Lincoln Electric CV-655 User 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 thoughtful 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.

CV-655

February, 2009

For use with machine Code Number 10120 thru 10129.

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

IP23

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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 & Cutting - ANSI Standard Z49.1” 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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 Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

1.d. Keep

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 nece ssary to remove 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.

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1.b. Operate engines in open, well-ventilated areas

or vent the engine exhaust fumes

outdoors.

1.c. Do not add th e fuel welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing 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.

all equipment safety guards, covers and devices in

1.f. Do not put your hands near the engine fan.

not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

near an open flame

safety

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS 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

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders 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.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning

the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

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SAFETY

ELECTRIC SHOCK can 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

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 Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. 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.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

skin or wet clothing. Wear dry, hole-free

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. I 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 personnel 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

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 circumstances, 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 specific 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 coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

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.

ventilation and/or exhaust at the arc to keep

vapors

5.e. Read and understand the manufacturer’s instructions for this

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.

5.f. Also see item 1.b.

Jan ‘09

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SAFETY

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WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and 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.

6.b. 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 Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. 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 been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

6.g. 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 circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Us e 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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “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. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés 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 couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

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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 power 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 competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current 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 problems 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;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) 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;

h) the time of day that welding or other activities are to be carried out.

L10093 3-1-96H

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SAFETY

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 recommendations. 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 equipment, 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 equipment 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.

vivi

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 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 connection 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 problems of interference. Screening of the entire welding installation may be considered for special applications. 1

_________________________

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”

L10093 3-1-96H

Page 8

Thank You

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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. 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 possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information 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 information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

CUSTOMER ASSISTANCE POLICY

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

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to 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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

Page 9

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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Technical Specifications – IDEALARC CV-655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Graphic Symbols that appear on Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

ELECTROMAGNETIC COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Fuse and Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Input Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Electrode and Work Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Auxiliary Power and Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Auxiliary Power Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

115Vac Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

14 Pin MS Type Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

TABLE OF CONTENTS

viii

Page

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

General Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Thermal Fan Control and Fan Motor Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Machine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

P.C. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9

Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-284 Series

Page 10

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – CV-655

INPUT - THREE PHASE ONLY

Standard

Voltage

Input Current at Rated Output

100% Duty Cycle

60% Duty Cycle

A-1

Code

Number

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

NEMA Class I (100)*

60% Duty Cycle

Current Range

INPUT

VOLTAGE /

208 230 416 460 575 200 230 380 400 415 440 500

Duty Cycle

70-815

FREQUENCY

94/47

94/47/38

104/52

38 94/54 56/43

107/54

116/58

116/58/47

128/64

58 47

116/67

69/53

132/67

RATED OUTPUT

Amps

650

815

Volts at Rated Amperes

OUTPUT

Maximum Open Circuit Voltage

See the OPERATION section

RECOMMENDED INPUT WIRE AND FUSE SIZES

HERTZ

60 60 60 60

60 50/60 50/60 50/60 50/60 50/60 50/60 50/60

INPUT AMPERE

RATING ON

NAMEPLATE

104

94 52 47 38

107

94 56 54 52 49 43

TYPE 75°C

COPPER WIRE

IN CONDUIT AWG(IEC-MM2) SIZES 40°C (104°F) Ambient

1 (43) 2 (34) 6 (14) 6 (14)

8 (8.4)

1 (43) 2 (34) 6 (14) 6 (14) 6 (14) 6 (14)

8 (8.4)

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG(IEC-MM2) SIZES

6 (14)

6 (14) 8 (8.4) 8 (8.4) 8 (8.4)

6 (14)

6 (14) 8 (8.4) 8 (8.4) 8 (8.4) 8 (8.4) 8 (8.4)

10120 10121 10122 10123 10124 10125 10126 10127 10128 10129

Auxiliary

for Auxiliary Power

information by model

Power

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

200 Amp 175 Amp

90 Amp 90 Amp

70 Amp 200 Amp 175 Amp 100 Amp 100 Amp

90 Amp

80 Amp

PHYSICAL DIMENSIONS

HEIGHT

27.5 in

699 mm

* European models meet IEC974-1 standards.

Also 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.

WIDTH

22.2 in

564 mm

CV-655

DEPTH

38.0 in

965 mm

WEIGHT

652 lbs.

283 kg.

Page 11

A-2

INSTALLATION

GRAPHIC SYMBOLS THAT APPEAR ON

RATING PLATE (LOCATED ON CASE BACK)

A-2

NEMA EW 1 (100%)

IEC 974-1

3 Phase transformer with rectified DC output

INPUT POWER

THREE PHASE

Designates welder complies with National Electrical Manufacturers Association requirements EW 1 Class I with 100% duty cycle at 650Amps output. (Domestic, Canadian, and Export models)

Designates welder complies with International Electrotechnical Commission requirements 974-1. (European Models)

NRTL/C

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)

CV-655

NRTL

Designates welder complies with Underwriters Laboratories (UL) standards. (Domestic Models)

Page 12

A-3

INSTALLATION

A-3

Read entire installation section before starting installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Turn the Power switch on the CV-655 “OFF” before connecting or disconnecting output cables, wire feeder or remote connections, or other equipment.

