Lincoln Electric IM983 User Manual [en, de, es, fr]
RED-D-ARC
DC655e (CE)
IM983
O
ctober, 2009
Red-D-Arc Spec-BuiltWelding Equipment
This
RED-D-ARC
welder is built to
RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends onYou
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful 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.
For use with machines having Code Numbers:
11532
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OPERATOR’S MANUAL
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i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
i
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.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
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 w et clothing. Wear dry, h ole -fr ee
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
mu st be per fo rmed und er el ec trica ll y h azard ou s
con ditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode r eel , welding he ad, nozzle or se mia utomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Ne ver si multa neously touch ele ctrical ly “ho t” par ts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS 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. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away fro m the breathing zone. When
we ldi ng with e lectr od es w hi ch r eq ui re s pe cial
ve ntilati on such as s ta inles s or har d f ac in g ( se e
in st ru ct io ns on c on ta in er or M SD S) or o n lead or
cadmium plated steel and other m eta ls or coa tin gs
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
venti lation. In confi ned space s or in so me circum st ances, out do or s, a r espirat or may be requi re d.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause inj ury or death. Alw ays use enoug h ve ntilatio n,
especially in confined areas, to insure breathing air is safe.
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
ma ter ia l safe ty dat a s heet ( MSDS) an d fo ll ow y ou r
employer’s safety practices. MSDS forms are available from
yo ur we lding d istri bu to r o r from th e m an uf actur er .
5.f. Also see item 1.b.
Jan ‘09
iii
SAFETY
iii
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
Re mem be r th at we ld in g spa rk s and hot
materials from welding can easily go through small cracks
an d openings to adjacent a re as. Avoi d w elding n ea r
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 hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) a nd the operating information f or the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Co nta in er s and P iping T ha t Hav e Held Ha za rdous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the we lding current p assing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the weldi ng s parks from start ing a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use onl y co mp resse d ga s cy li nd ers
containing the correct shielding gas for the
pr oce ss use d a nd p ro perly ope ra ting
re gul at or s d es igned for th e gas a nd
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Al ways keep cyl inder s in an u prigh t po sition se curely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Re ad and fo llow t he instr uc tions on compr es sed ga s
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equ ipment in accordance with the U. S. National
Electrical C ode, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ‘09
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 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 à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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 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. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation 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 construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
v
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
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 mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
vi
Welding 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 the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.
1
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”
L10093 3-1-96H
viivii
for selecting one of our QUALITY products. We want you to take
TThhaannkk YYoouu
CUSTOMER ASSISTANCE POLICY
The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to
meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for
advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the
results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing.
pride in operating this product ••• as much pride as we have in
bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code (if available)______________________________________________________
Serial Number (if available)__________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS
Page
Installation.......................................................................................................Section A
Technical Specifications........................................................................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location........................................................................................A-2
Electromagnetic Compatibility (EMC) .............................................................A-2
Stacking ..........................................................................................................A-2
Tilting...............................................................................................................A-2
Input Connections..................................................................................................A-2
Fuses and Wire Sizes.....................................................................................A-2
Ground Connection.........................................................................................A-2
Input Power Supply Connections....................................................................A-3
Reconnect Procedure............................................................................................A-3
Output Connections...............................................................................................A-4
Auxiliary Power and Control Connections......................................................A-5, A-6
________________________________________________________________________
Operation.........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description, Recommended Processes and Equipment..........................B-1
Design Features ....................................................................................................B-1
Welding Capabillity................................................................................................B-2
Graphic Symbols ...................................................................................................B-2
Controls and Settings .............................................................................B-3 Thru B-5
Case Back Connections ........................................................................................B-5
Auxiliary Power......................................................................................................B-5
Machine Protection.................................................................................B-5 Thru B-6
Welding Performance.............................................................................B-6 Thru B-7
________________________________________________________________________
viii viii
Accessories.....................................................................................................Section C
Power Wire Feeders..............................................................................................C-1
Field Installed Options...........................................................................................C-1
Remote Output Control..........................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Maintenance............................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ...........................................................................E-2 Thru E-7
P.C. Board Troubleshooting Guide................................................................E-8, B-9
________________________________________________________________________
Connection, Wiring Diagrams and Dimension Prints ..................................Section F
________________________________________________________________________
Parts List .....................................................................................................P-587 Series
________________________________________________________________________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – DC655e (CE)
INPUT - THREE PHASE ONLY
Standard
Voltage
100% Duty Cycle
Input Current at Rated Output
A-1
60% Duty Cycle
Duty Cycle
100% Duty Cycle
IEC974-1
60% Duty Cycle
Voltage Range
13-44 DC
INPUT
VOLTAGE /
FREQUENCY
230
400
HEIGHT
27.5 in
699 mm
230/400/50/60*
Current Range
50-815
RECOMMENDED INPUT WIRE AND FUSE SIZES
HERTZ
50/60
50/60
122/70
RATED OUTPUT
Amps
650
815
OUTPUT
Maximum Open Circuit Voltage
46 CV Mode
68 CC Mode
INPUT AMPERE
RATING ON
NAMEPLATE
122
70
TYPE 80°C
COPPER WIRE
IN CONDUIT
AWG(IEC-MM2) SIZES
40°C (104°F) Ambient
1 (43)
4 (21)
PHYSICAL DIMENSIONS
WIDTH
22.2 in
564 mm
DEPTH
38.0 in
965 mm
150/86
Volts at Rated Amperes
44
44
Auxiliary Power
See the OPERATION section for
Auxiliary Power information
Copper
GROUND WIRE
IN CONDUIT
AWG(IEC-MM2) SIZES
4 (21)
6 (14)
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
225 Amp
125 Amp
WEIGHT
720 lbs.
