Lincoln Electric IDEALARC DC-655 User Manual

SVM142-A
September, 2002
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
For use with machine code number 10501 thru 10510
IDEALARC
™
DC-655
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• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.

Lincoln Electric IDEALARC DC-655 Specifications

General

Frequency	60 Hz
Input Voltage	230/460/575 VAC
Input Phase	3 Phase
Output Voltage Range	10-44 V
Duty Cycle	100%
Open Circuit Voltage	80V
Processes	Stick, TIG
Rated Output	650A DC at 44V, 100% Duty Cycle

Summary

Essential Safety Precautions

Understanding Key Hazards

Covers electrical shock, EMF, fumes, gases, sparks, arc rays, and cylinder safety.

Installation and Setup Guide

Technical Specifications and Connections

Details welder specs, input/output connections, and grounding.

Reconnect Procedure and Auxiliary Power

Steps for voltage changes and connecting auxiliary equipment.

Operating and Performance Guide

Operational Safety and Controls

Safety warnings, control panel overview, and settings.

Machine Protection and Welding Performance

Details on protection features and how settings affect welding performance.

Accessories and Maintenance

Available Accessories

Describes optional kits and wire feeder connectivity.

Maintenance Procedures

Safety and general upkeep for the welder.

Theory of Operation

System Components and Function

Explains core components like transformers, boards, and rectification.

Protective Devices and SCR Operation

How protection circuits and SCRs function.

Troubleshooting and Repair Guide

Troubleshooting Methods and Procedures

Guide usage, PC board repair, and problem/solution tables.

Component Diagnostic Tests

Detailed tests for trigger circuits, firing board, transformers, contactors, and SCRs.

Waveform Analysis

Visual analysis of normal and abnormal machine operating waveforms.

Component Replacement and Retesting

Step-by-step replacement guides and post-repair retesting procedures.

Electrical Diagrams

Wiring Diagram

Comprehensive wiring diagram for the DC-655.

Schematics and Board Layouts

Schematics for control and firing boards, and board layouts.