• Do not touch electrically hot parts.

• Always connect the Idealarc CV-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 CV-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 CV655 above it.

TILTING

INPUT

CONTACTOR (CR1)

INPUT POWER SUPPLY CABLE WITH BUSHING

OR BOX CONNECTOR

FIGURE A.1 ELECTRICAL INPUT CONNECTIONS

RECONNECT

PANEL ASSEMBL Y

ELECTRICAL INPUT CONNECTIONS

Before installing the machine check that the input supply 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 manual.

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 thermal/magnetic circuit breakers.

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 CV-655 is Industrial, Scientific and Medical (ISM) group 2, class A.

The CV-655 is for industrial use only. (See prints L10093-1,

-2 safety pages in the Front of Instruction Manual for further details).

Locate the CV-655 away from radio controlled machinery. The normal operation of the CV-655 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment

CV-655

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 for proper grounding methods. Use grounding wire sizes that meet local electrical codes or see the Technical Specifications page in this manual.

Page 13

A-4

INSTALLATION

A-4

INPUT POWER SUPPLY 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 the door.

5. Connect the three-phase AC power supply leads L1, L2, and L3 to the input contactor terminals in the input box assembly. See Figure A.1.

RECONNECT PROCEDURE

WARNING

Electric Shock Can Kill

• Disconnect input power before performing this procedure.

------------------------------------------------------------------------

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 connected for the proper voltage.

CAUTION

Failure to follow these instructions can cause immediate failure of components within the machine.

------------------------------------------------------------------------

When powering welder from generator be sure to turn off welder first, before generator is shut down, in order to prevent damage to welder!

To reconnect a multiple voltage machine to a different voltage, remove input power and follow the input connection diagram located on the inside of case back input access door.

1. For dual voltage sample machine reconnect instructions, see Figure A.2.

FIGURE A.2 Dual Voltage Machine Reconnection Procedure

CV-655

Page 14

A-5

INSTALLATION

A-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

ft. (m)

0 (0) to 100 (30.4) 100 (30.4) to 200 (60.8) 200 (60.8) to 250 (76.2)

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.

For Positive Polarity:

1. Connect the electrode cable to either the low inductance terminal (marked " ") or the high inductance terminal (marked " "). See OPERATION section “Positive Output Terminals” for an explanation of the use of high or low inductance terminals.

Parallel Cables Cable Size

2 2 2

2/0 ( 70mm2) 3/0 ( 95mm2)

4/0 (120mm2)

2. Connect the work cable to the negative 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-receptacle must be connected to “-21”on the terminal strip.

Note: This is how the CV-655 is shipped from the factory.

5. Replace the terminal strip access cover panel.

For Negative Polarity:

1. Connect the work cable to either the low inductance terminal (marked " ") or the high inductance terminal (marked " "). See OPERATION section “Positive Output Terminals” for an explanation of the use of high or low inductance terminals.

2. Connect the electrode cable to the negative 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-receptacle must be connected to “+21”on the terminal strip.

5. Replace the terminal strip access cover panel.

FIGURE A.3 Output Connections

CV-655

Page 15

A-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 auxiliary power (Domestic and Canadian Models only) and a 14 Pin MS type receptacle for connection of auxiliary 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

Auxiliary Domestic Canadian European Export

Power Models Model Models Models

Connections (60Hz)

At Duplex 115V 20A 115V 15A No Duplex No Duplex

Receptacle

Terminal strip 115V 20A 115V 15A 115V 15A 115V 15A

terminals 31 & 32

MS-Receptacle 115V 20A 115V 15A

pins A & J

MS-Receptacle 42V 10A 42V 10A 42V 10A 42V 10A

pins I & K

At 220V

Receptacle

Connections for Various Models

(230/460/575V/60 Hz)

No Receptacle No Receptacle 220V 2A 220V 2A

(50/60 Hz) (50/60 Hz)

Open Circuit

115V 15A

14 PIN MS TYPE RECEPTACLE

(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)

Refer to the figure A.4 for the available circuits in the 14 pin receptacle.

42 VAC is available at receptacle pins I and K. A 10 amp circuit breaker protects this circuit.

115 VAC is available 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 connected to chassis ground.

FIGURE A.4 FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE

115VAC DUPLEX RECEPTACLE (DOMESTIC AND CANADIAN MODELS ONLY)

The 115VAC duplex receptacle is protected by a circuit breaker located below the receptacle (see Auxiliary Power Table). Receptacle is a NEMA 5-20R (protected by a 20 amp breaker) on Domestic Models and a NEMA 5-15R (protected by a 15 amp breaker) on Canadian Models.

230VAC 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 incidently contact and is a Schuko type. The circuit is protected 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.

PIN LEAD NO. FUNCTION

A 32 115 VAC B GND Chassis Connection C 2 Trigger Circuit D 4 Trigger Circuit E 77 Output Control F 76 Output Control G 75 Output Control

H 21 Work Sense Connection I 41 42 VAC

J 31 115 VAC

K 42 42 VAC L --- --M --- --N --- ---

115VAC circuit is not present on IEC 974-1 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.

