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Manual Lincoln Electric DC-655

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  • Lincoln Electric DC-655 - page 1

    SVM142-A September , 2002 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRE ...

  • Lincoln Electric DC-655 - page 2

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i IDEALARC DC-655 FOR ENGINE po wered equipment. 1.a. T ur n the engine off bef ore troubleshooting and maintenance wor k unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Oper ate engines in ...

  • Lincoln Electric DC-655 - page 3

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii IDEALARC DC-655 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. ...

  • Lincoln Electric DC-655 - page 4

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii IDEALARC DC-655 FOR ELECTRICALL Y po wered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S. National Electrical Code, all local co ...

  • Lincoln Electric DC-655 - page 5

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv IDEALARC DC-655 PRÉCAUTIONS DE SÛRETÉ Pour votre pr opre protection lir e et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- an ...

  • Lincoln Electric DC-655 - page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v IDEALARC DC-655 Page Safety ............................................................................................................................... ..................i-iv Installation ............................................................................................................... ...

  • Lincoln Electric DC-655 - page 7

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 IDEALARC DC-655 Installation .............................................................................................................................Section E T echnical Specifications - Ide ...

  • Lincoln Electric DC-655 - page 8

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 A-2 IDEALARC DC-655 INST ALLA TION TECHNICAL SPECIFICA TIONS – DC-655 V olts at Rated Amperes 44 44 Amps 650 815 A uxiliary Po wer See the OPERA TION section f or A uxilia ...

  • Lincoln Electric DC-655 - page 9

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-3 A-3 IDEALARC DC-655 3 Phase transf ormer with rectified DC output INPUT PO WER THREE PHASE Designates welder complies with National Electrical Manuf acturers ...

  • Lincoln Electric DC-655 - page 10

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T ur n the input power OFF at the disconnect switch or fuse box befor e working on this equipment. • T ur n the Power Switch on the DC-655 “OFF” befor e connecting ...

  • Lincoln Electric DC-655 - page 11

    INPUT POWER SUPPL Y CONNECTIONS A qualified electrician should connect the input power supply leads. 1. Follow all national and local electrical codes. 2. Use a three-phase line. 3. Remove the input access door at upper rear of the machine. 4. Follow input supply connection diagram located on the inside of the door . 5. Connect the three-phase AC p ...

  • Lincoln Electric DC-655 - page 12

    OUTPUT CONNECTIONS ELECTRODE AND WORK CABLES Use the shortest possible cable lengths. See T able A.1 for recommended cable sizes based on length. The output terminals are located at the lower fr ont of the welder behind a hinged door . Refer to Figure A.3. Route the welding cables through the slotted strain r eliefs of the base to the welding termi ...

  • Lincoln Electric DC-655 - page 13

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-7 A-7 IDEALARC DC-655 AUXILIAR Y POWER AND CONTROL CONNECTIONS Located at the lower front of the welder behind a hinged door is a 115 V AC duplex receptacle for ...

  • Lincoln Electric DC-655 - page 14

    TERMINAL STRIPS T erminal strips are available behind the cover panel on the lower case front to connect wir e 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 T erminal Strip charts. See Auxiliary Power T ab ...

  • Lincoln Electric DC-655 - page 15

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 IDEALARC DC-655 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Precautions ................ ...

  • Lincoln Electric DC-655 - page 16

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 IDEALARC DC-655 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY PRECAUTIONS ELECTRIC SHOCK ...

  • Lincoln Electric DC-655 - page 17

    GENERAL DESCRIPTION The DC-655 is an ener gy efficient constant voltage DC power source that pr oduces outstanding arc charac - teristics for multiple 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 Her ...

  • Lincoln Electric DC-655 - page 18

    1. INPUT POWER ON/OFF SWITCH - This tog- gle switch turns the machine on or off. Putting the switch in the ON position ener gizes the machine’ s input contactor applying input power to the machine. Switching the switch to the OFF position de-ener gizes the input contactor . This switch is also used to reset a machine shutdown. (See Machine Shutdo ...