326 kg.
1
1
Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
DC655e (CE) (RED-D-ARC)
A-2
INPUT POWER SUPPLY
C
ABLE WITH BUSHING
OR BOX CONNECTOR
INPUT
CONTACTOR (CR1)
R
ECONNECT
P
ANEL ASSEMBLY
Read entire installation section before starting
installation.
INSTALLATION
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the disconnect switch or fuse box before working on
this equipment.
• Turn the Power switch on the DC655e
(CE) “OFF” before connecting or disconnecting output cables, wire feeder or
remote connections, or other equipment.
• Do not touch electrically hot parts.
• Always connect the DC655e (CE) grounding terminal (located on the welder near
the reconnect panel) to a good
electrical earth ground.
SELECT SUITABLE LOCATION
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
minimum. Failure to observe these precautions can
result in excessive operating temperatures and
nuisance shut-downs.
ELECTROMAGNETIC COMPATIBILITY (EMC)
A-2
FIGURE A.1 ELECTRICAL INPUT CONNECTIONS
ELECTRICAL
INPUT CONNECTIONS
Before installing the machine check that the input supply voltage, phase, and frequency are the same as the
voltage, phase, and frequency as specified on the
welder nameplate.
Use input wire sizes that meet local electrical codes or
see the Technical Specifications page in this manual.
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 panel.
The EMC classification of the
Scientific and Medical (ISM) group 2, class A. The
(CE)
is for industrial use only. (See prints L10093-1, -2
Safety Pages in the front of Instruction Manual for further
details).
Locate the
machinery. The normal operation of the
may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the
equipment.
DC655e (CE)
STACKING
The DC655e (CE) may be stacked three-high provided the bottom machine is on a stable, hard, level surface. Be sure that the two pins in the roof fit into the
slots in the base of the DC655e (CE) above it.
TILTING
Do not place the machine on a surface that is inclined
enough to create a risk of the machine falling over.
away from radio controlled
DC655e (CE)
DC655e (CE)
is Industrial,
DC655e
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or thermal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in
“nuisance” tripping caused by inrush current even
when machine is not being used for welding at high
output currents.
GROUND CONNECTION
Ground the frame of the machine. A ground
terminal marked with the symbol ( ) is located inside
the case back of the machine near the input contactor.
Access to the input box assembly is at the upper rear
of the machine. See your local and national electrical
codes for proper grounding methods. Use grounding
wire sizes that meet local electrical codes or see the
Technical Specifications page in this manual.
DC655e (CE) (RED-D-ARC)
A-3
INSTALLATION
INPUT POWER SUPPLY 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.
A-3
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 connected for the proper voltage.
CAUTION
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 multiple voltage
machines, follow the diagram for the voltage that
is within 10% of your actual input line voltage.
5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
terminals in the input box assembly. See Figure
A.1.
RECONNECT PROCEDURE
WARNING
Electric Shock Can Kill
• Disconnect input power before performing this procedure.
------------------------------------------------------------------------
Failure to follow these instructions can cause
immediate failure of components within the
machine. When powering welder from a generator
be sure to turn off welder first, before generator is
shut down in order to prevent damage to welder.
------------------------------------------------------------------------
To reconnect a multiple voltage machine to a different
voltage, remove input power and refer to the input
connection diagram located on the inside of case back
input access door. Follow the diagram for the voltage
that is within 10% of your actual input line voltage.
1. Figure A.2 shows a sample of the reconnect
instructions for a dual voltage machine.
