Lincoln Electric DC-655 service manual Figure B.2 Lower Case Front Controls & Connections

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B-5

B-5

OPERATION

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CCmode may also be used for CC submerged arc with appropriate arc-sensing CC(VV) wire feeders if arc force is set high enough. Refer to Welding Performance section.

CV MIG provides a constant voltage output char- acteristic through the 13 to 44 volt range. The volt- age is adjusted within this range by the Output Control dial.

The dynamic characteristics of this mode are ideal for open arc processes including, MIG/MAG (GMAW), Innershield®, and other cored wire (FCAW) processes. Faster travel submerged arc processes and CV air carbon-arc gouging may also use this mode. Refer to the Welding Performance section.

CV Sub-Arc provides the same constant voltage output control range as CV MIG, but the dynamic characteristics of this mode make possible improved CV (constant wire speed) submerged arc welding. This improved process is most notice- able on high deposition slow travel speed welds. Fast travel, narrow bead subarc welds will have better performance in CV MIG mode.

7.ARC FORCE CONTROL - This control is only func- tional in CC Stick mode. It prevents “stubbing” of the electrode by providing the extra weld current that linearly increases as the welding voltage decreases below a level determined by the setting of the constant current control.

The Arc Force control knob, located behind the latched cover, adjusts arc force from “Min” (no cur- rent increase) to “Max” (higher short circuit current). The “mid” position (#5) is recommended for most CC welding. Refer to the Welding Performance Section.

8.OPTIONAL VOLTMETER & AMMETER - Digital or analog meter kits are available as field installed options. Refer to the Accessories Section of this manual.

9.THERMAL PROTECTION LIGHT - If the machine overheats due to lack of proper air flow through the machine or due to exceeding the machine’s duty cycle, thermostats will disable the welding output and this light will illuminate. Input power is still applied to the machine and the cool- ing fan will continue to run. When the machine cools the welding output will resume.

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FIGURE B.2 LOWER CASE FRONT CONTROLS & CONNECTIONS

1

2

3

4

 

 

 

6

 

5

7

1. 115 VAC DUPLEX RECEPTACLE (Domestic and

2. 115 VAC CIRCUIT BREAKER

- This breaker

Canadian Models) This receptacle provides up to

protects the 115 VAC auxiliary circuits located in

20 amps of 115 VAC auxiliary power on the

the duplex receptacle, terminal strip and MS-

Domestic Models and up to 15 amps on the

receptacle. Breaker is rated 20 amps on Domestic

Canadian Model.

Models and 15 amps on all other models.

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 Select Suitable Location Safety PrecautionsElectrical 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-2Recommended Processes and Equipment Design Features AdvantagesOperation General DescriptionDC-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 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 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
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