Lincoln Electric DC-655 IM602-A Operator'S Manual Download Page 16

A-7

INSTALLATION   

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.  See Auxiliary
Power Table for rating of circuit breaker in 115VAC
circuit. Remove a plug button from the terminal strip
cover and install an appropriate strain relief clamp for
the cable being used. NOTE: There are two work
sense lead connection points on the terminal strip.
Connect both the work sense lead #21 from the 14 pin
connector and #21 lead of the control cable to “-21”
when welding positive polarity or to “+21” when weld-
ing negative polarity.

TERMINAL STRIP 1 (T.S.1)

TERMINAL STRIP 2 (T.S.2)

Lead No.

Function

75

Output Control

76

Output Control

77

Output Control

1.

115VAC circuit is also present on IEC 974-1 European models.

2.

If connecting a feeder cable directly to the terminal strip, Lead #21
from the cable is connected to “-21” on the terminal strip for posi-
tive welding.  If welding negative polarity, connect lead #21 to the
“+21” connection point on the terminal strip.

Lead No.

Function

+21 Work 

Connection 

-21 Work 

Connection

2

41 

42 VAC  

4 Trigger 

Circuit 

2 Trigger 

Circuit 

31 115 

VAC

1

32 115 

VAC

1

Summary of Contents for DC-655 IM602-A

Page 1: ...STALL 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 For use with machine Code Nu...

Page 2: ...WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of...

Page 3: ...ooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders...

Page 4: ...adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent ha...

Page 5: ...i s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pant...

Page 6: ...ion with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve constructio...

Page 7: ...ng Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in...

Page 8: ...important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on t...

Page 9: ...ROCESSES AND EQUIPMENT B 1 DESIGN FEATURES AND ADVANTAGES B 1 WELDING CAPABILITY B 2 CONTROLS AND SETTINGS B 3 AUXILIARY POWER B 5 MACHINE PROTECTION B 5 WELDING PERFORMANCE B 6 ______________________...

Page 10: ...505 10506 10507 10508 10509 10510 100 Duty Cycle 122 61 122 61 49 135 67 5 61 49 122 70 74 56 64 140 70 68 60 Duty Cycle 150 75 150 75 60 166 83 75 60 150 86 90 69 78 172 86 83 Input Current at Rated...

Page 11: ...1 100 Designates welder complies with International Electrotechnical Commission requirements 974 1 European Models IEC 974 1 Designates welder complies with low voltage directive and with EMC directi...

Page 12: ...page in this manu al Input power supply entry is through the hole in the Case Back Assembly See Figure A 1 for the location of the machine s input cable entry opening Input Contactor CR1 and reconnect...

Page 13: ...H2 GND 5 MOUNT THE LINKS IN THE POSITIONS SHOWN CONNECT THE FLEX LEAD AS SHOWN LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN L1 LINES 4 CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELE...

Page 14: ...lower case front Refer to figure A 3 for the location 4 Work Sense lead 21 from the 14 Pin MS recepta cle must be connected to 21 on the terminal strip Note This is how the DC 655 is shipped from the...

Page 15: ...ian Code 10502 receptacle is a NEMA 5 15R protected by a 15 amp breaker 220VAC RECEPTACLE EUROPEAN AND EXPORT MODELS ONLY A Continental European receptacle is located on the rear panel for supplying 2...

Page 16: ...ense lead connection points on the terminal strip Connect both the work sense lead 21 from the 14 pin connector and 21 lead of the control cable to 21 when welding positive polarity or to 21 when weld...

Page 17: ...d for use with Lincoln s DH 10 or LN 10 as well as the LN 7 LN 7 GMA LN 15 LN 742 LN 8 LN 9 LN 9 GMA LN 23P and LN 25 semiautomatic wire feeders It is also recom mended for use with the NA 3 NA 5 and...

Page 18: ...nd thermostatic protection for current overload and excessive temperatures 42 VAC 10 amp auxiliary power available for the wire feeder circuit breaker protected 115 VAC auxiliary power protected by a...

Page 19: ...REMOTE position the DC 655 s output terminals will be electrically cold until a remote device such as a wire feeder closes the 2 and 4 circuit in the MS receptacle or terminal strip When this switch...

Page 20: ...eld current that linearly increases as the welding voltage decreases below a level determined by the setting of the constant current control The Arc Force control knob located behind the latched cover...

