-655...
  • Page 28 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. CV-655...
  • Page 29 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. CV-655...
  • Page 30 1000 amp current draw. If no short or 1000 amp load exists, replace Control Printed Circuit Board. 7. LED’s 9 & 11 should be OFF on CV-655 machines. 8. LED10 should be ON when machine power is ON. If not replace Control (PCB).
  • Page 31 2, 3, 4, or 5 are not ON when LED6 is ON, replacePrinted Circuit Board. 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. CV-655...

  • Page 32: Diagrams

    DIAGRAMS CV-655...
  • Page 33 DIAGRAMS CV-655...
  • Page 34 DIAGRAMS CV-655...
  • Page 35 DIAGRAMS CV-655...
  • Page 36 DIAGRAMS CV-655...
  • Page 37 DIAGRAMS CV-655...
  • Page 38 DIAGRAMS CV-655...
  • Page 39 DIAGRAMS CV-655...
  • Page 40 DIAGRAMS CV-655...
  • Page 41 F-10 F-10 DIAGRAMS CV-655...
  • Page 42 NOTES CV655...
  • Page 43 NOTES CV655...
  • Page 44 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 45 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 46 • 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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