Lincoln Electric DC-655

NOTES

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Contents

Main SVM142-A September, 2002 SERVICE MANUAL IDEALARC DC-655 i i FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. iii iii FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. iv iv IDEALARC DC-655 PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFOR- MATEUR ET REDRESSEUR MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATION SECTION - TECHNICAL SPECIFICATIONS DC-655 INPUT - THREE PHASE ONLY RECOMMENDED INPUT WIRE AND FUSE SIZES OUTPUT RATED OUTPUT GRAPHIC SYMBOLS THAT APPEAR ON RATING PLATE (LOCATED ON CASE BACK) CE S SMAW SAW Read this entire installation section before you start installation. SELECT SUITABLE LOCATION STACKING TILTING ELECTRICAL INPUT CONNECTIONS FUSE AND WIRE SIZES RECONNECT PROCEDURE OUTPUT CONNECTIONS ELECTRODE AND WORK CABLES AUXILIARY POWER AND CONTROL CONNECTIONS TERMINAL STRIP 1 (T.S.1) TERMINAL STRIP 2 (T.S.2) - OPERATION SECTION - OPERATING INSTRUCTIONS GENERAL DESCRIPTION RECOMMENDED PROCESSES AND EQUIPMENT DESIGN FEATURES AND ADVANTAGES WELDING CAPABILITY CONTROLS AND SETTINGS DC-655 7 65 3 4 1 2 CASE BACK CONNECTIONS 220 VAC AUXILIARY RECEPTACLE 220 VAC 2 AMP CIRCUIT BREAKER AUXILIARY POWER MACHINE PROTECTION THERMAL SHUTDOWN OVER CURRENT PROTECTION SHUTDOWN Note: REMOTE CONTROL LEADS FAULT PROTECTION SHUTDOWN SHORTED RECTIFIER FAULT PROTECTION WELDING PERFORMANCE LOW INDUCTANCE TERMINAL CV MODE CURRENT-LIMITING CC MODE ARC FORCE CC MODE HOT START - ACCESSORIES - FIELD INSTALLED OPTIONS AUTOMATIC WIRE FEEDERS* CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS AUTOMATIC WIRE FEEDERS Page Page SEMIAUTOMATIC WIRE FEEDERS } Page } - N.E. Page Page MAINTENANCE GENERAL MAINTENANCE MAINTENANCE Page Section E-1 Section E-1 FIGURE E.1 DC-655 BLOCK LOGIC DIAGRAM -THEORY OF OPERATION SECTION- GENERAL DESCRIPTION INPUT LINE, CONTACTOR, RECONNECT, FAULT PROTECTION AND TRANSFORMERS CONTROL BOARD, FIRING BOARD, SNUBBER/FAN, BOARD AND RECTIFICATION PROTECTIVE DEVICES AND SHUTDOWN CIRCUITS THERMAL PROTECTION OVER CURRENT PROTECTION PEAK CURRENT PROTECTION REMOTE CONTROL FAULT PROTECTION SCR OPERATION Page TROUBLESHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page Page TROUBLESHOOTING GUIDE Page Page Page Page Page WELDING PROBLEMS INTERNAL TRIGGER CIRCUIT TEST INTERNAL TRIGGER CIRCUIT TEST (continued) Page F-16 F-16 FIGURE F.3 SIMPLIFIED TRIGGER DIAGRAM P16 FIRING BOARD FIRING BOARD TEST Page FIRING BOARD TEST (continued) Page Page MAIN TRANSFORMER (T1) VOLTAGE TEST Page Page Page Page CONTROL TRANSFORMER (T2) TEST CONTROL TRANSFORMER (T2) TEST (continued) HIGH VOLTAGE CONTROL BOARD TRANSFORMER (T3) TEST CONTROL BOARD TRANSFORMER (T3) TEST (continued) INPUT CONTACTOR TEST INPUT CONTACTOR TEST (continued) TEST FOR CONTACT CONTINUITY X1, #256 #256 #255A #255A STATIC SCR TEST Page STATIC SCR TEST(continued) ACTIVE SCR TEST Page ACTIVE SCR TEST (continued) THERMAL FAN/SNUBBER BOARD LED CHART CONTROL BOARD LED CHART CONSTANT CURRENT MODE NO LOAD MAXIMUM OUTPUT SETTING NO LOAD MINIMUM OUTPUT SETTING NO LOAD TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED CONSTANT VOLTAGE MIG MODE TYPICAL SCR GATE VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING NO LOAD ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM ONE OUTPUT SCR NOT FUNCTIONING INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT CLEANING PROCEDURE CONTACTOR REPLACEMENT INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) REPLACEMENT PROCEDURE REPLACEMENT PROCEDURE (continued) L10124-[ ] REPLACEMENT PROCEDURE (continued) REASSEMBLY AND REPLACEMENT PROCEDURE Page AND REPLACEMENT PROCEDURE (continued) RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS MAXIMUM OPEN CIRCUIT VOLTAGES MINIMUM ACCEPTABLE OUTPUT VOLTAGE - AT MAXIMUM OUTPUT SETTINGS SVM ERROR REPORTING FORM Page G-2 Wiring Diagram (G3348-1) J3 5 106 G-2 G3348-1 I-UF G-3 Control Board Schematic (G3384) POWER SUPPLY A G3384 G3384 A Page Page Control Board Layout (G3385-1) Firing Board Layout (G2699-2) G-8 G-8 Thermal Fan/Snubber Board Layout (L10124-1) THERMAL FAN SNUBBER L10124-1 .25 ~.04