Lincoln Electric DC-655 service manual

Page 18

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B-4

B-4

OPERATION

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the DC-655. Refer to Figures B.1, and B.2 and corresponding explanations.

8

2

9

 

3

 

1

DC-655

7

4

5

6

 

FIGURE B.1 CONTROL PANEL CONTROLS

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1.INPUT POWER ON/OFF SWITCH - This tog- gle switch turns the machine on or off. Putting the

switch in the ON

position energizes the

machine’s input contactor applying input power to the machine. Switching the switch to the OFF position de-energizes the input contactor. This switch is also used to reset a machine shutdown. (See Machine Shutdown section)

2.PILOT LIGHT - When the power switch is in the ON position the machine’s white pilot light will illu- minate. If the input contactor de-energizes the machine in a shutdown situation, the pilot will still illuminate. In this situation it will be necessary to reset the machine by switching the power switch to the OFF then ON position. (See Machine Shutdown section)

3.OUTPUT CONTROL - This control provides continuous control of the machine’s output from minimum to maximum as it is rotated clockwise. The CV mode voltage range of control is 13 to 44V. The CC mode current range of control is 50 to 815A.

4.OUTPUT TERMINALS ON/REMOTE - When this switch is in the REMOTE position, the DC-655’s output terminals will be electrically “cold” until a

remote device such as a wire feeder closes the #2 and #4 circuit in the MS-receptacle or terminal strip. When this switch is in the ON position the machine’s output terminals will be electrically energized all the time.

5.LOCAL/REMOTE CONTROL SWITCH - When

this switch is set to the LOCAL position, con- trol of the output voltage is via the output control

on the DC-655’s control panel. When this switch is

set to the remote position, control is through a remote source such as a wire feeder via the #75, #76, and #77 leads in the MS-receptacle or termi- nal strip.

6.CC STICK/CV SUBARC/CV MIG MODE SWITCH - This switch selects the proper welding characteris- tics for the process being used:

CCStick provides a constant current output characteristic through the 50 to 815 amp range. The current is adjusted within this range by the Output Control dial. The open circuit (no load) voltage will be about 68 volts in this mode.

This mode is used for stick welding (SMAW) and CC air carbon-arc gouging, and employs a “Hot Start” feature and an Arc Force Control.

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.2 Table of Contents Operation Section OPERATIONB-2 Operating InstructionsGeneral Description Design Features AdvantagesOperation 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 CC Mode ARC Force CC Mode ARC Gouging CV Mode CURRENT-LIMITINGCC Mode HOT Start 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 ControlBridge Test LED ChartOutput 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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