Lincoln Electric DC-655 service manual Automatic Wire Feeders, SEMI-AUTOMATIC Wire Feeders

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C-3

 

C-3

 

 

ACCESSORIES

 

The DC-655 can be used to power any of

AUTOMATIC WIRE FEEDERS

 

the following Lincoln Wire feeders:

CONNECTING THE NA-3 OR LT-7 TO THE

 

 

 

 

SEMI-AUTOMATIC WIRE FEEDERS

IDEALARC DC-655 (TERMINAL STRIP)

 

• DH-10

• LN-9*

1. Set Idealarc DC-655 POWER toggle switch to the

 

 

OFF (0) position.

Return

TOC

•

LN-10

•

LN-9 GMA*

•

LN-7 GMA*

•

LN-23P

•

LN-742

•

LN-25

•

LN-7*

•

LN-8*

AUTOMATIC WIRE FEEDERS*

•

NA-3

•

NA-5R

•

NA-5

•

LT-7 Tractor

2.Disconnect main AC input power to the Idealarc DC-655.

3.Connect the wire feeder control cable leads to the Idealarc DC-655 terminal strip as shown in Figure C.1.

4.Connect the wire feeder control cable ground lead

to the frame terminal marked .

NOTE: The Idealarc DC-655 must be properly grounded.

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*European DC-655 models only provide 115VAC for these feeders at the ter- minal strip (TS2)

CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS

WARNING

ELECTRIC SHOCK can kill.

•Only qualified personnel should per- form this installation.

•Turn the input power OFF at the dis- connect switch or fuse box before working on this equipment.

•Do not touch electrically hot parts.

Auxiliary power for wire feeder operation is available at both a 14-pin MS receptacle and at terminal strips with screw-type connections located on the front of the machine. Refer to the Installation section for pinouts and lead designations. The two circuits are isolated, and each is protected by a circuit breaker.

The following descriptions show how to connect the wire feeders using either the 14-pin MS receptacle or the terminal strip.

FIGURE C.1 – NA-3 OR LT-7 WIRE FEEDER CONNECTION TO THE IDEALARC DC-655

14-PIN

 

RECEPTACLE

 

 

POWER SOURCE

 

CONTROL CABLE

 

 

 

FOR CONTROL CABLE

 

 

WITH 14 PIN

MS-TYPE

 

 

PLUG CONNECTOR

21

TO AUTOMATIC

OR

 

CONTROL BOX

 

 

 

 

CONTROL CABLE

FOR CONTROL CABLE

 

 

WITH TERMINAL STRIP

 

 

LEAD CONNECTORS

+21 - 21 41

4

2

31

32

75

76

77

 

 

 

 

 

 

 

77

 

 

 

 

 

 

 

76

 

 

 

 

 

 

 

75

 

 

 

 

 

 

 

32

 

 

 

 

 

 

 

31

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

GND

NEGATIVE

 

 

 

POSITIVE

 

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRODE CABLE

 

 

 

 

 

 

 

TO AUTOMATIC

 

 

 

 

 

 

 

EQUIPMENT

 

 

 

 

 

 

 

TO WORK

REMOTE VOLTAGE SENSING LEAD

5.Extend wire feeder control cable lead #21 so it can be connected directly to the work piece.

a.Make a bolted connection using AWG #14 or larger insulated wire. Tape the bolted connec- tion with insulating tape.

b.An S-16586- X remote voltage sensing work lead is available for this purpose.

c.Keep the #21 lead electrically separate from the work cable circuit and connection.

d.Tape the #21 lead to work cable for ease of use.

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-2Operation Design Features AdvantagesGeneral Description Recommended Processes and EquipmentDC-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 CC Mode HOT Start CV Mode CURRENT-LIMITING CC 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 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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