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IM602-A
DC-655
February, 2009
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 thought-
ful 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.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• 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
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Related Manuals for Lincoln Electric DC-655 IM602-A
Summary of Contents for Lincoln Electric DC-655 IM602-A
- Page 1 RETURN TO MAIN MENU IM602-A DC-655 February, 2009 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 ...
- Page 2 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.
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Page 3: Electric Shock Can Kill
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 skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 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 the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 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.
- Page 6 (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.
- Page 7 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 recommenda- tions.
- Page 8 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 9: Table Of Contents
INSTALLATION ..............SECTION A TECHNICAL SPECIFICATIONS –... -
Page 10: Installation
TECHNICAL SPECIFICATIONS – DC-655 Standard Volatge 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 Duty Cycle 100% Duty Cycle NEMA Class I (100)* 60% Duty Cycle Voltage Range Current Range 13-44 DC 50-815 RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT HERTZ VOLTAGE /... -
Page 11: Graphic Symbols That Appear On Rating Plate
Characteristics SMAW INSTALLATION NRTL/C NRTL DC-655 Constant Voltage Output Characteristics GMAW FCAW Designates welder can be used in environments with increased hazard electric shock. (European models) Designates welder complies with low voltage directive and with EMC directive. (European models) Designates welder complies with... -
Page 12: Safety Precautions
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. -
Page 13: Input Power Supply Connections
LINES CONTACTOR CONTROL TRANSF. LINKS THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. FIGURE A.2 Dual Voltage Machine Reconnection Procedure INSTALLATION 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 connect- ed for the proper voltage. -
Page 14: Output Connections
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. -
Page 15: Auxiliary Power And Control Connections
AUXILIARY POWER AND CONTROL CONNECTIONS Located at the lower front of the welder behind a hinged door is a 115VAC duplex receptacle for auxil- iary power (Domestic and Canadian Models only) and a 14 Pin MS type receptacle for connection of auxil- iary equipment such as wire feeders. -
Page 16: Terminal Strips
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. -
Page 17: Operation
SAFETY PRECAUTIONS Read and understand this entire section before oper- ating 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. -
Page 18: Design Features And Advantages
DESIGN FEATURES AND ADVANTAGES • 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. -
Page 19: Controls And Settings
CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the DC-655. Refer to Figures B.1, and B.2 and corresponding explanations. 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... - Page 20 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.
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Page 21: Auxiliary Power
3. 42VAC 10 AMP CIRCUIT BREAKER 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, wire feeder voltmeter sense lead and ground. -
Page 22: Welding Performance
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 Light on the case front (see figure B.1). - Page 23 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 section). As shipped, the DC-655 is set for “Hi” current limiting, which maintains constant voltage until the welding current exceeds a level proportional to the voltage set- ting, then falls off linearly at about 10 volts per 100...
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Page 24: Accessories
The DC-655 can be used to power any of the following Lincoln Wire feeders: SEMI-AUTOMATIC WIRE FEEDERS • LN-15 • DH-10 • • LN-10 • • LN-7 GMA* • • LN-742 • • LN-7* • AUTOMATIC WIRE FEEDERS* • NA-3 •... - Page 25 ACCESSORIES 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 desired.
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Page 26: 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 excessive dirt and dust build-up on inter- nal parts. -
Page 27: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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. - Page 28 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Input contactor (CR1) chatters. Machine input contactor does not operate. Machine input contactor operates, but no output when trying to weld. 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.
- Page 29 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Machine has output, but no control. Machine does not have maximum output. Poor arc striking with semiautomatic or automatic wire feeders. 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.
- Page 30 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Variable or sluggish welding arc. Output Control Pot not functioning in “Local” control only. No output control in “Remote” control only. 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.
- Page 31 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Machine will not weld. OCV is less than 1 volt. The wire feeder will not come on. 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.
- Page 32 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Poor arc characteristics. 115VAC receptacle not working. 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. TROUBLESHOOTING POSSIBLE CAUSE...
- Page 33 Observe all Safety Guidelines detailed throughout this manual 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. One or both Digital Meters not light- ing.
- Page 34 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Digital Ammeter not working properly or erratic display. Analog Meters not reading, or not reading correctly. 220VAC receptacle not working. (50/60 Hz Europe and Export mod- els only) 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.
- Page 35 Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE - 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.
- Page 36 E-10 Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE - BOARD NOTE: Fan will run for minimum of 5 minutes once fan turns on. 1. LED1 when ON indicates fan should be running. If ON and machine is cold, replace PCB. 2.
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Page 37: Diagrams
DIAGRAMS DC-655... - Page 38 DIAGRAMS DC-655...
- Page 39 DIAGRAMS DC-655...
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- Page 45 DIAGRAMS DC-655...
- Page 46 F-10 F-10 DIAGRAMS DC-655...
- Page 47 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 48 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 49 • 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...