Page 21: ...220VAC auxiliary circuit located in the 220VAC receptacle AUXILIARY POWER 42 volt AC auxiliary power as required for some wire feeders is available through the wire feeder recepta cle A 10 amp circui...

Page 22: ...ot be present This input shut down is reset by turning the DC 655 input power off then on If the fault is not corrected however the shutdown will re occur when turning on the input power SHORTED RECTI...

Page 23: ...hind the latched cover adjust Arc Force from Min no current increase to Max about 9A V increase A general guideline for CC welding is to set Arc Force to Mid position 5 and increase typically no more...

Page 24: ...Dual process switch NOTE A dirty air filter may cause the thermal protec tion of the DC 655 to prematurely activate Remove and blow out or wash and dry the filter every two months or less if in extre...

Page 25: ...either or both sides of the box and with proper connection can provide polarity change with just a switch change Selecting one side only energizes those output studs and opens the other side Installat...

Page 26: ...Blow out the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on inter nal parts 3 Periodically check the welding cables Inspect for any slits or punctur...

Page 27: ...AUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it...

Page 28: ...d to the DC 655 machine 2 The power switch SW1 may be faulty 3 The pilot transformer may be faulty If Power Pilot light is on 1 The input contactor may be faulty 2 Input shutdown may be activated LED3...

Page 29: ...W3 and associated leads See wiring diagram 2 Make sure the remote control leads 75 76 and or 77 are NOT grounded to either welding output 3 Make sure control cable to feeder if used is connected prope...

Page 30: ...nly No output control in Remote control only 1 Make sure the mode switch is in the proper position for the process 2 Make sure the welding cables are sized correctly and the connec tions are tight 3 M...

Page 31: ...BLE CAUSE RECOMMENDED COURSE OF ACTION Machine will not weld OCV is less than 1 volt The wire feeder will not come on 1 The machine may be in a over load condition Refer to Machine Protection in the o...

Page 32: ...BLE CAUSE RECOMMENDED COURSE OF ACTION Poor arc characteristics 115VAC receptacle not working 1 The negative welding cable may be connected to the wrong induc tance tap 2 Make sure the mode switch is...

Page 33: ...uld prevent the fan from turning 2 Check the fan control circuit See wiring diagram 3 The fan motor may be faulty 4 The Thermal Fan Snubber PC board may be faulty See PC board LED information 1 The Th...

Page 34: ...be receiving the auxiliary or sensing voltages Check plug P3 and plugs P12 P13 See wiring diagram 2 The current feedback circuit may be faulty From the shunt to the control board See wiring dia gram...

Page 35: ...indings for a possible open 5 LED s 1 through 6 indicate gate signals are being sent to the main SCR s 1 through 6 respectively If LED5 is on CONTROL BOARD along with LED7 8 and 9 on firing PCB and LE...

Page 36: ...ld replace PCB 2 LED2 when ON indicates welding current greater than 50 amps If ON and not drawing more than 40 amps replace PCB 3 LED3 when ON indicates Main SCR S need cooling and turns fan ON If ON...

Page 37: ...adds error to the LN 7 voltmeter Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power 41 4 2 31 32 75 76 77 NEGATIVE PO...

Page 38: ...r the electrode polarity is changed N G If lead 21 is to be connected to the terminal strip connect to N F The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual...

Page 39: ...al 21 on the terminal strip Note that this is not the preferred connection because it adds error N D Connect the control cable ground lead to the frame terminal marked near the power source terminal s...

Page 40: ...t the power source physically suitable for the installation An S16586 LENGTH N D N F INPUT CABLE PLUG CONTROL CABLE 41 4 2 31 32 75 76 77 N F 21 21 REMOTE VOLTAGE SENSING LEAD TO NA 5 5R BOLT TO CABLE...

Page 41: ...UT CONTROL OUTPUT CONTROL OUTPUT CONTROL TRIGGER CIRCUIT Only qualified persons should install use or service this machine Do not operate with covers removed Disconnect power source before servicing D...

Page 42: ...M 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 ma...

Page 43: ...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 encl...

Page 44: ...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 encl...

Page 45: ...F 9 DIAGRAMS F 9 DC 655...

Page 46: ...F 10 DIAGRAMS F 10 DC 655...

Page 47: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 48: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 49: ...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 World s Leader in Welding and Cutting Pr...

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