CV-655

Page 16

A-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 appropriate 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 welding negative polarity.

TERMINAL STRIP 1 (T.S.1)

Lead No. Function

75 Output Control 76 Output Control 77 Output Control

A-7

TERMINAL STRIP 2 (T.S.2)

Lead No. Function

+21 Work Connection

-21 Work Connection 41 42 VAC

4 Trigger Circuit

2 Trigger Circuit 31 115 VAC 32 115 VAC

115VAC circuit is not present on IEC 974-1 models.

CV-655

Page 17

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read and understand this entire section before operating the machine.

GENERAL WARNINGS

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.

GENERAL DESCRIPTION

The CV-655 is an energy efficient constant voltage DC power source that produces outstanding arc characteristics.

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 rated for IEC 974-1 Export - 50/60 Hertz models NEMA Class 1 rated

RECOMMENDED PROCESSES AND EQUIPMENT

The CV-655 is designed for GMAW (MIG), FCAW, (except NR-203 family electrodes) and CV semi-automatic submerged arc welding processes (SAW), plus the capability of air carbon arc gouging (AAC) up to 3/8” (10mm) diameter carbons. Limited CV automatic submerged arc welding with 5/64” and smaller wires.

The CV-655 is recommended for use with Lincoln’s DH-10 or LN-10 as well as the LN-7*, LN-7 GMA*, LN742, LN-8*, LN-9*, LN-9 GMA*, LN-23P and LN-25 semiautomatic wire feeders. It is also recommended for use with the NA-3, NA-5 and NA-5R automatic feeders, but “cold starting” for sub-arc cannot be used (it must be jumpered out).

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear and body protection.

Observe additional Safety Guidelines detailed throughout this manual.

* The 14-pin MS receptacle on the European models does not provide 115 VAC for these feeders; 115 VAC must be obtained from terminal strip.

There are no provisions on the CV-655 for paralleling.

DESIGN FEATURES AND ADVANTAGES

• Two inductance positions: operator can choose the optimum arc characteristics.

• Power on/off switch with pilot light and thermostat tripped indicator light.

• Full range output voltage control for easy operation.

• Panel switches for remote or local output control, and output on or remote selection.

• Hinged cover to protect output terminals and auxiliary connections.

• 42 VAC, 10 amp auxiliary power available for the wire feeder; circuit breaker protected.

CV-655

Page 18

B-2

OPERATION

DESIGN FEATURES AND ADVANTAGES (CONT’D)

• 115 VAC, auxiliary power available for the wire feeder; circuit breaker protected. 20 amp breaker on Domestic model and 15 amp breaker on Canadian, European, and Export Models.

• 115VAC duplex plug receptacle available on Domestic and Canadian Models. 20 amp breaker on Domestic Models and 15 amp breaker on Canadian Model.

• Single MS-type (14-pin) connection for wire feeder.

• Thermal Fan Control with electronic and thermostatic protection for current overload and excessive temperatures.

• Optional Field Installed Digital or Analog Voltmeter/Ammeter kits are available.

• 220 VAC receptacle on European and Export models for connecting to a water cooler. Protected by 2 amp breaker.

B-2

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%

CV-655

Page 19

B-3

OPERATION

B-3

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-

gle switch turns the machine on or off. Putting the switch in the ON position energizes the machine’s input contactor applying input power to the machine. Switching the switch to the OFF position de-energizes the input contactor.

2. PILOT LIGHT - When the power switch is in the

ON position the machine’s white pilot light will illuminate. If the input contactor de-energizes the machine in an overload 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 Overload Protection Section)

3. OUTPUT VOLTAGE CONTROL - This control

provides continuous control of the machine’s output voltage from minimum to maximum (typical full pot range between 15 to 44 volts) as it is rotated clockwise.

4. OUTPUT TERMINALS ON/REMOTE - When this

switch is in the REMOTE position, the CV-655’s output terminals will be electrically “cold” until a 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 energized all the time.

5. LOCAL/REMOTE CONTROL SWITCH - When this

switch is set to the LOCAL position, control of the output voltage is via the output voltage control on the CV-655’s control panel. When this switch is set to the REMOTE 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.

6. THERMAL PROTECTION LIGHT - 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.

7. OPTIONAL VOLTMETER & AMMETER - Digital

or analog meter kits are available as field installed options. Refer to the Accessories Section of this manual.

CV-655

Page 20

B-4

OPERATION

B-4

1 2

FIGURE B.2 LOWER CASE FRONT CONTROLS & CONNECTIONS

1. 115VAC DUPLEX RECEPTACLE (Domestic and

Canadian Models) This receptacle provides up to

20 amps of 115 VAC auxiliary power on the Domestic Models and up to 15 amps on the Canandian Model.

2. 115VAC CIRCUIT BREAKER - This breaker

protects the 115 VAC auxiliary circuits located in the duplex receptacle, terminal strip and MS- receptacle. Breaker is rated 20 amps on Domestic Models and 15 amps on all other models.

3. 42VAC 10 AMP CIRCUIT BREAKER - This

breaker protects the 42VAC auxiliary circuits located 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.

welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section of this manual.

