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Lincoln Electric IDEALARC DC-655 User's Manual

Contents

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4. o o Control Board Layout G3385 1 gt 5 s5 5 a o zo Olea ITEM PART IDENTIFICATION ITEM REVO w IGENTIFICWIUN S 8155 1 _ 519400 2673 267 1 4W 1 16 2 111577 26 1 100 o c o 2 8156 1 _ 519400 3320 332 174 C2 1
5. 945 348 dy 222 TEST E no IDLE SHUTDOWN az 4 POWER SUPPLY baz 2 5 3 3 gureur TIMER is ME IMER OUTPUT jj 20 184207 nev ee 1 281 8 n MER se 12 9 029 gis 28 0K CHIP OFF B e 222 nsnsz su onm Dis 280 ds m 2l sax J3 4 LED3 im a Pi ess 9 1 vaa LS R34 can 22K 2 dio lt s gt 14 5 2 RESET MONO x wi D45 1200 wur 9 75 E ann 14 c23 Ia dev 2 SHUTDOWN 815 mg 1 5 1 OHM 20 0K x5 al jay W 25 55 012 TIMER INPUT 8 4lour 1 13 47 ON 044 E 7 2 gt 35v MEN J2 144067 i gz SHORTED SCR ves 282 0 1 es 8 A C PROTECTION 7 50 8 8 By Pass TEST R32 R33 RIBG R194 9 00K c39 35 25 lt oy 4 ML POINT J tux o E 10v le THERMAL FAN 024 Saga 4 pi e ras R186 eee SNUBBER
6. ge FIRING BOARD TEST continued olo 5 FIGURE F 4 FIRING BOARD TRIGGER CIRCUIT TEST POINTS AND LEDs 5 019 ele 515 3 8 LED7 LEDs LED9 c LED1 LED2 G2699 LED10 J6 El 98 LED3 LED4 J7 e 8 8 eic LED6 FIRING BOARD TEST PROCEDURE A WARNING 1 Disconnect the AC input power to the DC ELECTRIC SHOCK can kill 2 Locate the firing board on the left side of the control box not touch electrically hot parts 3 Perform a visual inspection on the firing board to see if there are any loose or faulty connections or physical damage O10 515 gt 218 JE 2 1 4 Connect the correct AC input power the 5 Turn the power switch SW1 to the ON DC 655 position 6 LEDs 7 8 and 9 should be lit and equally bright See Figure F 4 to locate the LEDs Use Table F 1 to check operation of LEDs 7 8 and 9 The three LEDs should be of equal intensity Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN P 19 19 TROUBLESHOOTING amp REPAIR FIRING BOARD TEST continued TABLE F 1 LED 7 8 9 AND 10 Return to Section TOC Return to Master TOC LED 7 is ON 32 VAC power is being supplied to the firing board from lea
7. B 6 E Fan Motor FUSE utet eei ELLE DIL B 6 E Machine Ert R B 6 cL 7 Over Current Protection ShutdOwWn B 7 Remote Control Leads Fault Protection Shutdown 2 B 7 shorted Rectifier Fault Protection eene eee B 7 idie SHUtAOWN 7 Welding e EE 8 5 Low Inductance 2 o etie EI IRR B 8 gt CV Mode Current eater 8 Arc thes B 8 E CC Mode Hot B 8 CC Mode Arc 2 2 dni teu t RR UFU ed EU ETE B 8 Q 7 5 IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o 7 5 OPERATION uiis OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY PRECAUTIONS WARNING N ELECTRIC SHOCK kill Do not touch electrically live parts or electrodes with your
8. 2 3 Return to Section Return to Master TOC o 7 5 po 3 v NEMA EW 1 100 IEC 974 1 INSTALLATION GRAPHIC SYMBOLS THAT APPEAR ON RATING PLATE LOCATED ON CASE BACK 3 Phase transformer with rectified DC output INPUT POWER THREE PHASE Designates welder complies with National Electrical Manufacturers Association requirements EW 1 Class with 100 duty cycle at 650 output Domestic Canadian and Export models Designates welder complies with International Electrotechnical Commission requirements 974 1 European Models Designates the degree of envi ronmental protection provided by the power sources enclosure Constant Current Output Characteristics SMAW SAW IDEALARC DC 655 LINCOLN amp Constant Voltage Output Characteristics GMAW FCAW Designates welder can be used in environments with increased hazard of electric shock European models Designates welder complies with low voltage directive and with EMC directive European models Designates welder complies with both Underwriters Laboratories UL standards and Canadian Standards Association CSA standards Canadian Model Designates welder complies with Underwriters Laboratories UL standards Domestic Models Open Circuit Output Voltage Input Voltage Rating s Input Current Rating s