FIGURE A.2 Dual Voltage Machine Reconnection Procedure
DC655e (CE) (RED-D-ARC)
A-4
POSITIVE
OUTPUT
TERMINAL
LOW INDUCTANCE
NEGATIVE OUTPUT
TERMINAL
HIGH INDUCTANCE
NEGATIVE OUTPUT
TERMINAL
TERMINAL STRIP
COVER PANEL
14 PIN MS RECEPTACLE
6 PIN MS RECEPTACLE
INSTALLATION
A-4
OUTPUT CONNECTIONS
ELECTRODE AND WORK CABLES
Use the shortest possible cable lengths. See Table
A.1 for recommended cable sizes based on length.
TABLE A.1
Cable Sizes for Combined Lengths of Copper
Electrode and Work Cable
Cable Length
ft. (m)
0 (0) to 100 (30.4)
100 (30.4) to 200 (60.8)
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.
LOW INDUCTANCE TERMINAL
On the DC655e (CE), the inside right Negative (-) output terminal is lower choke inductance. This terminal
is presently only recommended for CV mode welding
with NR203Ni 1% negative polarity procedures. All
other processes are to be welded using the outside
right Negative (-) output terminal with higher choke
inductance. CC mode processes must use high
inductance.
For Positive Polarity:
1. Connect the work cable to the high inductance (-)
terminal (marked " ").
Parallel Cables Cable Size
2
2
2
2/0 ( 70mm2)
3/0 ( 95mm2)
4/0 (120mm2)
2. Connect the electrode cable to the positive terminal
marked “+”.
3. Remove the terminal strip access cover panel on
the lower case front. Refer to figure A.3 for the
location.
4. Work Sense lead #21 from the 14 Pin MS-receptacle must be connected to “-21”on the terminal strip.
Note: This is how the DC655e (CE) is shipped
from the factory.
5. Replace the terminal strip access cover panel.
For Negative Polarity:
1. Connect the electrode cable to the appropriate high
inductance (-) terminal (marked " ") or
to the low inductance (-) terminal
(marked " ") if using NR203Ni 1% electrode only.
2. Connect the work cable to the positive terminal
marked “+”.
3. Remove the terminal strip access cover panel on
the lower case front. Refer to figure A.3 for the
location.
4. Work Sense lead #21 from the 14 Pin MS-receptacle must be connected to “+21”on the terminal strip.
5. Replace the terminal strip access cover panel.
FIGURE A.3 Output Connections
DC655e (CE) (RED-D-ARC)
A-5
F=76
G=75
H=21
I
=41
J
K
=42
A
B=GND
C=2
D
=4
E=77
L
N
M
INSTALLATION
A-5
AUXILIARY POWER AND
CONTROL CONNECTIONS
Located at the lower front of the welder behind a
hinged door are a 6-Pin and a 14-Pin MS type receptacle for connection of auxiliary equipment such as
wire feeders. Also, terminal strips with 115VAC and
connections for auxiliary equipment are located
behind the access panel on the lower case of the
welder. A 220VAC receptacle for a water cooler is
located on the case back.
AUXILIARY POWER TABLE
Voltage and Circuit Breaker Ratings at Auxiliary Power
Connections
Auxiliary Export
Power Models
Connections (50/60 Hz)
Terminal strip 115V 15A
terminals 31 & 32
14 pin MSReceptacle 42V 10A
pins I & K
At 220V 220V 2A
Receptacle
220VAC RECEPTACLE
A Continental European receptacle is located on the
rear panel for supplying 220VAC to a water cooler.
The receptacle has a protective cover to prevent incidently contact and is a Schuko type. The circuit is protected by a 2 amp circuit breaker also located on the
rear panel. This circuit is electrically isolated from all
other circuits, but on the European Models one line is
connected to chassis ground.
FIGURE A.4 FRONT VIEW OF 14-PIN CONNECTOR
RECEPTACLE
PIN LEAD NO. FUNCTION
A --- --B GND Chassis Connection
C2 Trigger Circuit
D4 Trigger Circuit
E 77 Output Control
F 76 Output Control
G 75 Output Control
H 21 Work Sense Connection
I 41 42 VAC
J --- --K 42 42 VAC
L --- --M --- --N --- ---
1
As shipped from the factory Lead #21 from the 14 Pin connector is
connected to “-21” on the terminal strip. This is the configuration
for positive welding. If welding negative polarity, connect lead #21
to the “+21” connection point on the terminal strip.
1
14-PIN MS TYPE RECEPTACLE
(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
Refer to the figure A.4 for the available circuits in the
14 pin receptacle.
42 VAC is available at receptacle pins I and K.
A 10 amp circuit breaker protects this circuit.
Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other. However, one line of
the 115VAC is connected to chassis ground.
DC655e (CE) (RED-D-ARC)
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