7. POSITIVE OUTPUT TERMINALS - These output

terminals are for connecting a welding cable to either the High Inductance or Low Inductance Terminal for desired arc characteristics. High Inductance is recommended for Stainless Steel welding. Low Inductance is recommended for Short Arc GMAW. For Spray Arc and other processes either may be used to provide the preferred starting and welding arc characteristics: High Inductance will provide a “softer” arc, but will not provide as “crisp” of an arc start as the Low Inductance. To change welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section of this manual.

5. TERMINAL STRIP COVER PANEL - Remove this

panel to gain access to the circuits made available at the terminal strip. 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 21

B-5

OPERATION

B-5

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.

CAUTION

When using a CV-655 with wire feeders, there will be a small spark if the electrode contacts the work or ground with several seconds after releasing the trigger.

When used with some wire feeders with the electrical trigger interlock in the ON position, the arc might restart if the electrode touches the work or ground during these several seconds.

------------------------------------------------------------------------

AUXILIARY POWER

42 volt AC auxiliary power, as required for some wire feeders, is available through the wire feeder receptacle. A 10 amp circuit breaker protects the 42 volt circuit from overloads.

CV-655 machines can also supply 115 volt AC auxiliary power through the wire feeder receptacle. A 20 amp circuit breaker on the Domestic model, and a 15 amp on the Canadian and Export models protects the 115 volt circuit from overloads. 115VAC is not available in the MS-receptacle on the European models.

THERMAL FAN CONTROL

The machine’s cooling fan remains off when the temperature 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.

OVERLOAD PROTECTION

This welder has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. 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 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.

The CV-655 also has over-current protection. When the load exceeds a threshold current (about 900 amps), overcurrent shut down will occur after a period of time that shortens as the current increases beyond this threshold. If the current reaches about 1000 amps the output will be “clamped” at about 1000 amps and shut down will occur in about 5 seconds. When this overload shut down occurs the short circuit output of the machine drops to only about 20 amps on 60Hz, 40 amps on 50Hz, but the input contactor and input pilot light will remain on until reset by turning the power switch off, then back on with overload removed.

CAUTION

Note that some types of equipment, especially pumps and large motors, have starting currents 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 CV-655 auxiliary power for that equipment.

___________________________________________

FAN MOTOR FUSE (EUROPEAN MODEL)

A 10 amp slow blow fuse protects the fan motor circuit. This fuse is located inside the CV-655 mounted on the fan motor bracket.

CV-655

Page 22

C-1

ACCESSORIES

C-1

The CV-655 can be used to power any of the following Lincoln Wire feeders:

SEMI-AUTOMATIC WIRE FEEDERS

• DH-10 • LN-9*

• LN-10 • LN-9 GMA*

• LN-7 GMA* • LN-23P

• LN-742 • LN-25

• LN-7 • LN-8*

AUTOMATIC WIRE FEEDERS*

• NA-3 • NA-5R

• NA-5

* European CV-655 models only provide 115VAC for these feeders at the

terminal strip (TS2)

“Cold starting for sub-arc cannot be used. (It must be jumpered out. See Auto Feeder manual)

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).

NOTE: A dirty air filter may cause the thermal protection of the CV-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 CV-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 CV-655 lift bail is no longer functional. Do not attempt to 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 CV-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 connects to terminals 75, 76, and 77 on the terminal strip and the case grounding screw so marked with the symbol on the machine. These terminals are located behind the cover panel on the lower connection panel of the CV-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 CV-655.

K1484-1 Dual Feeder Kit - This kit replaces the 14 Pin MS-receptacle panel on the lower case front of the

REMOTE CONTROL ADAPTER CABLE (K864)

CV-655. It provides two 14 Pin MS-receptacles and a built in transfer circuit for connecting and operating two like-polarity wire feeders. European CV-655 mod-

STRAIGHT PLUG (14 PIN)

O POWER SOURCE

CABLE RECEPTACLE (6 SOCKET)

TO: K857 REMOTE CONTROL

els can only use 42V feeders with this kit. (Installation instructions are included with the kit).

CABLE RECEPTACLE (14 SOCKET)

K1485-1 Cable Hanger Bracket - Mounts over stan-

TO: LN-7 WIRE FEEDERS

dard lift bale of the CV-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

A “V” cable 12” (.30m) long to connect a K857 Remote Control (6 pin connector) with a wire-feeder (14-pin connector) and the machine (14-pin connector). If a remote control is used alone the wire-feeder connection is then not used.

front of the CV-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).

CV-655

Page 23

D-1

MAINTENANCE

SAFETY PRECAUTIONS

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.

D-1

2. In extremely dusty locations, dirt may restrict the cooling air causing the welder to run hot with premature tripping of thermal protection. Blow out the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

3. Periodically check the welding cables. Inspect for any slits or punctures. Also make sure that all connections are tight.

CV-655

Page 24

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

This Troubleshooting Guide is provided to help you locate and remedy possible problems with machine setup or operation. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. 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. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS.

If you have exhausted all of the recommended tests in Step 2, Consult your Local Authorized Field Service Facility.

