Lincoln Electric DC-655 Reassembly, SCR Rectifier Bridge LEG Assembly Mounting Brackets

Page 95

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F-53

F-53

TROUBLESHOOTING & REPAIR

SCR RECTIFIER BRIDGE REMOVAL AND

REPLACEMENT PROCEDURE (continued)

FIGURE F.20 – SCR RECTIFIER BRIDGE ASSEMBLY DETAILS

MAIN TRANSFORMER

SECONDARY LEADS

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SCR

RECTIFIER

BRIDGE

LEG

ASSEMBLY

MOUNTING

BRACKETS

5.Using the 1/2” socket wrench, remove the six transformer secondary leads from the heat sink assembly. The small “A” leads do not have to be removed. Note lead place- ment for reassembly. See the Wiring Diagram and Figure F.20.

6.With the 9/16” wrench, remove the shunt from the left side of the heat sink assembly.

7.With the 3/8” wrench, remove the four mounting bolts that hold the heat sink assembly to the horizontal mounting brack- ets. Be sure to remove the insulators and take note of placement for reassembly.

8.While supporting the heat sink assembly, remove the left side horizontal mounting bracket from the left side leg assembly. See Figure F.20.

9.Carefully slide the rectifier heat sink assem- bly from the machine. Clear all leads.

REASSEMBLY

1.Upon reassembly, apply a thin coating of Dow Corning 340 Heat Sink Compound to all bolted connections.

2.With the left side horizontal mounting brack- et removed, slide the heat sink assembly into the machine.

3.Support the heat sink assembly and install the left side mounting bracket. Then mount the heat sink assembly to the bracket with four bolts. Note insulator placement.

4.Attach the shunt to the left side of the heat sink assembly.

5.Install the six transformer secondary leads to the heat sink assembly. See the Wiring Diagram.

6.Connect lead #222 to the high inductance output terminal.

7.Install plugs J9 and J20 onto the thermal fan/snubber board.

8.Replace any cable ties cut at disassembly.

9.Install the case top and sides.

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 Electrical Input Connections Safety PrecautionsSelect Suitable Location 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-2Recommended Processes and Equipment Design Features AdvantagesOperation General DescriptionDC-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 Welding Performance CV Mode CURRENT-LIMITINGCC Mode HOT Start CC Mode ARC Force CC Mode ARC GougingTable 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 ChartPerform the SCR Bridge Test LED ChartOutput Bridge TestTransformer Test See the Idle Shut Down TimerMain Function Problems Thermal Fan/Snubber PC Troubleshooting & Repair Welding Problems See the Control Board Mode Current LimitingMaterials Needed Internal Trigger Circuit TestTest Description Internal Trigger Circuit Test Test ProcedureTrigger Diagram 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 SCR Rectifier Bridge Removal Replacement ProcedureProcedure 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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