Lincoln Electric DC-655 manual

SVM142-A September , 2002 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRE[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i IDEALARC DC-655 FOR ENGINE po wered equipment. 1.a. T ur n the engine off bef ore troubleshooting and maintenance wor k unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Oper ate engines in [...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii IDEALARC DC-655 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87.[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii IDEALARC DC-655 FOR ELECTRICALL Y po wered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S. National Electrical Code, all local co[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv IDEALARC DC-655 PRÉCAUTIONS DE SÛRETÉ Pour votre pr opre protection lir e et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- an[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v IDEALARC DC-655 Page Safety ............................................................................................................................... ..................i-iv Installation ...............................................................................................................[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 IDEALARC DC-655 Installation .............................................................................................................................Section E T echnical Specifications - Ide[...]

Retur n 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 A-2 A-2 IDEALARC DC-655 INST ALLA TION TECHNICAL SPECIFICA TIONS – DC-655 V olts at Rated Amperes 44 44 Amps 650 815 A uxiliary Po wer See the OPERA TION section f or A uxilia[...]

Retur n 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 INST ALLA TION A-3 A-3 IDEALARC DC-655 3 Phase transf ormer with rectified DC output INPUT PO WER THREE PHASE Designates welder complies with National Electrical Manuf acturers [...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T ur n the input power OFF at the disconnect switch or fuse box befor e working on this equipment. • T ur n the Power Switch on the DC-655 “OFF” befor e connecting [...]

INPUT POWER SUPPL Y CONNECTIONS A qualified electrician should connect the input power supply leads. 1. Follow all national and local electrical codes. 2. Use a three-phase line. 3. Remove the input access door at upper rear of the machine. 4. Follow input supply connection diagram located on the inside of the door . 5. Connect the three-phase AC p[...]

OUTPUT CONNECTIONS ELECTRODE AND WORK CABLES Use the shortest possible cable lengths. See T able A.1 for recommended cable sizes based on length. The output terminals are located at the lower fr ont of the welder behind a hinged door . Refer to Figure A.3. Route the welding cables through the slotted strain r eliefs of the base to the welding termi[...]

Retur n 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 INST ALLA TION A-7 A-7 IDEALARC DC-655 AUXILIAR Y POWER AND CONTROL CONNECTIONS Located at the lower front of the welder behind a hinged door is a 115 V AC duplex receptacle for[...]

TERMINAL STRIPS T erminal strips are available behind the cover panel on the lower case front to connect wir e feeder control cables that do not have a 14-Pin MS-type connector . Refer to Figure A.3 for the location of this cover panel. These terminals supply the connections as shown in the following T erminal Strip charts. See Auxiliary Power T ab[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 IDEALARC DC-655 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Precautions ................[...]

Retur n 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 B-2 B-2 IDEALARC DC-655 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY PRECAUTIONS ELECTRIC SHOCK[...]

GENERAL DESCRIPTION The DC-655 is an ener gy efficient constant voltage DC power source that pr oduces outstanding arc charac - teristics for multiple CV or CC welding processes. Four models are available: Domestic - all 60 Hertz models except 230/460/575v . NEMA Class 1 rated Canadian - 230/460/575v 60 Hertz NEMA Class 1 rated European - 50/60 Her[...]

1. INPUT POWER ON/OFF SWITCH - This tog- gle switch turns the machine on or off. Putting the switch in the ON position ener gizes the machine’ s input contactor applying input power to the machine. Switching the switch to the OFF position de-ener gizes the input contactor . This switch is also used to reset a machine shutdown. (See Machine Shutdo[...]

Retur n 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 OPERA TION B-5 B-5 IDEALARC DC-655 CC mode may also be used for CC submer ged arc with appropriate ar c-sensing CC(VV) wire feeders if arc for ce is set high enough. Refer to W [...]

3. 42 V AC 10 AMP CIRCUIT BREAKER - This br eaker pr otects the 42 V AC auxiliary circuits locat- ed in the terminal strip and MS-receptacle. 4. 14-PIN MS-RECEPT ACLE - This connector pr o- vides easy connection for a wire feeder contr ol cable. It provides connections for auxiliary power , output switching, remote output contr ol, wire feed- er vo[...]

