Lincoln Electric DC-655 Input Power Supply Connections, Input Supply Connection Diagram

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A-5

A-5

INSTALLATION

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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.

3.Remove the input access door at upper rear of the machine.

RECONNECT PROCEDURE

WARNING

Electric Shock Can Kill

Disconnect input power before per- forming this procedure.

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4. Follow input supply connection diagram located

Multiple voltage machines are shipped connected to

on the inside of the door.

5. Connect the three-phase AC power supply leads

the highest input voltage listed on the machine’s rating

plate. Before installing the machine, check that the

L1, L2, and L3 to the input contactor

reconnect panel in the input box assembly is connect-

terminals in the input box assembly. See Figure

ed for the proper voltage.

A.1.

 

 

CAUTION

 

Failure to follow these instructions can cause immedi-

 

ate failure of components within the machine.

 

To reconnect a multiple voltage machine to a different

 

voltage, remove input power and follow the input con-

 

nection diagram located on the inside of case back

 

input access door.

 

1. For dual voltage sample machine reconnect

 

instructions, see Figure A.2.

 

 

DUAL VOLTAGE MACHINE

Do not operate with covers

Do not touch electrically live parts

INPUT SUPPLY CONNECTION DIAGRAM

removed

Only qualified persons should install,

IMPORTANT: CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS.

Disconnect input power before

servicing

use or service this equipment

NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS

Return to

Return to

L3

W CR1

INPUT

V

LINES L2

CONTACTOR

L1

U

GND

H1

 

H3

 

CONTROL

 

TRANSF.

LINKS

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE

 

1

. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.

 

2

. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT

 

 

LEAST 600 VOLT INSULATION.

 

 

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 CONTROL TRANSFORMER

 

 

LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.

 

4

. CONNECT TERMINAL MARKED

TO GROUND PER LOCAL AND NATIONAL ELECTRIC

 

 

CODES.

 

H2

5. MOUNT THE LINKS IN THE POSITIONS SHOWN; DOUBLE OR TRIPLE STACK THE LINKS

 

 

IN THREE POSITIONS. LOOP THE FLEX LEAD IN THE POSITION SHOWN; POSITIONING

THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN

ALL OF THE HEX NUTS.

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CONNECTION FOR LOWEST RATING PLATE VOLTAGE

 

 

 

 

 

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.

 

 

L3

 

W CR1

2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT

INPUT

 

LEAST 600 VOLT INSULATION.

 

L2

 

V

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 CONTROL TRANSFORMER

LINES

 

 

CONTACTOR

LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.

 

 

L1

 

U

4. CONNECT TERMINAL MARKED

TO GROUND PER LOCAL AND NATIONAL ELECTRIC

 

GND

 

H1

CODES.

 

 

H2

5. MOUNT THE LINKS IN THE POSITIONS SHOWN. CONNECT THE FLEX LEAD AS SHOWN;

 

 

 

H3

 

 

 

 

CONTROL

POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS.

 

 

 

 

INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

 

 

 

 

TRANSF.

LINKS

 

 

 

 

D-UF

 

 

 

 

 

THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.

 

M18225

FIGURE A.2 - DUAL VOLTAGE MACHINE RECONNECTION PROCEDURE

IDEALARC DC-655

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Contents Idealarc DC-655 California Proposition 65 Warnings SafetyElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications DC-655 InstallationInput Power Three Phase Electrical Input Connections Safety PrecautionsSelect Suitable Location Input Supply Connection Diagram Input Power Supply ConnectionsElectrode and Work Cables Output ConnectionsAuxiliary Power Table Auxiliary Power Control ConnectionsTerminal Strip 2 T.S.2 Terminal Strip 1 T.S.1Table of Contents Operation Section Operating Instructions OPERATIONB-2Recommended Processes and Equipment Design Features AdvantagesOperation General DescriptionDC-655 Figure B.2 Lower Case Front Controls & Connections Case Back Connections Auxiliary PowerMachine Protection Over Current Protection Shutdown Remote Control Leads Fault Protection SHUTDOWN1Thermal Shutdown Welding Performance CV Mode CURRENT-LIMITINGCC Mode HOT Start CC Mode ARC Force CC Mode ARC GougingTable of Contents Accessories Remote Output Control Field Installed OptionsSEMI-AUTOMATIC Wire Feeders Automatic Wire FeedersSet the Idealarc DC-655 Power toggle Accessories Semiautomatic Wire Feeders Connecting the LN-7 to the Idealarc DC-655 Terminal Strip GND Negative Positive Figure C.4 Idealarc DC-655 Table of Contents Maintenance Electric Shock can kill General MaintenanceFigure D.1 General Component Locations Idealarc DC-655 Table of Contents Theory of Operation Section Theory of Operation Down Circuits Protective Devices and Shutdown Circuits Figure E.4 SCR Operation SCR OperationIdealarc DC-655 Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Troubleshooting Guide Control Board LED ChartPerform the SCR Bridge Test LED ChartOutput Bridge TestTransformer Test See the Idle Shut Down TimerMain Function Problems Thermal Fan/Snubber PC Troubleshooting & Repair Welding Problems See the Control Board Mode Current LimitingMaterials Needed Internal Trigger Circuit TestTest Description Internal Trigger Circuit Test Test ProcedureTrigger Diagram Section Simplified Trigger Diagram. If a resistanceFigure F.3 Simplified Trigger Diagram Firing Board Test Figure F.4 Firing Board Trigger Circuit Test Points and LEDs Firing Board TestMain Transformer Test Figure F.5 14-PIN Receptacle Figure F.4 Main Transformer T1 Voltage Test Figure F.6 Input Contactor and Primary Leads Main Transformer T1 Voltage TestTroubleshooting & Repair Figure F.8 Terminal Strip Figure F.9 Firing Board Plug J5 Pins Control Transformer T2 Test Figure F.10 Control Transformer Control Transformer T2 TestHigh Voltage is present at Control Board Transformer T3 Test Perform the Control Transformer T2 Test Control Board Transformer T3 TestInput Contactor Test Transformer T2 Test Input Contactor TestFigure F.13 Input Contactor Test Connections Test for Contact ContinuityStatic SCR Test Static SCR Test Figure F.15 Heat Sink Test Points Active SCR Test Active SCR Test Figure F.17 Heat Sink Test Points Anode Cathode LED Functions and Indications Thermal FAN/SNUBBER Board LED ChartLED # LED Functions and Indications Control Board LED ChartScope Settings Normal Open Circuit Voltage Waveform Constant Voltage MIG Maximum Output Setting no LoadMinimum Output Setting no Load Troubleshooting & Repair Typical SCR Gate Voltage Waveform Constant Voltage MIG Installation Description Input Contactor CR1 CLEANING/REPLACEMENTCleaning Procedure Input Contactor CR1 CLEANING/REPLACEMENTSCR Rectifier Bridge Removal Replacement Procedure SCR Rectifier Bridge Removal Replacement ProcedureProcedure SCR Rectifier Bridge LEG Assembly Mounting Brackets ReassemblyMain Transformer and Choke Removal Replacement Procedure Output Choke Removal Main Transformer and Choke RemovalMain Transformer Removal Input Idle Amps and Watts Retest After RepairSVM Error Reporting Form Section G Electrical Diagrams Control Board Schematic G3384 Firing Board Schematic G2792 Thermal Fan/Snubber Board Schematic L10123 Control Board Layout G3385-1 Firing Board Layout G2699-2 Thermal Fan/Snubber Board Layout L10124-1 Return to Section TOC