Gebruiksaanwijzing /service van het product IM602-A van de fabrikant Lincoln Electric
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DC-655 OPERA TOR’S MANUAL IM602-A February, 2009 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 thought- ful operation on your part.
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.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC RA YS 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.
iii SAFETY iii FOR ELECTRICALL Y 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.
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions 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.
v v 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).
vi vi 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.
vii vii Thank You 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! Read this Operators Manual completely before attempting to use this equipment.
viii viii T ABLE OF CONTENTS PAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION A TECHNICAL SPECIFICATIONS – IDEALARC DC-655 . . . . . . . . . . . .
A-1 DC-655 A-1 INST ALLA TION TECHNICAL SPECIFICA TIONS – DC-655 Volts at Rated Amperes 44 44 Auxiliary Power See the OPERATION section for Auxiliary Power information by model Amps 650 815 Maximum .
A-2 INST ALLA TION DC-655 A-2 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.
A-3 INST ALLA TION DC-655 A-3 Read entire installation section before starting installation. SAFETY PRECAUTIONS SELECT SUIT ABLE LOCA TION Place the welder where clean cooling air can freely circulate in through the front louvers and out through the rear louvers.
A-4 INST ALLA TION DC-655 A-4 INPUT POWER SUPPL Y CONNECTIONS A qualified electrician should connect the input power supply leads. 1. Follow all national and local electrical codes. 2. Use a three-phase line. 3. Remove the input access door at upper rear of the machine.
A-5 INST ALLA TION DC-655 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. The output terminals are located at the lower front of the welder behind a hinged door Refer to figure A.
A-6 INST ALLA TION DC-655 A-6 FIGURE A.4 FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE 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 2 I 41 42 VAC J 31 115 VAC 1.
A-7 INST ALLA TION DC-655 A-7 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.
B-1 OPERA TION B-1 GENERAL DESCRIPTION The DC-655 is an energy efficient constant voltage DC power source that produces outstanding arc characteristics for multi- ple CV or CC welding processes Four models are available: Domestic - all 60 Hertz models except 230/460/575v.
B-2 OPERA TION B-2 DESIGN FEA TURES AND ADV ANT AGES • Separate output terminals for selecting high or low inductance as recommended for the welding process. • Power on/off switch with pilot light and thermostat tripped indicator light. • Full range output voltage (CV mode) and current (CC mode) control for easy operation.
B-3 OPERA TION B-3 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.
B-4 OPERA TION B-4 This mode is used for stick welding (SMAW) and CC air carbon-arc gouging, and employs a “Hot Start” feature and an Arc Force Control. CC mode may also be used for CC submerged arc with appropriate arc-sensing CC(VV) wire feed- ers if arc force is set high enough.
B-5 OPERA TION B-5 DC-655 3. 42VAC 10 AMP CIRCUIT BREAKER - This breaker protects the 42VAC auxiliary circuits locat- ed in the terminal strip and MS-receptacle. 4. 14 PIN MS-RECEPTACLE - This connector pro- vides easy connection for a wire feeder control cable.
B-6 OPERA TION B-6 DC-655 THERMAL SHUTDOWN This welder has thermostatic protection from exces- sive duty cycles, overloads, loss of cooling, and high ambient temperature. When the welder is subjected to an overload or loss of cooling, a thermostat will open.
B-7 OPERA TION B-7 CV MODE CURRENT -LIMITING CV MIG and CV Sub-Arc modes employ electronic current limiting to limit excessive short circuit output current which can result in undesirable arc character- istics or nuisance over current protection shutdown (see Machine Protection section).
C-1 ACCESSORIES C-1 The DC-655 can be used to power any of the following Lincoln Wire feeders: SEMI-AUTOMA TIC WIRE FEEDERS • LN-15 • DH-10 • LN-9* • LN-10 • LN-9 GMA* • LN-7 GMA* • LN-2.
C-2 ACCESSORIES C-2 K1528-1 Dual Process Switch - (Cannot be used with K1486-1 Air Filter Kit) The Dual-Process Switch mounts easily to the front of the machine and is designed to provide a selection between left and right side output terminals.
D-1 MAINTENANCE D-1 DC-655 SAFETY PRECAUTIONS GENERAL MAINTENANCE 1. The fan motor has sealed bearings which require no service. 2. In extremely dusty locations, dirt may restrict the cooling air causing the welder to run hot with pre- mature tripping of thermal protection.
E-1 TROUBLESHOOTING E-1 DC-655 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.
E-2 TROUBLESHOOTING E-2 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-3 TROUBLESHOOTING E-3 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-4 TROUBLESHOOTING E-4 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-5 TROUBLESHOOTING E-5 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-6 TROUBLESHOOTING E-6 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-7 TROUBLESHOOTING E-7 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-8 TROUBLESHOOTING E-8 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-9 TROUBLESHOOTING E-9 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
E-10 TROUBLESHOOTING E-10 DC-655 Observe all Safety Guidelines detailed throughout this manual 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.
F-1 DIAGRAMS DC-655 F-1 N.C. T ape up bolted connection if lead # 21 is extended . N.D. C onnect the control cable ground lead to the frame terminal marked near the power source terminal strip .
F-2 DIAGRAMS F-2 DC-655 N.C. T ape up bolted connection if lead # 21 is extended . N.D. C onnect the control cable ground lead to the frame terminal marked near the power source terminal strip .
F-3 DIAGRAMS F-3 DC-655 A bove diagram shows electrode connected positive . T o change polarity , turn power off , reverse the electrode and work leads at the power NEGATIVE POSITIVE 32 31 2 4 GND 21 N.A. N.D. ELECTRODE CABLE TO WORK POWER SOURCE O nly qualified persons should install , use or service this machine .
F-4 DIAGRAMS F-4 DC-655 NEGATIVE POSITIVE 32 31 2 4 GND 21 N.A. N.D. TO WORK POWER SOURCE O nly qualified persons should install , use or service this machine . D o not operate with covers removed . D isconnect power source before servicing . D o not touch electrically live parts .
F-5 DIAGRAMS F-5 DC-655 S22 9 80 ELECTRODE CABLE - + 14 PIN AMPHENOL POWER SOURCE TO WORK AND 14-PIN CABLE PLUG, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW K = 42 I = 41 H = 21 D = 4 C = 2 PIN B C D .
F-6 DIAGRAMS F-6 DC-655 WIRING DIAGRAM FOR CODES 10501,10503, 10504, 10505 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.
F-7 DIAGRAMS F-7 DC-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.
F-8 DIAGRAMS F-8 DC-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.
F-9 DIAGRAMS F-9 DC-655.
F-10 DIAGRAMS F-10 DC-655.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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