  • Lincoln Electric DC-655 - page 19

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-5 B-5 IDEALARC DC-655 CC mode may also be used for CC submer ged arc with appropriate ar c-sensing CC(VV) wire feeders if arc for ce is set high enough. Refer to W ...

  • Lincoln Electric DC-655 - page 20

    3. 42 V AC 10 AMP CIRCUIT BREAKER - This br eaker pr otects the 42 V AC auxiliary circuits locat- ed in the terminal strip and MS-receptacle. 4. 14-PIN MS-RECEPT ACLE - This connector pr o- vides easy connection for a wire feeder contr ol cable. It provides connections for auxiliary power , output switching, remote output contr ol, wire feed- er vo ...

  • Lincoln Electric DC-655 - page 21

    THERMAL SHUTDOWN This welder has thermostatic protection fr om 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. This condition will be indicated by the illumination of the yellow Thermostatic Protection Light on the case fr ont ...

  • Lincoln Electric DC-655 - page 22

    WELDING PERFORMANCE LOW INDUCT ANCE TERMINAL The inside right Negative (-) terminal is lower choke inductance and presently is only r ecommended for welding with NR203Ni 1% procedur es. All other pr ocesses ar e to be welded using the outside right Negative (-) terminal with higher choke inductance. CV MODE CURRENT -LIMITING CV MIG and CV Sub-Arc m ...

  • Lincoln Electric DC-655 - page 23

    T ABLE OF CONTENTS - ACCESSORIES - Accessories.................................................................................................................... .......Section C Field Installed Options ................................................................................................................C-2 Connection of Lincoln Electric ...

  • Lincoln Electric DC-655 - page 24

    FIELD INST ALLED OPTIONS K1482-1 Digital Ammeter/V oltmeter Kit - Installs easily to the front contr ol panel and provides digital display of actual welding voltage and amperage while welding. (Installation instructions are included with the kit). K1483-1 Analog Ammeter/V oltmeter Kit - Installs easily to the front contr ol panel and provides analo ...

  • Lincoln Electric DC-655 - page 25

    The DC-655 can be used to power any of the following Lincoln Wire feeders: SEMI-AUTOMA TIC WIRE FEEDERS • DH-10 • LN-9* • LN-10 • LN-9 GMA* • LN-7 GMA* • LN-23P • LN-742 • LN-25 • LN-7* • LN-8* AUTOMA TIC WIRE FEEDERS* • NA-3 • NA-5R • NA-5 • L T -7 T r actor * European DC-655 models only provide 115V AC f or these feede ...

  • Lincoln Electric DC-655 - page 26

    NOTE: The connection diagram shown in Figure C.1 shows the electrode connected for positive polarity . T o change polarity: a. Set the Idealarc DC-655 POWER toggle switch to the OFF (0) position. b. Move the electrode cable to the negative (-) output terminal. (High inductance or low inductance, as needed). c. Move the work cable to the positive (+ ...

  • Lincoln Electric DC-655 - page 27

    6. Connect NA-5/-5R wire feeder contr ol jumpers on V oltage Control Boar d. See NA-5/-5R Operator’ s Manual. NOTE: The connection diagram shown in Figure C.2 shows the electrode connected for positive polarity . T o change polarity: a. Set the Idealarc DC-655 POWER toggle switch to the OFF (0) position. b. Move the electrode cable to the negativ ...

  • Lincoln Electric DC-655 - page 28

    SEMIAUTOMA TIC WIRE FEEDERS CONNECTING THE LN-7 TO THE IDEALARC DC-655 (14-PIN MS RECEPT ACLE) 1. Set the POWER toggle switch to the OFF (0) posi- tion. 2. Disconnect main AC input power to the Idealarc DC-655. 3. Connect the electrode cable fr om the control cable to the “+” terminal of the welder and to the LN-7 wire feeder . Connect the work ...

