Lincoln Electric Comprehensive Manual for the Lincoln DC 655 Welder: Installation and Specifications

Page 8

Section TOC

Master TOC

A-2

A-2

INSTALLATION

TECHNICAL SPECIFICATIONS – DC-655

INPUT - THREE PHASE ONLY

Standard

Input Current at Rated Output

Code

Return to

Return to

Voltage

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

100% Duty Cycle

122/61

122/61/49

135/67.5

61

49

122/70

74/56

64

140/70

68

60% Duty Cycle

150/75

150/75/60

166/83

75

60

150/86

90/69

78

172/86

83

Number

10501

10502

10503

10504

10505

10506

10507

10508

10509

10510

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

RATED OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Duty Cycle

 

 

 

 

 

 

Amps

 

 

 

Volts at Rated Amperes

 

 

100% Duty Cycle

 

 

 

 

 

 

650

 

 

 

 

 

 

44

 

 

 

 

 

NEMA Class I (100)*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

60% Duty Cycle

 

 

 

 

 

 

815

 

 

 

 

 

 

44

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Voltage Range

 

 

Current Range

 

 

Maximum Open Circuit Voltage

 

 

 

 

Auxiliary Power

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

46 CV Mode

 

 

 

See the OPERATION section for

 

 

 

13-44 DC

 

 

 

50-815

 

 

 

 

 

68 CC Mode

 

 

 

 

Auxiliary Power

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

information by model

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RECOMMENDED INPUT WIRE AND FUSE SIZES

 

 

 

 

 

 

 

INPUT

 

 

HERTZ

INPUT AMPERE

 

TYPE 80°C

 

 

 

 

Copper

 

 

 

 

 

 

 

 

 

 

COPPER WIRE

 

GROUND WIRE

 

(SUPER LAG)

 

 

VOLTAGE /

 

 

 

 

 

 

 

RATING ON

 

 

 

 

 

 

 

 

 

 

 

 

 

IN CONDUIT

 

 

IN CONDUIT

OR BREAKER

 

 

FREQUENCY

 

 

 

 

 

 

NAMEPLATE

 

 

 

 

 

 

 

 

 

 

 

 

AWG(IEC-MM2) SIZES

 

AWG(IEC-MM2) SIZES

 

SIZE (AMPS)1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

40°C (104°F) Ambient

 

 

 

 

 

 

 

 

 

 

 

 

 

208

 

60

135

 

 

1 (43)

 

4 (21)

250

Amp

 

 

230

 

60

122

 

 

1 (43)

 

4 (21)

225

Amp

 

 

416

 

60

67.5

 

 

6 (14)

 

6 (14)

125

Amp

 

 

460

 

60

61

 

 

6 (14)

 

6 (14)

110

Amp

 

 

575

 

60

49

 

 

8 (8.4)

 

8 (8.4)

 

 

90 Amp

 

 

200

 

50/60

140

 

 

1/0 (54)

 

4 (21)

250

Amp

 

 

230

 

50/60

122

 

 

1 (43)

 

4 (21)

225

Amp

 

 

380

 

50/60

74

 

 

4 (21)

 

6 (14)

125

Amp

 

 

400

 

50/60

70

 

 

4 (21)

 

6 (14)

125

Amp

 

 

415

 

50/60

68

 

 

6 (14)

 

6 (14)

110

Amp

 

 

440

 

50/60

64

 

 

6 (14)

 

6 (14)

110

Amp

 

 

500

 

50/60

56

 

 

6 (14)

 

6 (14)

110

Amp

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PHYSICAL DIMENSIONS

 

 

 

 

 

 

 

 

 

 

 

 

HEIGHT

 

 

 

 

WIDTH

 

 

DEPTH

 

 

 

 

 

WEIGHT

 

 

27.5 in

 

 

 

 

22.2 in

 

 

38.0 in

 

 

 

 

 

720 lbs.

 

 

 

 

699 mm

 

 

 

 

564 mm

 

 

965 mm

 

 

 

 

 

326 kg.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

* European models meet IEC974-1 standards.

1Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.