THERMAL SHUTDOWN This welder has thermostatic protection fr om exces- sive duty cycles, overloads, loss of cooling, and high ambient temperature. When the welder is subjected to an overload or loss of cooling, a thermostat will open. This condition will be indicated by the illumination of the yellow Thermostatic Protection Light on the case fr ont [...]

WELDING PERFORMANCE LOW INDUCT ANCE TERMINAL The inside right Negative (-) terminal is lower choke inductance and presently is only r ecommended for welding with NR203Ni 1% procedur es. All other pr ocesses ar e to be welded using the outside right Negative (-) terminal with higher choke inductance. CV MODE CURRENT -LIMITING CV MIG and CV Sub-Arc m[...]

T ABLE OF CONTENTS - ACCESSORIES - Accessories.................................................................................................................... .......Section C Field Installed Options ................................................................................................................C-2 Connection of Lincoln Electric[...]

FIELD INST ALLED OPTIONS K1482-1 Digital Ammeter/V oltmeter Kit - Installs easily to the front contr ol panel and provides digital display of actual welding voltage and amperage while welding. (Installation instructions are included with the kit). K1483-1 Analog Ammeter/V oltmeter Kit - Installs easily to the front contr ol panel and provides analo[...]

The DC-655 can be used to power any of the following Lincoln Wire feeders: SEMI-AUTOMA TIC WIRE FEEDERS • DH-10 • LN-9* • LN-10 • LN-9 GMA* • LN-7 GMA* • LN-23P • LN-742 • LN-25 • LN-7* • LN-8* AUTOMA TIC WIRE FEEDERS* • NA-3 • NA-5R • NA-5 • L T -7 T r actor * European DC-655 models only provide 115V AC f or these feede[...]

NOTE: The connection diagram shown in Figure C.1 shows the electrode connected for positive polarity . T o 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 inductance, as needed). c. Move the work cable to the positive (+[...]

6. Connect NA-5/-5R wire feeder contr ol jumpers on V oltage Control Boar d. See NA-5/-5R Operator’ s Manual. NOTE: The connection diagram shown in Figure C.2 shows the electrode connected for positive polarity . T o change polarity: a. Set the Idealarc DC-655 POWER toggle switch to the OFF (0) position. b. Move the electrode cable to the negativ[...]

SEMIAUTOMA TIC WIRE FEEDERS CONNECTING THE LN-7 TO THE IDEALARC DC-655 (14-PIN MS RECEPT ACLE) 1. Set the POWER toggle switch to the OFF (0) posi- tion. 2. Disconnect main AC input power to the Idealarc DC-655. 3. Connect the electrode cable fr om the control cable to the “+” terminal of the welder and to the LN-7 wire feeder . Connect the work[...]

CONNECTING THE LN-7 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 contr ol cable leads to the Idealar c DC-655 terminal strip as shown in Figure C.3. 4. Connect the wire feeder contr ol cable ground [...]

CONNECTING THE LN-8 OR LN-9 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 contr ol cable leads to the Idealar c DC-655 terminal strip as shown in Figur e C.4. 4. Connect the wire feeder contr ol cabl[...]

CONNECTING THE LN-8 OR LN-9 TO THE IDEALARC DC-655 (14-PIN MS RECEPT ACLE) 1. Set the POWER toggle switch to the OFF (0) posi- tion. 2. Disconnect main AC input power to the Idealarc DC-655. 3. Connect the electrode cable fr om the LN-8 or LN-9 to the “+” terminal of the welder . Connect the work cable to the “-” terminal of the welder (Hig[...]

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[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 IDEALARC DC-655 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions..............................[...]

SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this maintenance. • T ur n the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. GENERAL MAINTENANCE 1. The fan motor has sealed bearings which r equire no service. 2. In extremely[...]

Retur n 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 MAINTENANCE D-3 D-3 IDEALARC DC-655 DC-655 DC-655 2 15 14 10 8 3 3 4 1 1 7 1 13 12 9 5 6 FIGURE D.1 - GENERAL COMPONENT LOCA TIONS 1. CASE FR ONT 2. OUTPUT TERMINALS 3. CASE SID[...]

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[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 IDEALARC DC-655 Theory of Operation ............................................................................................................. Section E General Description .................................................................[...]