  • Lincoln Electric DC-655 - page 29

    CONNECTING THE LN-7 TO THE IDEALARC DC-655 (TERMINAL STRIP) 1. Set the Idealarc DC-655 POWER toggle switch to the OFF (0) position. 2. Disconnect main AC input power to the Idealarc DC 655. 3. Connect the wire feeder contr ol cable leads to the Idealar c DC-655 terminal strip as shown in Figure C.3. 4. Connect the wire feeder contr ol cable ground ...

  • Lincoln Electric DC-655 - page 30

    CONNECTING THE LN-8 OR LN-9 TO THE IDEALARC DC-655 (TERMINAL STRIP) 1. Set the Idealarc DC-655 POWER toggle switch to the OFF (0) position. 2. Disconnect main AC input power to the Idealarc DC-655. 3. Connect the wire feeder contr ol cable leads to the Idealar c DC-655 terminal strip as shown in Figur e C.4. 4. Connect the wire feeder contr ol cabl ...

  • Lincoln Electric DC-655 - page 31

    CONNECTING THE LN-8 OR LN-9 TO THE IDEALARC DC-655 (14-PIN MS RECEPT ACLE) 1. Set the POWER toggle switch to the OFF (0) posi- tion. 2. Disconnect main AC input power to the Idealarc DC-655. 3. Connect the electrode cable fr om the LN-8 or LN-9 to the “+” terminal of the welder . Connect the work cable to the “-” terminal of the welder (Hig ...

  • Lincoln Electric DC-655 - page 32

    NOTES IDEALARC DC-655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric DC-655 - page 33

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 IDEALARC DC-655 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions.............................. ...

  • Lincoln Electric DC-655 - page 34

    SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this maintenance. • T ur n 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 r equire no service. 2. In extremely ...

  • Lincoln Electric DC-655 - page 35

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-3 D-3 IDEALARC DC-655 DC-655 DC-655 2 15 14 10 8 3 3 4 1 1 7 1 13 12 9 5 6 FIGURE D.1 - GENERAL COMPONENT LOCA TIONS 1. CASE FR ONT 2. OUTPUT TERMINALS 3. CASE SID ...

  • Lincoln Electric DC-655 - page 36

    NOTES IDEALARC DC-655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric DC-655 - page 37

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 IDEALARC DC-655 Theory of Operation ............................................................................................................. Section E General Description ................................................................. ...

  • Lincoln Electric DC-655 - page 38

    GENERAL DESCRIPTION The DC-655 is a three-phase, SCR contr olled DC power source. It is capable of either constant curr ent or constant voltage output. It is rated at 650 amps, 100% duty cycle with outstanding arc characteristics for multiple welding processes. INPUT LINE, CONT ACTOR, RECONNECT , F AUL T PROTECTION AND TRANSFORMERS The desired thr ...

  • Lincoln Electric DC-655 - page 39

    CONTROL BOARD, FIRING BOARD, SNUBBER/F AN, BOARD AND RECTIFICA TION The “neutrals” of the welding secondary windings in the main transformer are connected together , and the six starts are connected to the six Silicon Contr olled Rectifier (SCR) assemblies to form a six-phase output. This six-phase AC output from the main transformer secondary ...

  • Lincoln Electric DC-655 - page 40

    THEOR Y OF OPERA TION E-4 E-4 IDEALARC DC-655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROTECTIVE DEVICES AND SHUTDOWN CIRCUITS THERMAL PROTECTION T wo thermostats protect the DC-655 fr om excessive operating temperatur ...

  • Lincoln Electric DC-655 - page 41

    SCR OPERA TION A silicon controlled r ectifier (SCR) is a three-terminal device used to control rather lar ge currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is current flow fr om anode to cathode. In the ON state the SCR acts like a closed switch. When the SCR is tur ned ...

  • Lincoln Electric DC-655 - page 42

    NOTES IDEALARC DC-655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric DC-655 - page 43

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 IDEALARC DC-655 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide .............................................................. ...

  • Lincoln Electric DC-655 - page 44

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may ...

  • Lincoln Electric DC-655 - page 45

    TROUBLESHOOTING & REP AIR F-3 F-3 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical ...

