Lincoln Electric DC-655 service manual Auxiliary Power Control Connections, Auxiliary Power Table

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A-7

A-7

INSTALLATION

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AUXILIARY POWER AND

CONTROL CONNECTIONS

Located at the lower front of the welder behind a hinged door is a 115 VAC duplex receptacle for auxil- iary power (Domestic and Canadian Models only) and a 14-pin MS type receptacle for connection of auxiliary equipment such as wire feeders. Also, terminal strips with 115 VAC and connections for auxiliary equipment are located behind the access panel on the lower case of the welder. A 220 VAC receptacle for a water cooler (European and Export Models only) is located on the case back.

AUXILIARY POWER TABLE

Voltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various Models

Auxiliary

Domestic

Canadian

European

Export

Power

Models

Model

Models

Models

Connections

(60Hz)

(230/460/575V/60 Hz)

(50/60 Hz)

(50/60 Hz)

 

 

 

 

 

At Duplex

115V 20A

115V 15A

No Duplex

No Duplex

Receptacle

 

 

 

 

 

 

 

 

 

Terminal strip

115V 20A

115V 15A

115V 15A

115V 15A

terminals 31 & 32

 

 

 

 

 

 

 

 

 

MS-Receptacle

115V 20A

115V 15A

Open Circuit

115V 15A

pins A & J

 

 

 

 

 

 

 

 

 

MS-Receptacle

42V 10A

42V 10A

42V 10A

42V 10A

pins I & K

 

 

 

 

 

 

 

 

 

At 220V

No Receptacle

No Receptacle

220V 2A

220V 2A

Receptacle

 

 

 

 

 

 

 

 

 

115 VAC DUPLEX RECEPTACLE (DOMESTIC AND CANADIAN MODELS ONLY)

The 115 VAC duplex receptacle is protected by a cir- cuit breaker located below the receptacle (see Auxiliary Power Table). Receptacle is a NEMA 5-20R (protected by a 20 amp breaker) on Domestic Models and a NEMA 5-15R (protected by a 15 amp breaker) on Canadian Models.

230 VAC RECEPTACLE (EUROPEAN AND EXPORT MODELS ONLY)

A Continental European receptacle is located on the rear panel for supplying 220 VAC to a water cooler. The receptacle has a protective cover to prevent acciden- tal contact and is a Schuko type. The circuit is pro- tected 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.

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.

115 VAC is available at receptacle pins A and J (Domestic, Canadian and Export Models). This circuit is protected by a circuit breaker (see Auxiliary Power Table). Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other. However, on the European model one line of the 115 VAC is connected to chassis ground.

FIGURE A.4 - FRONT VIEW OF 14-PIN

CONNECTOR RECEPTACLE

 

 

K = 4 2

 

A = 3 2

 

J = 3 1

 

B = G N D

 

I = 4 1

 

L

 

N

 

C = 2

 

H = 2 1

 

 

 

 

D = 4

 

G = 7 5

 

 

 

 

E = 7 7

 

F = 7 6

 

 

 

M

 

 

 

 

PIN

LEAD NO.

 

FUNCTION

 

 

 

 

A

32

 

115 VAC

B

GND

 

Chassis Connection

C

2

 

Trigger Circuit

D

4

 

Trigger Circuit

E

77

 

Output Control

F

76

 

Output Control

G

75

 

Output Control

H

21

 

Work Sense Connection2

I

41

 

42 VAC

J

31

 

115 VAC1.

K

42

 

42 VAC

L

---

 

---

M

---

 

---

N

---

 

---

1.115VAC circuit is not present in the 14-pin connector on IEC 974- 1 European models.

2.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.

IDEALARC DC-655

Image 13
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 Select Suitable Location Safety Precautions Electrical Input Connections 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-2Operation Design Features AdvantagesGeneral Description Recommended Processes and EquipmentDC-655 Figure B.2 Lower Case Front Controls & Connections Machine Protection Auxiliary PowerCase Back Connections Thermal Shutdown Remote Control Leads Fault Protection SHUTDOWN1Over Current Protection Shutdown CC Mode HOT Start CV Mode CURRENT-LIMITINGCC Mode ARC Force CC Mode ARC Gouging Welding PerformanceTable 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 ChartOutput LED ChartBridge Test Perform the SCR Bridge TestMain See the Idle Shut Down TimerTransformer Test Function Problems Thermal Fan/Snubber PC Troubleshooting & Repair Welding Problems See the Control Board Mode Current LimitingTest Description Internal Trigger Circuit TestMaterials Needed Trigger Diagram Test ProcedureInternal Trigger Circuit Test 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 Procedure Replacement ProcedureSCR Rectifier Bridge Removal 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