E-1

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

_____________________________________________________________________

CV-655

Page 25

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-2

PROBLEMS

(SYMPTOMS)

Input contactor (CR1) chatters.

Machine input contactor does not operate.

POSSIBLE

CAUSE

PROBLEMS

1. Faulty input contactor (CR1).

2. Low line voltage.

1. Make sure the proper threephase input power is applied to the CV655 machine.

2. The input contactor may be faulty.

3. The power switch (SW1) may be faulty.

4. The pilot transformer may be faulty.

RECOMMENDED

COURSE OF ACTION

Machine input contactor operates, but no output when trying to weld.

1. Electrode or work cables may be

loose or broken.

2. Firing P.C. board is not connected

or is faulty. See PC board LED information.

4. 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 terminal strip. LED 6 on the control PC board should go ON. If it does not light check for opens in the #2 and #4 circuit. See wiring diagram. If LED 6 does light the control board may be faulty.

5. If the thermal protection light is ON the machine is overheated. The choke or secondary thermostats may be open. Make sure the fan is operating and remove the cause of the overheating problem. See PC board LED information.

If all recommended possible areas of misadjustments have been checked and the problem persists,

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.

CV-655

Page 26

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-3

PROBLEMS

(SYMPTOMS)

Machine has maximum output, but no control.

PPOSSIBLE

CAUSE

PROBLEMS

1. Check the Local/Remote output switch (SW3) and associated leads. See wiring diagram.

2. Make sure the remote control leads #75, #76 and /or #77 are NOT grounded to the negative welding output.

3. The output control potentiometer may be faulty.

4. The control board or control board transformer (T3) may be faulty.

RECOMMENDED

COURSE OF ACTION

Machine has minimum output and no control.

Machine does not have maximum output.

Poor arc striking with semiautomatic or automatic wire feeders.

1. The remote control leads #75, #76 and/or #77 may be grounded to the positive welding output.

1. Make sure the correct threephase input is applied to the CV655 machine.

2. The output control potentiometer may be faulty.

3. The Local/Remote switch (SW3) may be faulty.

4. The control or firing boards may be faulty. See PC board LED information.

1. Make sure the welding cables and connections are secure.

2. Check for correct welding porcedures.

If all recommended possible areas of misadjustments have been checked and the problem persists,

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.

CV-655

Page 27

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-4

PROBLEMS

(SYMPTOMS)

Variable or sluggish welding arc.

Machine will not shut off.

Output Control Pot not functioning in “Local” control.

PPOSSIBLE

CAUSE

PROBLEMS

1. Make sure the welding cables are sized correctly and the connections are tight.

2. Make sure the welding proce-

dures are correct.

1. The input power switch (SW1) may be faulty.

2. The input contactor (CR1) may be faulty.

1. Check the Local/Remote control switch and associated leads. See wiring diagram.

2. The machine output control potentiometer may be faulty. Also check associated leads. See wiring diagram.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

No output control in “Remote” control.

1. Output Control Switch in wrong

position.

2. Faulty Output Control Switch.

3. Faulty Remote Control Pot.

4. 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.

CV-655

Page 28

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-5

PROBLEMS

(SYMPTOMS)

Machine will not weld. OCV is less than 1 volt.

The wire feeder will not come on.

Poor starting.

POSSIBLE

CAUSE

PROBLEMS

1. The machine may be in a overload condition. Remove the short circuit or excessive load on the output terminals.

2. See the PC board LED information.

1. Either the 42VAC or the 115VAC circuit breakers may be tripped. Reset if necessary.

2. Check for the presence of the required voltage to operate the wire feeder.

3. The control cable or wire feeder may be faulty.

1. The capacitor discharge resistor (R2) may be faulty. See wiring diagram.

2. The control board may be faulty. See PC board LED information.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

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.

CV-655

Page 29

E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-6

PROBLEMS

(SYMPTOMS)

Poor arc characteristics.

POSSIBLE

CAUSE

PROBLEMS

1. The positive welding cable may be

connected to the wrong inductance tap.

2. The output capacitors may be faulty. Warning:The liquid electrolyte in the these capacitors is toxic. Avoid contact with any portion of your body. Clean up vented electrolyte using rubber gloves and a water dampaned cloth. Any electrolyte which gets on the skin, clean with soap and water.

3. The control board may be faulty.

See PC board LED information.

RECOMMENDED

COURSE OF ACTION

115VAC receptacle not working. (60HZ machines only)

1. Check the 115VAC circuit break-

er. Reset if necessary. Make sure the load on the receptacle does not exceed the rating of the 115VAC breaker (either 15A or 20A). See wiring diagram.

If all recommended possible areas of misadjustments have been checked and the problem persists,

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.

CV-655

Page 30

E-7

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-7

PROBLEMS

(SYMPTOMS)

Thermal Protection Light comes ON and fan does not run.

NOTE: Fan is thermal controlled and does not continuously run when machine is powered up.

Fan runs continuously.