  • Lincoln Electric DC-655 - page 46

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do ...

  • Lincoln Electric DC-655 - page 47

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do ...

  • Lincoln Electric DC-655 - page 48

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 IDEALARC DC-655 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do ...

  • Lincoln Electric DC-655 - page 49

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do ...

  • Lincoln Electric DC-655 - page 50

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do ...

  • Lincoln Electric DC-655 - page 51

    TROUBLESHOOTING & REP AIR F-9 F-9 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do ...

  • Lincoln Electric DC-655 - page 52

    TROUBLESHOOTING & REP AIR F-10 F-10 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you d ...

  • Lincoln Electric DC-655 - page 53

    TROUBLESHOOTING & REP AIR F-11 F-11 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you d ...

  • Lincoln Electric DC-655 - page 54

    TROUBLESHOOTING & REP AIR F-12 F-12 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you d ...

  • Lincoln Electric DC-655 - page 55

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 IDEALARC DC-655 INTERNAL TRIGGER CIRCUIT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained pe ...

  • Lincoln Electric DC-655 - page 56

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 IDEALARC DC-655 ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. TEST PROCEDURE 1. With the correct input power applied ...

  • Lincoln Electric DC-655 - page 57

    4. Check for the presence of 42 V AC at the ter- minal strip ( #2 to #41). See the Simplified T rigger Diagram. 5. If 42 V AC is not present at the terminal strip, check the circuit br eaker and leads #42A and #41 at the P15 connector . See the Simplified T rigger Diagram. Also perform the Main T ransformer T est. 6. Remove the main input supply po ...

  • Lincoln Electric DC-655 - page 58

    9. Check continuity (zero ohms) fr om lead #41 (plug P15 pin-10) to plug J5-pin 1 at the fir- ing board. See the Simplified T rigger Diagram and Figure F .1. If a resistance of any value is indicated, check the associat- ed wires, plugs and thermostats. TROUBLESHOOTING & REP AIR F-16 F-16 IDEALARC DC-655 Return to Section TOC Return to Section ...

  • Lincoln Electric DC-655 - page 59

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 IDEALARC DC-655 FIRING BOARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained person- nel. U ...

  • Lincoln Electric DC-655 - page 60

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 IDEALARC DC-655 FIRING BOARD TEST (continued) FIGURE F .4 – FIRING BOARD TRIGGER CIRCUIT TEST POINTS AND LEDs FIRING BOARD G2699-[ ] 16 ...

  • Lincoln Electric DC-655 - page 61

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 IDEALARC DC-655 FIRING BOARD TEST (continued) IF THEN LED 7 is ON 32 V AC power is being supplied to the firing board from leads #203 and ...

  • Lincoln Electric DC-655 - page 62

    7. Connect a jumper wire fr om pin C (lead #2) to pin D (lead #4) at the 14-pin receptacle. See Figure F .5. (Or put the Output T erminal Switch in the ON position.) This should ini- tiate machine output at the welding termi- nals. LED 10 on the firing board should now be on. See T able F .1. If LED 10 does not glow when leads #2 and #4 are con- ne ...

  • Lincoln Electric DC-655 - page 63

    12. T est for 9.5 VDC to 11.0 VDC between leads #231 and #215 on the firing board. Make sure the Mode Switch (SW2) is in a constant voltage (CV) position. Locate plug J5 on the firing board. Locate leads #231 (pin-13) and #215 (pin-12). See Figure F .4. Connect a jumper wire fr om pin C (lead #2) to pin D (lead #4) at the 14-pin receptacle. (Or put ...

  • Lincoln Electric DC-655 - page 64

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 IDEALARC DC-655 W ARNING MAIN TRANSFORMER (T1) VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory tra ...

  • Lincoln Electric DC-655 - page 65

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 IDEALARC DC-655 MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) FIGURE F .6 – INPUT CONT ACTOR AND PRIMARY LEADS TEST PROCEDURE 1. Dis ...

