Lincoln Electric DC-655 service manual Output Connections, Electrode and Work Cables

Page 12

A-6

A-6

INSTALLATION

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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

Parallel Cables

Cable Size

 

ft. (m)

 

 

 

 

 

 

0

(0) to 100 (30.4)

2

2/0 ( 70mm2)

100

(30.4) to 200 (60.8)

2

3/0 ( 95mm2)

200

(60.8) to 250 (76.2)

2

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-recepta- cle must be connected to “-21”on the terminal strip.

Note: This is how the DC-655 is shipped from the factory.

5.Replace the terminal strip access cover panel.

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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 DC-655, the inside right Negative (-) output ter- minal 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 " ").

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.

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-recepta- cle must be connected to “+21”on the terminal strip.

5.Replace the terminal strip access cover panel.

14 PIN MS RECEPTACLE

POSITIVE

LOW INDUCTANCE

HIGH INDUCTANCE

OUTPUT

NEGATIVE OUTPUT

NEGATIVE OUTPUT

TERMINAL

TERMINAL

 

TERMINAL STRIP

TERMINAL

 

COVER PANEL

 

 

FIGURE A.3 - OUTPUT CONNECTIONS

IDEALARC DC-655

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Contents Idealarc DC-655 Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications DC-655Input Power Three Phase Safety Precautions Select Suitable LocationElectrical Input Connections Input Power Supply Connections Input Supply Connection DiagramOutput Connections Electrode and Work CablesAuxiliary Power Control Connections Auxiliary Power TableTerminal Strip 1 T.S.1 Terminal Strip 2 T.S.2Table of Contents Operation Section OPERATIONB-2 Operating InstructionsDesign Features Advantages OperationGeneral Description Recommended Processes and EquipmentDC-655 Figure B.2 Lower Case Front Controls & Connections Auxiliary Power Machine ProtectionCase Back Connections Remote Control Leads Fault Protection SHUTDOWN1 Thermal ShutdownOver Current Protection Shutdown CV Mode CURRENT-LIMITING CC Mode HOT StartCC Mode ARC Force CC Mode ARC Gouging Welding PerformanceTable of Contents Accessories Field Installed Options Remote Output ControlAutomatic Wire Feeders SEMI-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 General Maintenance Electric Shock can killFigure 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 SCR Operation Figure E.4 SCR OperationIdealarc DC-655 Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Troubleshooting Guide Board LED Chart ControlLED Chart OutputBridge Test Perform the SCR Bridge TestSee the Idle Shut Down Timer MainTransformer Test Function Problems Thermal Fan/Snubber PC Troubleshooting & Repair Welding Problems Mode Current Limiting See the Control BoardInternal Trigger Circuit Test Test DescriptionMaterials Needed Test Procedure Trigger DiagramInternal Trigger Circuit Test Simplified Trigger Diagram. If a resistance SectionFigure F.3 Simplified Trigger Diagram Firing Board Test Firing Board Test Figure F.4 Firing Board Trigger Circuit Test Points and LEDsMain Transformer Test Figure F.5 14-PIN Receptacle Figure F.4 Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Input Contactor and Primary LeadsTroubleshooting & Repair Figure F.8 Terminal Strip Figure F.9 Firing Board Plug J5 Pins Control Transformer T2 Test Control Transformer T2 Test Figure F.10 Control TransformerHigh Voltage is present at Control Board Transformer T3 Test Control Board Transformer T3 Test Perform the Control Transformer T2 TestInput Contactor Test Input Contactor Test Transformer T2 TestTest for Contact Continuity Figure F.13 Input Contactor Test ConnectionsStatic 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 Thermal FAN/SNUBBER Board LED Chart LED Functions and IndicationsControl Board LED Chart LED # LED Functions and IndicationsScope Settings Maximum Output Setting no Load Normal Open Circuit Voltage Waveform Constant Voltage MIGMinimum Output Setting no Load Troubleshooting & Repair Typical SCR Gate Voltage Waveform Constant Voltage MIG Installation Input Contactor CR1 CLEANING/REPLACEMENT DescriptionInput Contactor CR1 CLEANING/REPLACEMENT Cleaning ProcedureSCR Rectifier Bridge Removal Replacement Procedure Replacement Procedure ProcedureSCR Rectifier Bridge Removal Reassembly SCR Rectifier Bridge LEG Assembly Mounting BracketsMain Transformer and Choke Removal Replacement Procedure Main Transformer and Choke Removal Output Choke RemovalMain Transformer Removal Retest After Repair Input Idle Amps and WattsSVM 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
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