POSSIBLE

CAUSE

PROBLEMS

1. Check for obstructions that could prevent the fan from turning.

2. Check the fan control ciruit. See wiring diagram.

3. The fan motor may be faulty.

4. The Thermal Fan/Snubber PC board may be faulty. See PC board LED information.

1. The Thermal Fan Thermistor may be faulty. See wiring diagram.

2. The Thermal Fan/Snubber PC board may be faulty. See PC board LED information.

RECOMMENDED

COURSE OF ACTION

One or both Digital Meters not lighting.

Digital Voltmeter not working properly or erratic display.

1. The meters may not be receiving the voltages from the auxiliary transformer. Check plug P13. See wiring diagram.

2. The Digital meter PC board may be faulty.

1. Meter may not be receiving auxil-

iary or sensing voltages. Make sure plug P12 & P13 are securely plugged into the Digital meter PC board and also plug P3 is securely plugged into the control board.

2. The may be an open in the volt-

age feedback circuit. See wiring diagram.

3. The Digital meter PC board may be faulty.

If all recommended possible areas of misadjustments have been checked and the problem persists,

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.

CV-655

Page 31

E-8

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-8

PROBLEMS

(SYMPTOMS)

Digital Ammeter not working properly or erratic display.

Analog Meters not reading, or not reading correctly.

POSSIBLE

CAUSE

PROBLEMS

1. The meter PC board may not be receiving the auxiliary or sensing voltages. Check plug P3 and plugs P12 & P13. See wiring diagram.

2. The current feedback circuit may be faulty. From the shunt to the control board. See wiring diagram.

3. The Digital meter PC board may be faulty.

1. The meters may not be receiving voltage or current feedback signals. Make sure plug P3 is securely plugged in the control board and plug J14 (in-line connector) is securely seated in the plug assembly from the control board.

2. Check the current feedback and voltage feedback circuits. See wiring diagram.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

3. The meter(s) may be defective.

220VAC receptacle not working. (50/60 HZ machines only)

1. Check the circuit breaker. Reset if necessary.

2. Check for broken or loose connections 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.

CV-655

Page 32

E-9

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-9

PC 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 & 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 P5 from the firing board. Turn the machine back on and check the following voltages:

Light that was off Check AC voltage between Voltage should be approximately

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 Printed Circuit Board (PCB).

4. If voltages were not present then check the wiring back to the auxiliary windings for a possible open.

5. LED 10 senses when 2 and 4 are closed. Close 2 & 4, LED 10 should be “on”. Open 2 & 4, LED 10 should be “off”.

6. LED’s 1 through 6 indicate gate signals are being sent to the main SCR’s 1 through 6 respectively If LED5 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.

7. If any one of LED 1 through 6 are not on and LED’s 7,8, and 9 are on, replace the firing (PCB) .

TROUBLESHOOTING GUIDE - FIRING PRINTED CIRCUIT BOARD

7 P5 pins 15 & 16 (wires 203,204) 32VAC 8 P5 pins 7 & 8 (wires 205,206) 32VAC 9 P5 pins 5 & 6 (wires 207,208) 32VAC

PC BOARD

1. LED1 indicates AC input voltage necessary to generate the DC supply voltages is present. These voltages power the control board circuitry. LED2 indicates the -10V supply is OK. LED3 indicates the +16V supply is OK. If LED1, 2, or 3 are not ON when machine POWER IS ON, Replace Printed Circuit Board.

2. LED4 should not be on. If this LED comes on while welding, the machine will phase back to about 10 amps and stay there. This was do to either a short across output, or a current draw of about 1000A. Remove short or reduce output current. If no short or 1000 amp load exists, replace Control Printed Circuit Board.

3. LED5 indicates control voltage is present. With trigger circuit OPEN and CONTROL POT set to minimum, LED5 should be very bright. Closing trigger circuit and Turning CONTROL POT towards maximum, LED5 should dim and then go out. Replace Printed Circuit Board if LED5 does not go ON.

4. LED6 indicates trigger condition. LED6 ON indicates trigger is CLOSED. LED6 OFF indicates trigger is OPEN. If LED6 does not come ON, look for open connections in the 2 & 4 circuit.

5. LED7 indicates welder output voltage is being sensed on the control board. When turning the Control Pot towards maximum, LED7 should glow brighter. If LED7 does not light, made sure lead 222 from the negative output lead is connected to J1 PIN 14.

6. LED8 indicates a fault condition. When LED8 is ON the machine is phased back to 10 amps and will stay there until the POWER SWITCH is turned OFF then back ON. This fault is do to a short across welder’s output, or 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).

TROUBLESHOOTING GUIDE - CONTROL PRINTED 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 33

E-10

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

E-10

PC BOARD

TROUBLESHOOTING GUIDE - THERMAL FAN/ SNUBBER PRINTED

CIRCUIT BOARD

NOTE:

1. LED1 when ON indicates fan should be running. If ON and machine is cold, replace Printed Circuit Board.

2. LED2 when ON indicates welding current greater than 50 amps. If ON and not drawing more than 40 amps,

3. LED3 when ON indicates Main SCR’S need cooling and turns fan ON. If ON and machine is cold, replace

4. LED4 when ON indicates an open Thermal Fan Thermistor, or open connection to Printed Circuit Board. Fan

5. LED5 when ON indicates an open thermostat. Thermal Protection light should also be ON. If Thermal

6. LED6 when ON indicates fan should be running. LED6 will be ON whenever LED’s 2, 3 4 or 5 is ON. If LED’s

Fan will run for minimum of 5 minutes once fan turns on.

replace Printed Circuit Board.