  • Lincoln Electric DC-655 - page 66

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 IDEALARC DC-655 MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) FIGURE F .7 - MAIN TRANSFORMER SECONDAR Y LEADS TO COMMON BUS VOL T AGE ...

  • Lincoln Electric DC-655 - page 67

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 IDEALARC DC-655 MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) 10. T est for 115 V AC between leads #31 and #32 on the terminal strip. ...

  • Lincoln Electric DC-655 - page 68

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-26 F-26 IDEALARC DC-655 15. Locate plug J5 on the firing board. See Figure F .9. ELECTRIC SHOCK can kill. • Do not touch electrically hot parts ...

  • Lincoln Electric DC-655 - page 69

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 IDEALARC DC-655 W ARNING CONTROL TRANSFORMER (T2) TEST Service and repair should be performed by only Lincoln Electric factory trained pe ...

  • Lincoln Electric DC-655 - page 70

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 IDEALARC DC-655 CONTROL TRANSFORMER (T2) TEST (continued) FIGURE F .10 – CONTROL TRANSFORMER TEST PROCEDURE 1. Disconnect the main AC i ...

  • Lincoln Electric DC-655 - page 71

    TROUBLESHOOTING & REP AIR F-29 F-29 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Locate the control transformer secondary leads. See Figure F .10. Lead X1 is con- nected to the coil terminal on the C ...

  • Lincoln Electric DC-655 - page 72

    TROUBLESHOOTING & REP AIR F-30 F-30 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING CONTROL BOARD TRANSFORMER (T3) TEST Service and repair should be performed by only Lincoln Electric factory trai ...

  • Lincoln Electric DC-655 - page 73

    F-31 F-31 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR CONTROL BOARD TRANSFORMER (T3) TEST (continued) TEST PROCEDURE 1. Disconnect the main AC input power to the DC-655 machin ...

  • Lincoln Electric DC-655 - page 74

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 IDEALARC DC-655 W ARNING INPUT CONT ACTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. ...

  • Lincoln Electric DC-655 - page 75

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 IDEALARC DC-655 INPUT CONT ACTOR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 3/ ...

  • Lincoln Electric DC-655 - page 76

    TEST FOR CONT ACT CONTINUITY 1. Disconnect the main input supply power to the DC-655 machine. 2. Locate, label and remove the thr ee leads connected to the input contactor coil (X1/#256 and #255A). See Figure F .13. ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. 3. Using the external 120 V AC supply , apply 120 V AC to the termin ...

  • Lincoln Electric DC-655 - page 77

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 IDEALARC DC-655 W ARNING ST A TIC SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Una ...

  • Lincoln Electric DC-655 - page 78

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 IDEALARC DC-655 ST A TIC SCR TEST (continued) FIGURE F .14 – THERMAL F AN/SNUBBER BOARD AND FIRING BOARD PLUG LOCA TIONS THERMAL F AN / ...

  • Lincoln Electric DC-655 - page 79

    6. If a high or infinite resistance is indicated for both steps #4 and #5, SCR1 is not shorted. 7. If a low resistance is indicated in either steps #4 or #5, there is a shorted SCR in the out- put rectifier bridge. Repeat steps #4 and #5 for each of the six SCRs. It may be neces- sary to disconnect the transformer sec- ondary leads from the r ectif ...

  • Lincoln Electric DC-655 - page 80

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 IDEALARC DC-655 W ARNING ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unaut ...

  • Lincoln Electric DC-655 - page 81

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 IDEALARC DC-655 ACTIVE SCR TEST (continued) FIGURE F .16 – THERMAL F AN/SNUBBER BOARD AND FIRING BOARD PLUG LOCA TIONS THERMAL F AN / S ...

  • Lincoln Electric DC-655 - page 82

    4. Construct the circuit shown in Figur e F .17. One 6-volt lantern battery can be used. Set the voltmeter scale low , at approximately 0- 5 volts or 0-10 volts. a. T est the voltage level of the battery . Short leads (A) and (C). Close switch SW-1. Battery voltage should be 4.5 volts or higher . If lower , r eplace the bat- tery . 5. Connect the T ...

