Lincoln Electric DC-655 service manual Machine Protection, Case Back Connections, Auxiliary Power

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B-6

B-6

OPERATION

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3.42 VAC 10 AMP CIRCUIT BREAKER - This breaker protects the 42 VAC auxiliary circuits locat- ed in the terminal strip and MS-receptacle.

4.14-PIN MS-RECEPTACLE - This connector pro- vides easy connection for a wire feeder control cable. It provides connections for auxiliary power, output switching, remote output control, wire feed- er voltmeter sense lead and ground. Refer to 14- Pin MS Type Receptacle in the Installation Section of this manual for information about the cir- cuits made available at this receptacle.

5.TERMINAL STRIP COVER PANEL - Remove this panel to gain access to the circuits made available at the terminal strip and the 4-pin receptacle for the optional paralleling kit. This terminal strip contains the same circuits as the 14-pinMS-receptacle. The cover also provides for installation of cable strain relief clamps.

6.POSITIVE OUTPUT TERMINAL - This output ter- minal is for connecting a welding cable. To change welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section of this manual.

7.NEGATIVE OUTPUT TERMINALS - These output terminals are for connecting a welding cable to either the High Inductance or Low Inductance Terminal for desired arc characteristics. To change welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section of this manual.

DC-655 machines can also supply 115 volt AC auxil- iary power through the wire feeder receptacle. A 20 amp circuit breaker on the Domestic model, and a 15 amp on the Canadian and Export models protects the 115 volt circuit from overloads. 115 VAC is not avail- able in the MS-receptacle on the European models.

CAUTION

Note that some types of equipment, especially pumps and large motors, have starting currents which are sig- nificantly higher than their running current. These high- er starting currents may cause the circuit breaker to open. If this situation occurs, the user should refrain from using the DC-655 auxiliary power for that equip- ment.

MACHINE PROTECTION

THERMAL FAN CONTROL

The machine’s cooling fan remains off when the tem- perature of the rectifiers and windings inside the machine are below that requiring air flow cooling, as determined by electronic monitoring of several thermal sensors and the welding current of the machine. Depending upon the operating temperature of the machine, the fan may remain off while welding but once the fan is activated, it will remain on for at least 5 minutes to assure proper cooling. This feature saves energy and also minimizes the amount of dirt and other air borne particles being drawn into the machine.

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CASE BACK CONNECTIONS

220 VAC AUXILIARY RECEPTACLE

(European and Export Models)

This receptacle provides up to 2 amps of 220 VAC auxiliary power for a water cooler.

220 VAC 2 AMP CIRCUIT BREAKER

(European and Export Models)

This breaker protects the 220 VAC auxiliary circuit located in the 220 VAC receptacle.

AUXILIARY POWER

42 volt AC auxiliary power, as required for some wire feeders, is available through the wire feeder recepta- cle. A 10 amp circuit breaker protects the 42 volt cir- cuit from overloads.

FAN MOTOR FUSE (European Model)

A 10 amp slow blow fuse protects the fan motor cir- cuit. This fuse is located inside the DC-655 mounted on the fan motor bracket.

MACHINE SHUTDOWN

The DC-655 provides shutdown modes for thermal over-heating, excessive load currents and faults. It also provides an idle timer shutdown feature for addi- tional operating economy.

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 Electrical Input Connections Safety PrecautionsSelect Suitable Location 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 Instructions Design Features Advantages Operation General 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 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 TestTransformer Test See the Idle Shut Down TimerMain Function Problems Thermal Fan/Snubber PC Troubleshooting & Repair Welding Problems Mode Current Limiting See the Control BoardMaterials Needed Internal Trigger Circuit TestTest Description Internal Trigger Circuit Test Test ProcedureTrigger Diagram 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 SCR Rectifier Bridge Removal Replacement ProcedureProcedure 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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