GENERAL DESCRIPTION The DC-655 is a three-phase, SCR contr olled DC power source. It is capable of either constant curr ent or constant voltage output. It is rated at 650 amps, 100% duty cycle with outstanding arc characteristics for multiple welding processes. INPUT LINE, CONT ACTOR, RECONNECT , F AUL T PROTECTION AND TRANSFORMERS The desired thr [...]

CONTROL BOARD, FIRING BOARD, SNUBBER/F AN, BOARD AND RECTIFICA TION The “neutrals” of the welding secondary windings in the main transformer are connected together , and the six starts are connected to the six Silicon Contr olled Rectifier (SCR) assemblies to form a six-phase output. This six-phase AC output from the main transformer secondary [...]

THEOR Y OF OPERA TION E-4 E-4 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 PROTECTIVE DEVICES AND SHUTDOWN CIRCUITS THERMAL PROTECTION T wo thermostats protect the DC-655 fr om excessive operating temperatur[...]

SCR OPERA TION A silicon controlled r ectifier (SCR) is a three-terminal device used to control rather lar ge currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is current flow fr om anode to cathode. In the ON state the SCR acts like a closed switch. When the SCR is tur ned [...]

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[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 IDEALARC DC-655 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ..............................................................[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may[...]

TROUBLESHOOTING & REP AIR F-3 F-3 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 IDEALARC DC-655 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 IDEALARC DC-655 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do [...]

TROUBLESHOOTING & REP AIR F-9 F-9 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do [...]

TROUBLESHOOTING & REP AIR F-10 F-10 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you d[...]

TROUBLESHOOTING & REP AIR F-11 F-11 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you d[...]

TROUBLESHOOTING & REP AIR F-12 F-12 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you d[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 IDEALARC DC-655 INTERNAL TRIGGER CIRCUIT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained pe[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 IDEALARC DC-655 ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. TEST PROCEDURE 1. With the correct input power applied [...]

4. Check for the presence of 42 V AC at the ter- minal strip ( #2 to #41). See the Simplified T rigger Diagram. 5. If 42 V AC is not present at the terminal strip, check the circuit br eaker and leads #42A and #41 at the P15 connector . See the Simplified T rigger Diagram. Also perform the Main T ransformer T est. 6. Remove the main input supply po[...]

9. Check continuity (zero ohms) fr om lead #41 (plug P15 pin-10) to plug J5-pin 1 at the fir- ing board. See the Simplified T rigger Diagram and Figure F .1. If a resistance of any value is indicated, check the associat- ed wires, plugs and thermostats. TROUBLESHOOTING & REP AIR F-16 F-16 IDEALARC DC-655 Return to Section TOC Return to Section [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 IDEALARC DC-655 FIRING BOARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained person- nel. U[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 IDEALARC DC-655 FIRING BOARD TEST (continued) FIGURE F .4 – FIRING BOARD TRIGGER CIRCUIT TEST POINTS AND LEDs FIRING BOARD G2699-[ ] 16[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 IDEALARC DC-655 FIRING BOARD TEST (continued) IF THEN LED 7 is ON 32 V AC power is being supplied to the firing board from leads #203 and[...]

7. Connect a jumper wire fr om pin C (lead #2) to pin D (lead #4) at the 14-pin receptacle. See Figure F .5. (Or put the Output T erminal Switch in the ON position.) This should ini- tiate machine output at the welding termi- nals. LED 10 on the firing board should now be on. See T able F .1. If LED 10 does not glow when leads #2 and #4 are con- ne[...]

12. T est for 9.5 VDC to 11.0 VDC between leads #231 and #215 on the firing board. Make sure the Mode Switch (SW2) is in a constant voltage (CV) position. Locate plug J5 on the firing board. Locate leads #231 (pin-13) and #215 (pin-12). See Figure F .4. Connect a jumper wire fr om pin C (lead #2) to pin D (lead #4) at the 14-pin receptacle. (Or put[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 IDEALARC DC-655 W ARNING MAIN TRANSFORMER (T1) VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory tra[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 IDEALARC DC-655 MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) FIGURE F .6 – INPUT CONT ACTOR AND PRIMARY LEADS TEST PROCEDURE 1. Dis[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 IDEALARC DC-655 MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) FIGURE F .7 - MAIN TRANSFORMER SECONDAR Y LEADS TO COMMON BUS VOL T AGE [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 IDEALARC DC-655 MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) 10. T est for 115 V AC between leads #31 and #32 on the terminal strip. [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-26 F-26 IDEALARC DC-655 15. Locate plug J5 on the firing board. See Figure F .9. ELECTRIC SHOCK can kill. • Do not touch electrically hot parts[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 IDEALARC DC-655 W ARNING CONTROL TRANSFORMER (T2) TEST Service and repair should be performed by only Lincoln Electric factory trained pe[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 IDEALARC DC-655 CONTROL TRANSFORMER (T2) TEST (continued) FIGURE F .10 – CONTROL TRANSFORMER TEST PROCEDURE 1. Disconnect the main AC i[...]