  • Lincoln Electric DC-655 - page 83

    TROUBLESHOOTING & REP AIR F-41 F-41 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL F AN/SNUBBER BOARD LED CHAR T LED # LED FUNCTIONS AND INDICA TIONS (Machine is ON) 1 Indicates fan should be runn ...

  • Lincoln Electric DC-655 - page 84

    TROUBLESHOOTING & REP AIR F-42 F-42 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL BOARD LED CHAR T LED # LED FUNCTIONS AND INDICA TIONS (Machine is ON) 1 Indicates that the mode switch (SW2) is i ...

  • Lincoln Electric DC-655 - page 85

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-43 F-43 IDEALARC DC-655 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical ...

  • Lincoln Electric DC-655 - page 86

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 IDEALARC DC-655 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical ...

  • Lincoln Electric DC-655 - page 87

    TROUBLESHOOTING & REP AIR F-45 F-45 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical ...

  • Lincoln Electric DC-655 - page 88

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-46 F-46 IDEALARC DC-655 This is the typical DC open circuit voltage wave- form generated from a pr operly operating machine. Note that each verti ...

  • Lincoln Electric DC-655 - page 89

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 IDEALARC DC-655 This is the typical DC open circuit voltage wave- form. The machine was in an open circuit con- dition (no load) and oper ...

  • Lincoln Electric DC-655 - page 90

    INST ALLA TION F-48 F-48 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC This is NOT the typical DC open circuit voltage waveform. One output SCR is not functioning. Note the “gap” in the waveform. One SCR ...

  • Lincoln Electric DC-655 - page 91

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 IDEALARC DC-655 W ARNING INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT Service and repair should be performed by only Lincoln Electric fact ...

  • Lincoln Electric DC-655 - page 92

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-50 F-50 IDEALARC DC-655 CLEANING PROCEDURE 1. Remove the main input supply power to the machine. 2. Locate and get access to the input contac- to ...

  • Lincoln Electric DC-655 - page 93

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 IDEALARC DC-655 W ARNING SCR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT PROCEDURE Service and repair should be performed by only Lincoln E ...

  • Lincoln Electric DC-655 - page 94

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 IDEALARC DC-655 PROCEDURE 1. Remove the input power to the DC-655 machine. 2. Using the 3/8” wrench, r emove the case top and sides. 3. ...

  • Lincoln Electric DC-655 - page 95

    Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 IDEALARC DC-655 FIGURE F .20 – SCR RECTIFIER BRIDGE ASSEMBL Y DET AILS SCR RECTIFIER BRIDGE LEG ASSEMBL Y MOUNTING BRACKETS MAIN TRANSF ...

  • Lincoln Electric DC-655 - page 96

    TROUBLESHOOTING & REP AIR F-54 F-54 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING MAIN TRANSFORMER AND CHOKE REMOV AL AND REPLACEMENT PROCEDURE Service and repair should be performed by only Lin ...

  • Lincoln Electric DC-655 - page 97

    TROUBLESHOOTING & REP AIR F-55 F-55 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .21 – OUTPUT CHOKE/MAIN TRANSFORMER ASSEMBL Y DET AILS CHOKE THERMOST A T (LEADS #273 AND 41A) CHOKE / FRAME M ...

  • Lincoln Electric DC-655 - page 98

    TROUBLESHOOTING & REP AIR F-56 F-56 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND CHOKE REMOV AL AND REPLACEMENT PROCEDURE (continued) MAIN TRANSFORMER REMOV AL 10. With the 1/2” w ...

  • Lincoln Electric DC-655 - page 99

    TROUBLESHOOTING & REP AIR F-57 F-57 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REP AIR Should a machine under test be rejected for any r eason requiring the r emoval of any mechanical par ...

  • Lincoln Electric DC-655 - page 100

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information w ...

  • Lincoln Electric DC-655 - page 101

    ELECTRICAL DIA GRAMS G-1 G-1 DC 655 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section...........................................................................................Section G Wiring Diagram (60 Hz Domestic) (G3348-1)............................................................. ...

