Lincoln Electric Comprehensive Guide to Lincoln DC 655 Welder Accessories and Options

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C-2

C-2

ACCESSORIES

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FIELD INSTALLED OPTIONS

K1482-1 Digital Ammeter/Voltmeter Kit - Installs easily to the front control panel and provides digital display of actual welding voltage and amperage while welding. (Installation instructions are included with the kit).

K1483-1 Analog Ammeter/Voltmeter Kit - Installs easily to the front control panel and provides analog display of actual welding voltage and amperage while welding. (Installation instructions are included with the kit).

K1484-1 Dual Feeder Kit - This kit replaces the 14- Pin MS-receptacle panel on the lower case front of the DC-655. It provides two 14-PinMS-receptacles and a built in transfer circuit for connecting and operating two like-polarity wire feeders. European DC-655 mod- els can only use 42V feeders with this kit. (Installation instructions are included with the kit).

K1485-1 Cable Hanger Bracket - Mounts over stan- dard lift bale of the DC-655 and provides a cable hanger on both sides of the power source, each side capable of holding up to 100 ft. of weld cable. (Installation instructions are included with the kit).

K1486-1 Air Filter Kit - Removable metal filter easily slides in and out of a bracket which mounts to the front of the DC-655. Filter is designed to trap 80% of entering particles which are 5 microns, or larger, in size. (Installation instructions are included with the kit). Cannot be used with K1528-1 Dual process switch.

NOTE: A dirty air filter may cause the thermal protec- tion of the DC-655 to prematurely activate. Remove and blow out, or wash and dry, the filter every two months, or less if in extremely dirty conditions. Replace if necessary.

Undercarriage (K817P, K842) - The DC-655 is designed for use with the Lincoln K817P or K842 Undercarriage. Complete installation instructions are included with each undercarriage. When any of the undercarriages are installed, the DC-655 lift bail is no longer functional. Do not attempt to lift the machine with the undercarriage attached. The undercarriage is designed for moving the machine by hand only. Mechanized towing can lead to injury and /or damage to the DC-655.

REMOTE OUTPUT CONTROL

(K775 OR K857 WITH K864 ADAPTER)

An optional “remote output control” is available. This is the same remote control that is used on other Lincoln power sources (K775). The K775 consists of a control box with 28 ft (8.5m) of four conductor cable. This connects to terminals 75, 76, and 77 on the terminal strip and the case grounding screw so marked with the symbol on the machine. These terminals are locat- ed behind the cover panel on the lower connection panel of the DC-655. This control will give the same control as the output control on the machine.

The K857 has a 6-pin MS-style connector. The K857 requires a K864 adapter cable which connects to the 14-pin connector on the DC-655.

REMOTE CONTROL ADAPTER CABLE (K864)

STRAIGHT PLUG (14 PIN)

CABLE RECEPTACLE (6 SOCKET)

TO POWER SOURCE

TO: K857 REMOTE CONTROL

 

CABLE RECEPTACLE (14 SOCKET)

TO: LN - 7 WIRE FEEDERS

A “V” cable 12” (.30m) long to connect a K857 Remote Control (6 pin connector) with a wire-feeder (14-pin connector) and the machine (14-pin connector). If a remote control is used alone the wire-feeder connec- tion is then not used.

K1528-1 Dual Process Switch - (Cannot be used with K1486-1 Air Filter Kit) The Dual-Process Switch mounts easily to the front of the machine and is designed to provide a selection between left and right side output terminals. Each pair of output terminals can be switched to either the DC-655, high or low inductance terminals as desired. Wire feed unit cables and air carbon arc cables can be connected to either or both sides of the box and with proper connection can provide polarity change with just a switch change. Selecting one side only energizes those output studs and opens the other side. Installation instructions are included with the switch.)

K1611-1 Paralleling Kit - Provides interconnection of two DC-655 machines in parallel for doubling the cur- rent capacity of one machine. This “master” and “slave” connection configuration allows the “master” to control the balanced output of both machines. Individual protection circuits of both machines func- tion normally. (Installation instructions are included with the switch.)

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.2Table of Contents Operation Section OPERATIONB-2 Operating InstructionsDesign Features Advantages OperationGeneral Description 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 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 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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