Lincoln-electric IM602 IDEALARC DC-655 User Manual

DC-655OPERATORʼS MANUALIM602-AAugust, 2011Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. Howe

A-1DC-655A-1INSTALLATIONTECHNICAL SPECIFICATIONS – DC-655Volts at Rated Amperes4444Auxiliary PowerSee the OPERATION sectionfor Auxiliary Power informa

A-2INSTALLATION DC-655A-23 Phase transformer with rectified DC outputINPUT POWERTHREE PHASEDesignates welder complies withNational Electrical Manufa

A-3INSTALLATION DC-655A-3Read entire installation section before startinginstallation.SAFETY PRECAUTIONSSELECT SUITABLE LOCATIONPlace the welder whe

A-4INSTALLATION DC-655A-4INPUT POWER SUPPLY CONNECTIONSA qualified electrician should connect the input powersupply leads.1. Follow all national and

A-5INSTALLATION DC-655A-5OUTPUT CONNECTIONSELECTRODE AND WORK CABLESUse the shortest possible cable lengths. See TableA.1 for recommended cable size

A-6INSTALLATION DC-655A-6FIGURE A.4 FRONT VIEW OF 14-PIN CONNECTORRECEPTACLEPIN LEAD NO. FUNCTIONA 32 115 VACB GND Chassis ConnectionC 2 Trigger Cir

A-7INSTALLATION DC-655A-7TERMINAL STRIPSTerminal strips are available behind the cover panelon the lower case front to connect wire feeder controlca

B-1OPERATIONB-1GENERAL DESCRIPTIONThe DC-655 is an energy efficient constant voltage DC powersource that produces outstanding arc characteristics for

B-2OPERATIONB-2DESIGN FEATURES AND ADVANTAGES• Separate output terminals for selecting high or lowinductance as recommended for the weldingprocess.• P

B-3OPERATIONB-31. INPUT POWER ON/OFF SWITCH - This tog-gle switch turns the machine on or off. Putting theswitch in the ON position ener

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-4OPERATIONB-4This mode is used for stick welding (SMAW) andCC air carbon-arc gouging, and employs a “HotStart” feature and an Arc Force Control. CC

B-5OPERATIONB-5DC-6553. 42VAC 10 AMP CIRCUIT BREAKER - Thisbreaker protects the 42VAC auxiliary circuits locat-ed in the terminal strip and MS-re

B-6OPERATIONB-6DC-655THERMAL SHUTDOWNThis welder has thermostatic protection from exces-sive duty cycles, overloads, loss of cooling, and highambient

B-7OPERATIONB-7CV MODE CURRENT-LIMITINGCV MIG and CV Sub-Arc modes employ electroniccurrent limiting to limit excessive short circuit outputcurrent wh

C-1ACCESSORIESC-1The DC-655 can be used to power any ofthe following Lincoln Wire feeders:SEMI-AUTOMATIC WIRE FEEDERS • LN-15• DH-10 • LN-9*• LN-10 •

C-2ACCESSORIESC-2K1528-1 Dual Process Switch - (Cannot be usedwith K1486-1 Air Filter Kit) The Dual-Process Switchmounts easily to the front of the ma

D-1MAINTENANCED-1DC-655SAFETY PRECAUTIONSGENERAL MAINTENANCE1. The fan motor has sealed bearings which requireno service.2. In extremely dusty locat

E-1TROUBLESHOOTINGE-1DC-655If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

E-2TROUBLESHOOTINGE-2DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

E-3TROUBLESHOOTINGE-3DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

E-4TROUBLESHOOTINGE-4DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

E-5TROUBLESHOOTINGE-5DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

E-6TROUBLESHOOTINGE-6DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

E-7TROUBLESHOOTINGE-7DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

E-8TROUBLESHOOTINGE-8DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

E-9TROUBLESHOOTINGE-9DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or

E-10TROUBLESHOOTINGE-10DC-655Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures

F-1DIAGRAMSDC-655F-1 N.C. Tape up bolted connection if lead #21 is extended. N.D. Connect the control cable ground lead to the frame terminal

F-2DIAGRAMSF-2DC-655 N.C. Tape up bolted connection if lead #21 is extended. N.D. Connect the control cable ground lead to the frame terminal

F-3DIAGRAMSF-3DC-655

iiiSAFETYiiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b.

F-4DIAGRAMSF-4DC-655

F-5DIAGRAMSF-5DC-655 S22980 ELECTRODE CABLE-+14 PINAMPHENOLPOWER SOURCETO WORK AND 14-PIN CABL

F-6DIAGRAMSF-6DC-655WIRING DIAGRAM FOR CODES 10501,10503, 10504, 10505WIRING DIAGRAM FOR CODES 10501,10503, 10504, 10505This diagram is for reference

F-7DIAGRAMSF-7DC-655This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a par

F-8DIAGRAMSF-8DC-655This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a par

F-9DIAGRAMSF-9DC-655

F-10DIAGRAMSF-10DC-655

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

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ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui par

vvSAFETYElectromagnetic Compatibility (EMC)ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 1

viviSAFETYElectromagnetic Compatibility (EMC)The size of the surrounding area to be considered will depend on the structure of the building and othera

viiviiThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as

viii viiiTABLE OF CONTENTSPAGEINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .