Lincoln Electric service manual Set the Idealarc DC-655 Power toggle

Page 26

C-4

C-4

ACCESSORIES

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NOTE: The connection diagram shown in Figure C.1 shows the electrode connected for positive polarity. To change polarity:

a. Set the Idealarc DC-655 POWER toggle

switch to the OFF (0) position.

b. Move the electrode cable to the negative (-)

output terminal. (High inductance or low

FIGURE C.2 – NA-5/-5R 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 NA-5/-5R

OR

 

 

INPUT CABLE PLUG

CONTROL CABLE

FOR CONTROL CABLE

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inductance, as needed).

c.

Move the work cable to the positive (+) output

 

terminal.

d.

If connecting lead #21 to the terminal strip,

 

connect it to the +21 terminal (to match work

 

polarity). If work polarity changes back to

 

negative, lead #21 must be connected to the

 

-21 terminal.

e.

Reverse the leads on the back of the ammeter

 

and voltmeter in the automatic control box.

f.

If the automatic controls include a variable

 

voltage board, connect its jumper lead to pin

 

“L”. This will permit the inch down button to

 

operate. However, the jumper also disables

 

the cold starting/autostop feature of the auto-

 

matic controls. Only hot starting will be avail-

 

able.

6. Set the DC-655 OUTPUT CONTROL switch to the

“Remote” position and the OUTPUT TERMINALS

switch in the “Remote” position.

CONNECTING THE NA-5/-5R TO THE IDEALARC DC-655 (TERMINAL STRIP)

1.Set the Idealarc DC-655 POWER toggle switch to the OFF (0) position.

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.2.

WITH TERMINAL STRIP

LEAD CONNECTORS

+21 - 21 41

4

2

31

32

75

76

77

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

32

 

 

 

 

 

 

 

31

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

GND

NEGATIVE

 

 

 

POSITIVE

 

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOLT TO CABLES FROM NA-5/-5R

 

 

 

 

 

 

 

WIRE CONTACT AS'BLY

 

 

 

 

 

 

 

TO WORK

REMOTE VOLTAGE SENSING LEAD

4.Connect the wire feeder control cable ground lead

to the frame terminal marked .

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

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.

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IDEALARC DC-655

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Page 25 Page 27
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 InstructionsGeneral Description Design Features AdvantagesOperation 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 CC Mode ARC Force CC Mode ARC Gouging CV Mode CURRENT-LIMITINGCC Mode HOT Start Welding Performance Table 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 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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