Lincoln Electric DC-655 Operation, General Description, Recommended Processes and Equipment

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B-3

B-3

OPERATION

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GENERAL DESCRIPTION

The DC-655 is an energy efficient constant voltage DC power source that produces outstanding arc charac- teristics for multiple CV or CC welding processes.

Four models are available:

Domestic - all 60 Hertz models except 230/460/575v.

NEMA Class 1 rated

Canadian - 230/460/575v 60 Hertz

NEMA Class 1 rated

European - 50/60 Hertz models “CE” qualified and rated for IEC 974-1

Export - 50/60 Hertz models NEMA Class 1 rated

RECOMMENDED PROCESSES AND EQUIPMENT

The DC-655 is designed for CV or CC processes.

CV processes include: GMAW (MIG) and FCAW (flux- cored) welding, plus the capability of CV submerged arc welding and air carbon arc gouging. It produces outstanding welding performance with a single range full output control knob.

CCprocesses include stick welding, CC submerged arc and superior air carbon arc gouging with up to 3/8” (10 mm) diameter carbons. The same single range full output control knob is used and paralleling capability is provided.

The DC-655 is recommended for use with Lincoln’s DH-10 or LN-10 as well as the LN-7*, LN-7 GMA*, LN- 742, LN-8*, LN-9*, LN-9 GMA*, LN-23P and LN-25 semiautomatic wire feeders. It is also recommended for use with the NA-3, NA-5 and NA-5R automatic feeders. “Cold starting” for sub-arc or across arc “touch-sensing” can be used.

*The 14-pin MS receptacle on the European models does not provide 115 VAC for these feeders; 115 VAC must be obtained from terminal strip.

Two DC-655’s may be paralleled in a “master” and “slave” interconnection using the K1611-1 Paralleling kit.

•Power on/off switch with pilot light and thermostat tripped indicator light.

•Full range output voltage (CV mode) and current (CC mode) control for easy operation.

•Panel switches behind a latched front panel for remote or local output control, output on or remote selection, and CC, CV Sub-arc or CV MIG mode selection.

•Panel knob settable CC arc force control with built- in adjustable “Hot Start”.

•High efficiency output, and selectable “sleep mode” idle mode timer which shuts down input power if not used for extra energy conservation.

•Fan as needed (F.A.N.). Solid state thermally con- trolled fan operates cooling fan only when required. Minimizes power consumption, operating noise and dust intake.

•Hinged cover to protect output terminals and auxil- iary connections.

•Electronic and 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 available for the wire feed- er; circuit breaker protected. 20 amp breaker on Domestic model and 15 amp breaker on Canadian, European, and Export Models.

•115 VAC duplex plug receptacle available on Domestic and Canadian Models. 20 amp breaker on Domestic Models and 15 amp breaker on Canadian Model.

•220 VAC receptacle on European and Export models for connecting to a water cooler. Protected by 2 amp breaker.

•Single MS-type (14-pin) connection for wire feeder.

•Optional Field Installed Digital or Analog Voltmeter/ Ammeter kits are available.

•Optional dual feeder kit for like polarity connection of two wire feeders. Easy panel installation.

•Optional Dual Process Switch for two processes with polarity change and electrical isolation.

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DESIGN FEATURES AND

ADVANTAGES

•Separate output terminals for selecting high or low inductance as recommended for the welding process.

WELDING CAPABILITY

The DC-655 has the following Output and Duty Cycle based on operation for a 10 minute period:

650 Amps, 44 Volts at 100%

815 Amps, 44 Volts at 60%

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-2Operation Design Features AdvantagesGeneral Description Recommended Processes and EquipmentDC-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 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 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
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