For use with machine Code Number 10501 thru 10510, 11324
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
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
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
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
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 so me cases it may be nece ssary t o 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.
1.b. Operate engines in open, well-ventilated
areas
or vent the engine exhaust fumes
outdoors.
1.c. Do no t add t he 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.
Do
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
ii
SAFETY
ii
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
to
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
iii
SAFETY
iii
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
Rememberthatweldingsparksandhot
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
iv
SAFETY
iv
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
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.
vv
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
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
_________________________
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
Thank You
viivii
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.
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.
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
DC-655
DEPTH
38.0 in
965 mm
WEIGHT
720 lbs.
326 kg.
A-2
INSTALLATION
GRAPHIC SYMBOLS THAT APPEAR ON
RATING PLATE (LOCATED ON CASE BACK)
A-2
NEMA EW 1 (100%)
IEC 974-1
IP-23
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)
Designates the degree of environmental protection provided by
the power sources enclosure.
S
CE
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
R
both Underwriters Laboratories
(UL) standards and Canadian
Standards Association (CSA)
standards. (Canadian Model)
Constant Current Output
Characteristics
SMAW
SAW
DC-655
NRTL
U
o
U
1
I
1
X
U
2
I
2
R
Designates welder complies with
Underwriters Laboratories (UL)
standards. (Domestic Models)
Open Circuit Output Voltage
Input Voltage Rating(s)
Input Current Rating(s)
Output Duty Cycle Rating(s)
Output Voltage Rating(s)
Output Current Rating(s)
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 DC-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 DC-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
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.
The DC-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 DC-655 above it.
TILTING
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 DC-655 is Industrial,
Scientific and Medical (ISM) group 2, class A.
The DC-655 is for industrial use only. (See prints
L10093-1, -2 safety pages in the Front of Instruction
Manual for further details).
Locate the DC-655 away from radio controlled
machinery. The normal operation of the DC-655 may
adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to
the equipment.
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machine
being used. They are also called inverse time or thermal/magnetic circuit breakers.
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.
DC-655
A-4
INSTALLATION
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.
A-4
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
3. Remove the input access door at upper rear of the
machine.
4. Follow input supply connection diagram located
on the inside the door. For multiple voltage
machines, follow the diagram for the voltage that
is within 10% of your actual input line voltage.
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.
Failure to follow these instructions can cause immediate failure of components within the machine. When
powering welder from a 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 refer to the input
connection diagram located on the inside of case back
input access door. Follow the diagram for the voltage
that is within 10% of your actual input line voltage.
. Figure A.2 shows a sample of the reconnect
1
instructions for a dual voltage machine.
Do not operate with covers
removed
Disconnect input power before
servicing
Do not touch electrically live parts
Only qualified persons should install,
use or service this equipment
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE
CR1
H3
W
V
CONTACTOR
U
H1
CONTROL
TRANSF.
H2
INPUT
LINES
LINKS
L3
L2
L1
GND
CONNECTION FOR LOWEST RATING PLATE VOLTAGE
CR1
H2
W
V
CONTACTOR
U
H1
CONTROL
TRANSF.
H3
L3
INPUT
L2
LINES
L1
GND
LINKS
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
FIGURE A.2 Dual Voltage Machine Reconnection Procedure
DUAL VOLTAGE MACHINE
IMPORTANT: CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 CONTROL TRANSFORMER
LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN; DOUBLE OR TRIPLE STACK THE LINKS
IN THREE POSITIONS. LOOP THE FLEX LEAD IN THE POSITION SHOWN; POSITIONING
THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN
ALL OF THE HEX NUTS.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 CONTROL TRANSFORMER
LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN. CONNECT THE FLEX LEAD AS SHOWN;
POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
INPUT SUPPLY CONNECTION DIAGRAM
M18225
D-UF
DC-655
A-5
T
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.
LOW INDUCTANCE TERMINAL
On the DC-655, the inside right Negative (-) output
terminal is lower choke inductance. This terminal is
presently only recommended for CV mode welding
with NR203Ni 1% negative polarity procedures. All
other processes are to be welded using the outside
right Negative (-) output terminal with higher choke
inductance. CC mode processes must use high
inductance.
For Positive Polarity:
1. Connect the work cable to the high inductance (-)
terminal (marked " ").
Parallel CablesCable Size
2
2
2
2/0 ( 70mm2)
3/0 ( 95mm2)
4/0 (120mm2)
2. Connect the electrode cable to the positive 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 DC-655 is shipped from
the factory.
5. Replace the terminal strip access cover panel.
For Negative Polarity:
1. Connect the electrode cable to the appropriate high
inductance (-) terminal (marked " ") or
to the low inductance (-) terminal
(marked " ") if using NR203Ni 1% electrode only.
2. Connect the work cable to the positive 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.
POSITIVE
OUTPUT
TERMINAL
14 PIN MS RECEPTACLE
LOW INDUCTANCE
NEGATIVE OUTPUT
TERMINAL STRIP
COVER PANEL
TERMINAL
FIGURE A.3 Output Connections
DC-655
HIGH INDUCTANCE
NEGATIVE OUTPU
TERMINAL
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
MS-Receptacle 42V 10A42V 10A42V 10A42V 10A
pins I & K
At 220VNo ReceptacleNo Receptacle220V 2A220V 2A
Receptacle
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
K=42
A=32
B=GND
LN
C=2
D=4
E=77
J=31
I=41
H=21
G=75
F=76
M
PINLEAD NO.FUNCTION
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 and
Canadian Models, except Canadian Code 10502
receptacle is a NEMA 5-15R, protected by a 15 amp
breaker.
220VAC 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.
A32115 VAC
BGNDChassis Connection
C2Trigger Circuit
D4Trigger Circuit
E77Output Control
F76Output Control
G75Output Control
H21Work Sense Connection
I4142 VAC
J31115 VAC
1.
K4242 VAC
L-----M-----N------
1.
115VAC circuit is not present on IEC 974-1 European models.
2.
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.
2
DC-655
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