  • Lincoln Electric DC-655 - page 102

    G-2 ELECTRICAL DIA GRAMS DC 655 Wiring Diagram (G3348-1) BRASS 305 G2 G5 G4 G3 G1 G6 41 222 1 2 3 4 1 J7 2 G5 3 4 5 A B 2 GREEN (FRONT VIEW) RECEPTACLE (FRONT VIEW) (FRONT VIEW) 77 RECEPTACLE 41 14-PIN 42 RECEPTACLE (LEFT) GREEN 2 4 42 31 76 32 2 14-PIN STANDARD 2 GREEN 4 OPTIONS H3 H4 H2 H1 G2 4 SCR 2 A4 SCR G4 A2 SCR 6 G6 A6 G2 14 J8 3 4 6 7 G5 8 ...

  • Lincoln Electric DC-655 - page 103

    G-3 ELECTRICAL DIA GRAMS DC 655 G-3 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Contr ol Board Sc hematic (G3384) PROTECTION CURRENT PEAK OVER PROTECTION CURRENT REFERENCE POT FAULT IDLE ZERO CV FEEDBACK >15 AMP SWITCH ...

  • Lincoln Electric DC-655 - page 104

    G-4 ELECTRICAL DIA GRAMS DC 655 Firing Board Sc hematic (G2792) 7-17-98A G2792 G-4 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board lev e ...

  • Lincoln Electric DC-655 - page 105

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-5 ELECTRICAL DIA GRAMS SQU ARE W A VE TIG 275 Thermal Fan/Sn ubber Board Sc hematic (L10123) 5-16-97A L10123 G-5 NO TE: Lincoln Electric assumes no responsibility for liab lil ...

  • Lincoln Electric DC-655 - page 106

    ELECTRICAL DIA GRAMS G-6 G-6 DC 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Contr ol Boar d Lay out (G3385-1) G3385-1 C-R W CAP A CIT ORS = MFD/VOL TS RESIST ORS = OHMS/1/4 W A TT UNLESS O THERWISE SPECIFIED C-RW G3385 ...

  • Lincoln Electric DC-655 - page 107

    ELECTRICAL DIA GRAMS G-7 G-7 DC 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Firing Board La yout (G2699-2) DESCRIPTION PART NO. ITEM REQ'D FIRING BOARD G2699-2 CAPACITORS = MFD/VOLTS RESISTORS = OHMS 7-17-98A G269 ...

  • Lincoln Electric DC-655 - page 108

    ELECTRICAL DIA GRAMS G-8 G-8 DC 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Thermal Fan/Sn ubber Board La yout (L10124-1) CAPACITORS = MFD/VOLTS ~.04 IDENTIFICATION PART NO. REQ'D ITEM RESISTORS = OHMS 0 5.75 6.00 ...

  • Lincoln Electric DC-655 - page 109

    NO TES DC 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Manufacturer Lincoln Electric Category Soldering Gun

Documents that we receive from a manufacturer of a Lincoln Electric DC-655 can be divided into several groups. They are, among others:
- Lincoln Electric technical drawings
- DC-655 manuals
- Lincoln Electric product data sheets
- information booklets
- or energy labels Lincoln Electric DC-655
All of them are important, but the most important information from the point of view of use of the device are in the user manual Lincoln Electric DC-655.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Lincoln Electric DC-655, service manual, brief instructions and user manuals Lincoln Electric DC-655. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Lincoln Electric DC-655.

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A complete manual for the device Lincoln Electric DC-655, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Lincoln Electric DC-655 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Lincoln Electric DC-655.

A complete Lincoln Electric manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Lincoln Electric DC-655 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Lincoln Electric DC-655, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Lincoln Electric DC-655, that we can find in the current document
3. Tips how to use the basic functions of the device Lincoln Electric DC-655 - which should help us in our first steps of using Lincoln Electric DC-655
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Lincoln Electric DC-655
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Lincoln Electric DC-655 in a specific country, if it was not possible to solve the problem on our own.

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