Printed Circuit Board.

will run constantly. Check Thermal Fan Thermistor for an open. If open replace. If not open Replace Printed Circuit Board.

Protection light is not ON, and LED5 is ON, replace Printed Circuit Board.

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 34

F-1

DIAGRAMS

F-1

CV-655

Page 35

F-2

DIAGRAMS

F-2

CV-655

Page 36

F-3

Only qualified persons should install, use or

service this machine.

Do not touch electrically live parts.

Disconnect power source before

servicing.

Do not operate with covers removed.

DIAGRAMS

electrode polarity is

work polarity. This

the terminal strip,

F-3

10-30-98F

S22978

changed.

Illustration does not necessarily represent actual position of

appropriate output studs. Refer to power source operating

If lead #21 is to be connected to

connect to the #21 terminal that matches

connection must be changed whenever the

N.F.

REMOTE VOLTAGE SENSING LEAD

manual for more information.

N.G.

Reverse the leads on the back of the ammeter and voltmeter

For proper setting of switches on power source,

see power source operating manual.

source.

in the automatic control box. Also refer to note N.F.

Above diagram shows electrode connected positive. To change polarity,

turn power off, reverse the electrode and work leads at the power

FOR CONTROL CABLE

CONTROL CABLE

RECEPTACLE

14-PIN

POWER SOURCE

WITH 14 PIN MS-TYPE

PLUG CONNECTOR

TO AUTOMATIC

CONTROL BOX

duty cycle of immediate and future applications.

N.B. Extend lead #21 from control cable with terminal strip connectors

N.A. Welding cables must be of proper capacity for the current and

LEAD CONNECTORS

FOR CONTROL CABLE

WITH TERMINAL STRIP

CONTROL CABLE

75 76

4231

41 21

permit the inch down button to operate. This jumper, however,

controls, permitting only hot starting techniques to be used.

the jumper lead on the VV board must be connected to pin "L" to

remote voltage sensing work lead may be ordered for this purpose.

physically suitable for the installation. An S16586-[LENGTH]

Connect it directly to the work piece keeping it electrically

or from 14-pin receptacle using #14 AWG or larger insulated wire

separate form the welding work lead circuit and connection. For

control cable lead #21 does not need to be extended and can be

convenience, this extended #21 lead should be taped to the

directly connected to terminal #21 on the terminal strip. Note

welding work lead. (If the length of work lead circuit is

short, and connections can be expected to be reliable, then

that this is not the preferred connection because it adds error

to the wire feeder voltmeter reading.)

marked near the power source terminal strip. The power

source grounding terminal (marked and located near the power

source input power connections) must be properly connected to

N.C. Tape up bolted connection if lead #21 is extended.

N.D. Connect the control cable ground lead to the frame terminal

GND

electrical ground per the power source operating manual.

N.D.

EQUIPMENT

ELECTRODE CABLE

TO AUTOMATIC

will disable the cold starting/autostop feature of the automatic

N.E. If a variable voltage board is present in the automatic controls,

TO WORK

POSITIVE

N.G.

N.A.

N.B. & N.C.

N.F.

NEGATIVE

CONNECTION OF NA-3, LT-5 OR LT-7 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE

CV-655

Page 37

F-4

Only qualified persons should install, use or

service this machine.

Do not touch electrically live parts.

Disconnect power source before

servicing.

Do not operate with covers removed.

DIAGRAMS

follows:

to the #21

must be changed

F-4

10-30-98F

S22979

FOR CONTROL CABLE

CONTROL CABLE

RECEPTACLE

14-PIN

WITH 14 PIN MS-TYPE

PLUG CONNECTOR

FOR CONTROL CABLE

INPUT CABLE PLUG

TO NA-5/-5R

CONTROL CABLE

source input power connections) must be properly connected to

marked near the power source terminal strip. The power

welding work lead. (If the length of work lead circuit is

Connect it directly to the work piece keeping it electrically

convenience, this extended #21 lead should be taped to the

duty cycle of immediate and future applications.

N.B. Extend lead #21 from control cable with terminal strip connectors

or from 14-pin receptacle using #14 AWG or larger insulated wire

N.A. Welding cables must be of proper capacity for the current and

LEAD CONNECTORS

WITH TERMINAL STRIP

separate from the welding work lead circuit and connection. For

remote voltage sensing work lead may be ordered for this purpose.

physically suitable for the installation. An S16586-[LENGTH]

control cable lead #21 does not need to be extended and can be

directly connected to terminal #21 on the terminal strip. Note

short, and connections can be expected to be reliable, then

to the NA-5/-5R voltmeter reading.)

that this is not the preferred connection because it adds error

GND

source grounding terminal (marked and located near the power

N.D. Connect the control cable ground lead to the frame terminal

N.C. Tape up bolted connection if lead #21 is extended.