TROUBLESHOOTING & REP AIR F-29 F-29 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Locate the control transformer secondary leads. See Figure F .10. Lead X1 is con- nected to the coil terminal on the C[...]

TROUBLESHOOTING & REP AIR F-30 F-30 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING CONTROL BOARD TRANSFORMER (T3) TEST Service and repair should be performed by only Lincoln Electric factory trai[...]

F-31 F-31 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR CONTROL BOARD TRANSFORMER (T3) TEST (continued) TEST PROCEDURE 1. Disconnect the main AC input power to the DC-655 machin[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 IDEALARC DC-655 W ARNING INPUT CONT ACTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 IDEALARC DC-655 INPUT CONT ACTOR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 3/[...]

TEST FOR CONT ACT CONTINUITY 1. Disconnect the main input supply power to the DC-655 machine. 2. Locate, label and remove the thr ee leads connected to the input contactor coil (X1/#256 and #255A). See Figure F .13. ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. 3. Using the external 120 V AC supply , apply 120 V AC to the termin[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 IDEALARC DC-655 W ARNING ST A TIC SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Una[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 IDEALARC DC-655 ST A TIC SCR TEST (continued) FIGURE F .14 – THERMAL F AN/SNUBBER BOARD AND FIRING BOARD PLUG LOCA TIONS THERMAL F AN /[...]

6. If a high or infinite resistance is indicated for both steps #4 and #5, SCR1 is not shorted. 7. If a low resistance is indicated in either steps #4 or #5, there is a shorted SCR in the out- put rectifier bridge. Repeat steps #4 and #5 for each of the six SCRs. It may be neces- sary to disconnect the transformer sec- ondary leads from the r ectif[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 IDEALARC DC-655 W ARNING ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unaut[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 IDEALARC DC-655 ACTIVE SCR TEST (continued) FIGURE F .16 – THERMAL F AN/SNUBBER BOARD AND FIRING BOARD PLUG LOCA TIONS THERMAL F AN / S[...]

4. Construct the circuit shown in Figur e F .17. One 6-volt lantern battery can be used. Set the voltmeter scale low , at approximately 0- 5 volts or 0-10 volts. a. T est the voltage level of the battery . Short leads (A) and (C). Close switch SW-1. Battery voltage should be 4.5 volts or higher . If lower , r eplace the bat- tery . 5. Connect the T[...]

TROUBLESHOOTING & REP AIR F-41 F-41 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL F AN/SNUBBER BOARD LED CHAR T LED # LED FUNCTIONS AND INDICA TIONS (Machine is ON) 1 Indicates fan should be runn[...]

TROUBLESHOOTING & REP AIR F-42 F-42 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL BOARD LED CHAR T LED # LED FUNCTIONS AND INDICA TIONS (Machine is ON) 1 Indicates that the mode switch (SW2) is i[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-43 F-43 IDEALARC DC-655 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 IDEALARC DC-655 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical[...]

TROUBLESHOOTING & REP AIR F-45 F-45 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-46 F-46 IDEALARC DC-655 This is the typical DC open circuit voltage wave- form generated from a pr operly operating machine. Note that each verti[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 IDEALARC DC-655 This is the typical DC open circuit voltage wave- form. The machine was in an open circuit con- dition (no load) and oper[...]