IDEALARC DC-655

Image 8
Contents Idealarc DC-655 Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications DC-655Input Power Three Phase Electrical Input Connections Safety PrecautionsSelect Suitable Location Input Power Supply Connections Input Supply Connection DiagramOutput Connections Electrode and Work CablesAuxiliary Power Control Connections Auxiliary Power TableTerminal Strip 1 T.S.1 Terminal Strip 2 T.S.2Table of Contents Operation Section OPERATIONB-2 Operating InstructionsDesign Features Advantages OperationGeneral Description Recommended Processes and EquipmentDC-655 Figure B.2 Lower Case Front Controls & Connections Case Back Connections Auxiliary PowerMachine Protection Over Current Protection Shutdown Remote Control Leads Fault Protection SHUTDOWN1Thermal Shutdown CV Mode CURRENT-LIMITING CC Mode HOT StartCC Mode ARC Force CC Mode ARC Gouging Welding PerformanceTable of Contents Accessories Field Installed Options Remote Output ControlAutomatic Wire Feeders SEMI-AUTOMATIC Wire FeedersSet the Idealarc DC-655 Power toggle Accessories Semiautomatic Wire Feeders Connecting the LN-7 to the Idealarc DC-655 Terminal Strip GND Negative Positive Figure C.4 Idealarc DC-655 Table of Contents Maintenance General Maintenance Electric Shock can killFigure D.1 General Component Locations Idealarc DC-655 Table of Contents Theory of Operation Section Theory of Operation Down Circuits Protective Devices and Shutdown Circuits SCR Operation Figure E.4 SCR OperationIdealarc DC-655 Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Troubleshooting Guide Board LED Chart ControlLED Chart OutputBridge Test Perform the SCR Bridge TestTransformer Test See the Idle Shut Down TimerMain Function Problems Thermal Fan/Snubber PC Troubleshooting & Repair Welding Problems Mode Current Limiting See the Control BoardMaterials Needed Internal Trigger Circuit TestTest Description Internal Trigger Circuit Test Test ProcedureTrigger Diagram Simplified Trigger Diagram. If a resistance SectionFigure F.3 Simplified Trigger Diagram Firing Board Test Firing Board Test Figure F.4 Firing Board Trigger Circuit Test Points and LEDsMain Transformer Test Figure F.5 14-PIN Receptacle Figure F.4 Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Input Contactor and Primary LeadsTroubleshooting & Repair Figure F.8 Terminal Strip Figure F.9 Firing Board Plug J5 Pins Control Transformer T2 Test Control Transformer T2 Test Figure F.10 Control TransformerHigh Voltage is present at Control Board Transformer T3 Test Control Board Transformer T3 Test Perform the Control Transformer T2 TestInput Contactor Test Input Contactor Test Transformer T2 TestTest for Contact Continuity Figure F.13 Input Contactor Test ConnectionsStatic SCR Test Static SCR Test Figure F.15 Heat Sink Test Points Active SCR Test Active SCR Test Figure F.17 Heat Sink Test Points Anode Cathode Thermal FAN/SNUBBER Board LED Chart LED Functions and IndicationsControl Board LED Chart LED # LED Functions and IndicationsScope Settings Maximum Output Setting no Load Normal Open Circuit Voltage Waveform Constant Voltage MIGMinimum Output Setting no Load Troubleshooting & Repair Typical SCR Gate Voltage Waveform Constant Voltage MIG Installation Input Contactor CR1 CLEANING/REPLACEMENT DescriptionInput Contactor CR1 CLEANING/REPLACEMENT Cleaning ProcedureSCR Rectifier Bridge Removal Replacement Procedure SCR Rectifier Bridge Removal Replacement ProcedureProcedure Reassembly SCR Rectifier Bridge LEG Assembly Mounting BracketsMain Transformer and Choke Removal Replacement Procedure Main Transformer and Choke Removal Output Choke RemovalMain Transformer Removal Retest After Repair Input Idle Amps and WattsSVM Error Reporting Form Section G Electrical Diagrams Control Board Schematic G3384 Firing Board Schematic G2792 Thermal Fan/Snubber Board Schematic L10123 Control Board Layout G3385-1 Firing Board Layout G2699-2 Thermal Fan/Snubber Board Layout L10124-1 Return to Section TOC
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