Lincoln Electric IM602-A manual

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. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL A[...]

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. 4.b. Us e suitable clothing made from durable flame-resistant material to protect your ski[...]

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. 8.c. Ground the equipment in accordance with the U.S. Nation[...]

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. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

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). It was manufactured in conformity with a national standard that implements [...]

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. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mai[...]

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. Save this manual and keep it handy for quick reference.[...]

viii viii T ABLE OF CONTENTS PAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION A TECHNICAL SPECIFICATIONS – IDEALARC DC-655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 GRAPHIC SYMBOLS THAT APPEAR ON RATING PLATE . [...]

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 Open Circuit Voltage 46 CV Mode 68 CC Mode Duty Cycle 100% Duty Cycle NEMA Class I (100)* 60% Duty Cycle INPUT - THREE PHASE ONL Y OUTPUT * European m[...]

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. (Domestic, Canadian, and Export models) Designates welder complies with both Underwriters Laboratories (UL)[...]

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. Dirt, dust or any foreign material that can be drawn into the welder should be kept at[...]

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. 4. Follow input supply connection diagram located on the inside the door. For m[...]

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.3. Route the welding cables through the slotted strain reliefs of the [...]

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. K 42 42 VAC L --- --- M --- --- N --- --- F =7 6 G[...]

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. These terminals supply the connections as shown in the following Terminal Strip charts[...]

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. NEMA Class 1 rated Canadian - 230/460/575v 60 Hertz NEMA Class 1 rated Europe[...]

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. • Panel switches [...]

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. This switch is also used to reset a machine shut- down. (S[...]

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. Refer to Welding Performance Section . CV MIG provides a consta[...]

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. It provides connections for auxiliary power, output switching, remote output control, w[...]

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. This condition will be indicated by the illumination of the yellow Thermostatic Protection [...]

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). As shipped, the DC-655 is set for “Hi” current limiting, [...]

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-23P • LN-742 • LN-25 • LN-7* • LN-8* AUTOMA TIC WIRE FEEDERS* • NA-3 • NA-5R • NA-5 LT-7 Tractor * European DC-655 models only provide 11[...]

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. Each pair of output terminals can be switched to either the DC-655, high or low inductance terminals as [...]

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. Blow out the welder with low pressure air at regular intervals to eliminate[...]

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. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible [...]

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. CAUTION PROBLEMS PROBLEM[...]

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. CAUTION PROBLEMS PROBLEM[...]

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. CAUTION PROBLEMS PROBLEM[...]

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. CAUTION PROBLEMS PROBLEM[...]

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. CAUTION PROBLEMS PROBLEM[...]

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. CAUTION PROBLEMS PROBLEM[...]

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. CAUTION PROBLEMS PROBLEM[...]

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. CAUTION PC BOARD TROUBLE[...]

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. CAUTION PC BOARD TROUB[...]

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 . T he power source grounding terminal (marked and located near the power source input power connections) must be properly connected to electrical ground per[...]

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 . T he power source grounding terminal (marked and located near the power source input power connections) must be properly connected to electrical ground per[...]

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 . D o not operate with covers remo[...]

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 . 21 FOR CONTROL CABLE WITH 14 PIN MS-TYPE PLUG CONNECTOR OR FOR CONT[...]

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 E F 7 5 7 6 77 4 2 LEAD 42V AC 42V AC TRIGGER CIRCUIT ( SEE APPROPRIATE WIRING DIAGRAM ) FUNCTION FUNCTIONS ARE LISTED FOR REFERENCE ONLY AND EACH MAY[...]

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. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL U[...]

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. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro[...]

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