INST ALLA TION F-48 F-48 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC This is NOT the typical DC open circuit voltage waveform. One output SCR is not functioning. Note the “gap” in the waveform. One SCR[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 IDEALARC DC-655 W ARNING INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT Service and repair should be performed by only Lincoln Electric fact[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-50 F-50 IDEALARC DC-655 CLEANING PROCEDURE 1. Remove the main input supply power to the machine. 2. Locate and get access to the input contac- to[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 IDEALARC DC-655 W ARNING SCR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT PROCEDURE Service and repair should be performed by only Lincoln E[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 IDEALARC DC-655 PROCEDURE 1. Remove the input power to the DC-655 machine. 2. Using the 3/8” wrench, r emove the case top and sides. 3.[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 IDEALARC DC-655 FIGURE F .20 – SCR RECTIFIER BRIDGE ASSEMBL Y DET AILS SCR RECTIFIER BRIDGE LEG ASSEMBL Y MOUNTING BRACKETS MAIN TRANSF[...]

TROUBLESHOOTING & REP AIR F-54 F-54 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING MAIN TRANSFORMER AND CHOKE REMOV AL AND REPLACEMENT PROCEDURE Service and repair should be performed by only Lin[...]

TROUBLESHOOTING & REP AIR F-55 F-55 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .21 – OUTPUT CHOKE/MAIN TRANSFORMER ASSEMBL Y DET AILS CHOKE THERMOST A T (LEADS #273 AND 41A) CHOKE / FRAME M[...]

TROUBLESHOOTING & REP AIR F-56 F-56 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND CHOKE REMOV AL AND REPLACEMENT PROCEDURE (continued) MAIN TRANSFORMER REMOV AL 10. With the 1/2” w[...]

TROUBLESHOOTING & REP AIR F-57 F-57 IDEALARC DC-655 Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REP AIR Should a machine under test be rejected for any r eason requiring the r emoval of any mechanical par[...]

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information w[...]

ELECTRICAL DIA GRAMS G-1 G-1 DC 655 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section...........................................................................................Section G Wiring Diagram (60 Hz Domestic) (G3348-1).............................................................[...]

G-2 ELECTRICAL DIA GRAMS DC 655 Wiring Diagram (G3348-1) BRASS 305 G2 G5 G4 G3 G1 G6 41 222 1 2 3 4 1 J7 2 G5 3 4 5 A B 2 GREEN (FRONT VIEW) RECEPTACLE (FRONT VIEW) (FRONT VIEW) 77 RECEPTACLE 41 14-PIN 42 RECEPTACLE (LEFT) GREEN 2 4 42 31 76 32 2 14-PIN STANDARD 2 GREEN 4 OPTIONS H3 H4 H2 H1 G2 4 SCR 2 A4 SCR G4 A2 SCR 6 G6 A6 G2 14 J8 3 4 6 7 G5 8[...]

G-3 ELECTRICAL DIA GRAMS DC 655 G-3 Retur n 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 Contr ol Board Sc hematic (G3384) PROTECTION CURRENT PEAK OVER PROTECTION CURRENT REFERENCE POT FAULT IDLE ZERO CV FEEDBACK >15 AMP SWITCH[...]

G-4 ELECTRICAL DIA GRAMS DC 655 Firing Board Sc hematic (G2792) 7-17-98A G2792 G-4 Retur n 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 NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board lev e[...]

Retur n 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 G-5 ELECTRICAL DIA GRAMS SQU ARE W A VE TIG 275 Thermal Fan/Sn ubber Board Sc hematic (L10123) 5-16-97A L10123 G-5 NO TE: Lincoln Electric assumes no responsibility for liab lil[...]

ELECTRICAL DIA GRAMS G-6 G-6 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 Contr ol Boar d Lay out (G3385-1) G3385-1 C-R W CAP A CIT ORS = MFD/VOL TS RESIST ORS = OHMS/1/4 W A TT UNLESS O THERWISE SPECIFIED C-RW G3385[...]

ELECTRICAL DIA GRAMS G-7 G-7 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 Firing Board La yout (G2699-2) DESCRIPTION PART NO. ITEM REQ'D FIRING BOARD G2699-2 CAPACITORS = MFD/VOLTS RESISTORS = OHMS 7-17-98A G269[...]

ELECTRICAL DIA GRAMS G-8 G-8 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 Thermal Fan/Sn ubber Board La yout (L10124-1) CAPACITORS = MFD/VOLTS ~.04 IDENTIFICATION PART NO. REQ'D ITEM RESISTORS = OHMS 0 5.75 6.00[...]

NO TES 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[...]