N.D.

BOLT TO CABLES FROM NA-5/-5R

75 76

the terminal strip, connect

permitting only Hot Starting techniques to be used.

NA-5/-5R Voltage P.C. board. This jumper, however, will disable the

Cold Starting/Auto-Stop/Touching-Work feature of the NA-5/-5R,

button will not operate unless a jumper is connected between the two

When using NA-5/-5R controls above Code 8300, the NA-5/-5R Inch Down

tab terminals, labeled "AUTO", located above the transformer on the

Connect white jumper to pin "B".

Connect red jumper to pin "S".

electrical ground per the power source operating manual.

N.E. The jumpers on the NA-5/-5R voltage board must be connected as

If lead #21 is to be connected to

N.F.

NA-5/-5R control box.

whenever the electrode polarity is changed.

terminal that matches work polarity. This connection

N.G. For proper NA-5/-5R operation, the electrode cables must be snugged under

for more information.

appropriate output studs. Refer to power source operating manual

the clamp bar on the left side of the

N.H. Illustration does not necessarily represent actual position of

N.D. & N.F.

TO WORK

WIRE CONTACT AS'BLY

REMOTE VOLTAGE SENSING LEAD

POWER SOURCE

CONNECTION OF NA-5/-5R TO THE CV-655, DC-655 OR DC-600 POWER SOURCE

4231

41 21

N.F.

POSITIVE

N.B. & N.C.

NEGATIVE

N.H.

N.A.

see power source operating manual.

For proper setting of switches on power source,

FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OR NA-5R OPERATING MANUAL.

box polarity connections. Also refer to note N.F.

Above diagram shows electrode connected positive. To change polarity,

turn power off, reverse the electrode and work leads at the power source.

Refer to NA-5 or NA-5R Operating Manual for required NA-5 or NA-5R control

CV-655

Page 38

F-5

DIAGRAMS

F-5

10-30-98F

S22980

C=2

B=GND

D=4

E=77

Only qualified persons should install, use or

service this machine.

Do not touch electrically live parts.

Disconnect power source before

servicing.

Do not operate with covers removed.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

AND DUTY CYCLE OF APPLICATION.

WIRE

FEEDER

K=42

MORE INFORMATION.

REFER TO POWER SOURCE OPERATING MANUAL FOR

ACTUAL POSITION OF APPROPRIATE OUTPUT STUDS.

N.D. IF LEAD #21 IS TO BE CONNECTED TO THE

N.C. PINS NOT LISTED ARE NOT CONNECTED

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO

CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT

ON CABLE.

POWER SOURCE.

TERMINAL THAT MATCHES WORK POLARITY.

TERMINAL STRIP, CONNECT TO THE #21

WIRE FEEDER

9 PIN

AMPHENOL

N.E. ILLUSTRATION DOES NOT NECESSARILY REPRESENT

THIS CONNECTION MUST BE CHANGED WHENEVER

THE ELECTRODE POLARITY IS CHANGED.

K=42

INPUT CABLE

ASSEMBLY

I=41

B=GND

H=21

C=2

F=76

G=75

14-SOCKET BOX RECEPTACLE, REAR VIEW

AND 14-PIN CABLE PLUG, FRONT VIEW

G=75

F=76

E=77

D=4

14-SOCKET BOX RECEPTACLE, FRONT VIEW

AND 14-PIN CABLE PLUG, REAR VIEW

14 PIN

AMPHENOL

N.E.

ELECTRODE CABLE

TO WORK

42V AC

FUNCTION

CONNECTION OF DH-10 OR LN-10 TO POWER SOURCE WITH 14 PIN AMPHENOL

LINCOLN

POWER SOURCE

FOR PROPER SETTINGS OF SWITCHES ON POWER SOURCE,

SEE POWER SOURCE OPERATING MANUAL.

FUNCTIONS ARE LISTED FOR REFERENCE

ONLY AND EACH MAY OR MAY NOT BE

PRESENT IN YOUR EQUIPMENT.

CHASSIS CONNECTION

GND

LEAD

(SEE APPROPRIATE WIRING DIAGRAM)

OUTPUT CONTROL

TRIGGER CIRCUIT

WORK

OUTPUT CONTROL

42V AC

CV-655

Page 39

F-6

DIAGRAMS

F-6

CV655 WIRING DIAGRAM CODES 10120, 10122, 10123, 10124

This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels.

CV-655

Page 40

F-7

DIAGRAMS

F-7

CV655 WIRING DIAGRAM CODE 10121

CV-655

This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels.

Page 41

F-8

DIAGRAMS

F-8

CV655 WIRING DIAGRAM CODES 10125, 10126, 10127, 10128, 10129

This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels.

CV-655

Page 42

F-9

DIAGRAMS

F-9

CV-655

Page 43

F-10

DIAGRAMS

F-10

CV-655

Page 44

NOTES

CV655

Page 45

WARNING

Spanish

AVISO DE

PRECAUCION

● 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 o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y 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 PRODUITS 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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 46

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 47

• 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

Lincoln Electric CV-655 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual