Lincoln Electric DC-655 service manual Section, Simplified Trigger Diagram. If a resistance

Page 57

F-15

F-15

TROUBLESHOOTING & REPAIR

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FIGURE F.2 – TERMINAL STRIP AND 14-PIN RECEPTACLE

to Section

to Master

 

 

 

 

 

 

 

 

 

 

 

 

Return

Return

 

 

 

 

 

 

 

 

K=42

 

 

 

 

 

 

 

A=32

J=31

 

 

 

 

14 PIN MS RECEPTACLE

 

 

 

 

 

 

 

 

 

B=GND

I=41

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C=2

H=21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D=4

G=75

 

 

 

 

 

 

 

 

 

 

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E=77

F=76

Section

Master

 

 

 

 

 

 

 

POSITIVE

 

 

 

 

LOW INDUCTANCE

HIGH INDUCTANCE

M

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

NEGATIVE OUTPUT

 

 

 

 

 

 

NEGATIVE OUTPUT

 

TERMINAL

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

TERMINAL STRIP

 

 

TERMINAL

 

 

 

 

 

 

 

Return to

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COVER PANEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+21

-21 41

4

2

31 32

75

76

77

 

 

 

 

 

TERMINAL STRIP

 

 

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Section

Master

4.

Check for the presence of 42 VAC at the ter-

8.

Check continuity (zero ohms) from pin “D”

 

 

to

to

 

minal strip ( #2 to #41). See the Simplified

 

(lead #4) at the 14-pin receptacle to the out-

 

Trigger Diagram.

 

put terminal switch and also to plug J5-pin

Return

Return

 

 

 

check the circuit breaker and leads #42A

 

9 at the firing board. See the Simplified

 

 

5. If 42 VAC is not present at the terminal strip,

 

Trigger Diagram and Figures F.1 and F.2. If

 

 

 

 

 

 

 

 

and #41 at the P15 connector. See the

 

a resistance of any value is indicated, check

 

 

 

 

the associated wires and plugs.

 

 

 

Simplified Trigger Diagram. Also perform

 

 

 

 

 

 

 

 

 

the Main Transformer Test.

 

 

 

 

6. Remove the main input supply power to the

 

 

 

 

 

DC-655 machine.

 

 

 

 

7. Check continuity (zero ohms) from lead

 

 

TOC

TOC

 

#42A ( plug P15 pin-13) to lead #2 at the 14-

 

 

 

pin receptacle pin “C”. Also check continu-

 

 

 

 

 

 

 

Section

Master

 

ity to the output terminal switch. See the

 

 

 

Simplified Trigger Diagram. If a resistance

 

 

 

 

 

 

 

 

 

 

of any value is indicated, check the associ-

 

 

Return to

Return to

 

ated wires and plugs.

 

 

 

IDEALARC DC-655

 

 

 

 

 

Image 57
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 Safety Precautions Select Suitable LocationElectrical 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 Auxiliary Power Machine ProtectionCase Back Connections Remote Control Leads Fault Protection SHUTDOWN1 Thermal ShutdownOver Current Protection Shutdown CC Mode HOT Start CV Mode CURRENT-LIMITINGCC 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 TestSee the Idle Shut Down Timer MainTransformer Test Function Problems Thermal Fan/Snubber PC Troubleshooting & Repair Welding Problems See the Control Board Mode Current LimitingInternal Trigger Circuit Test Test DescriptionMaterials Needed Test Procedure Trigger DiagramInternal 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 Replacement Procedure 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