9. ueriuuoe 10 0161900 ur pue jo EV 5 1 pue jaaa 2u199 3 pepi o4d stu 3143913 U OOUI jou 5 e jenpiaipuj Ajueuew AJojoej 1no Od seqe 40 Ajjiqisuodses ou seuinsse 4 ujoour 56 NE 2101 4 26 91 9 c SHOISIS3H EFN O SLION GSW SHOLIOVAVO 8 i lt SS 91 810915 S S ES diAV dO 7 821915 6 PEE gt 55 O l Nid 91 21 810919 8 5 8 A183SSV LV3H OVlul 10 96815 1 202 1002 007615 9 098 69 89 98 9958 ALES 1119 00 615 278 92 291 291 00761S 978 oz s 26 00v618 ae m lt 001 0001 00615 S E D 508 1528 0076 LS x 4496 6195 0076 LS Sed 4021 635 4 5 1001 05615 2 LOH teH 3 266 2466 007615 6 999 96 Ley e
10. 440880 E 2 Control Board Firing Board Snubber Fan Board and E 3 Protective Devices and Shutdown Circuits nennen nennen nnns E 4 Thermal PEOLGCHOLE were ecu caa 4 Over Current Protection E 4 Peak Current PEOLeGUOTD o e E rr Eos S nr ed on vase eso Dua veto E 4 Remote Control Fault enne nnne nennen E 4 Shorted Output Rectifier Fault 4 ps Riesen 5 D 2 5 FIGURE E 1 655 BLOCK LOGIC DIAGRAM a CONTROL TRANSFORMER 115 SAC 3 f ore TRANSFORMER CR2 Z FAULT PROTECTION CONTROL ARG FORGE O RING CONTROL SIGNAL 5 TIG pan n EJA C t gt E 9 ae 118 46 BOARD kl SWITCH 5 GATE SIGNAL D 42VAC E tc VAS NAY w TRANSFORMER H 5 IC E UNT C O E sant gt aa PK T D CONTAGTOR el SCR BRIDGE IGH NEGATIVE CHOKE ic TERMINAL TO OPTIONAL METER BOARD 2 o 0 5 IDEALARC DC 655 LI
11. Internal Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Return to Section TOC Return to Master TOC Q 7 B 5 F 48 F 48 INSTALLATION ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE MIG ONE OUTPUT SCR NOT FUNCTIONING 0 volts 20 volts 2ms This is NOT the typical DC open circuit voltage waveform One output SCR is not functioning Note the gap in the waveform One SCR gate is disconnected to simulate an open or non functioning output SCR Each vertical division represents 20 volts and each horizontal division represents 2 milliseconds in time Note Scope probes connected at machine out put terminals probe to positive terminal probe to negative high inductance terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master
12. eessssssseseseeeeeeeennen enne nennen nnne nnns F 2 PC Board Troubleshooting Procedures sessssssssseseeseeeeennee enne enne nnne nnn nnns F 3 Troubleshooting F 4 F 12 Test Procedures Internal Trigger Circuit F 13 Fring Board TOS p F 17 Main Transformer T1 Voltage 022220 22 Control Transformer T2 Voltage Test enne F 27 Control Board Transformer 22 220020 000 enne nnne F 30 Contactor TeSt F 32 TOS ius etu uui d LU Ie F 35 Active SCR TeS tarsier F 38 Thermal Fan Snubber Board LED 1 F 41 Control Board LED Chart iani uta Ee yas Ea RE F 42 Oscilloscope Waveforms Normal Open Circuit Voltage Waveform Constant Current F 43 Normal Open Circuit Voltage Waveform Constant Voltage MIG Maximum Output F 44 Normal Open Circuit Voltage Waveform Constant Voltage MIG Minimum Output F 45 Typical Output Voltage Waveform Constant Voltage F 46 Typical SCR Gate Voltage Waveform Constant Voltage F 47 Abnormal Open Circuit Vo
13. 7 HOT START 2 a a xi SWITCHING GAIN 27 af RU we posa n Allset 460 s Ihs 6 2 100 Vib a oT e m BER PES Tih x ws Leg TO CV ME SLOPE 222 1 RIZ Vor 8 sig xi tX nid ARC FORCE vi yr 4 BUFFER 1 u 178 OUTPUT STUD _ S rU wee Vc711 8 62Vo 02 22 lg sw ell tes 100 wt mak X oae Ire 20 0K e V 22 s 22 xe 7 8 Tun V V Ret 7 je S 7 wx 2 R85 amp ax 2 mum Os 10 0K Iset F Varc Vcol qo aeti E TK A D LEDI where to 15 TOT ag 5 a Tr POINT 0 5 CC CONTROL Vco 03Iset 10 FS 1 p 414 FIRING 200K E REFERENCE 033 INTERCEPT CV Ref RI4I i 28 0K 8 BUFFER INTERFACE os VFB V 20 0K w 10 0K 12 2 147K 147K d N R R2 BUFFER n T CONTROL SIGNAL 1 LED2 10v ev x mi TO FIRING PCB sx g V 09 Iw Vref lt E 5 150 g Valovi TO CVI 041 2 i 82 5K 82 5K 4m e gt REF 10K c37 w 5 5 L T tdeo 5 coe gt s CURRENT SWITCH RA v Y 1 T CY OUTPUT ag 4 i 0 5 SEC TIMER 57 V iis 320v RIZ zux e 344
14. gt T 71 C m R POSITIVE lt TERMINAL 2 0918 N SHUNT E 5 5 D T B m _ CAE RESISTOR s SCR BRIDGE 5 HIGH NEGATIVE TERMINAL CHOKE A reconnect panel allows the user to configure the machine for the desired input voltage This three phase AC input is applied to the primary of the main transformer The transformer changes the high volt age low current input power to a lower voltage high er current output The finishes or neutrals of the main secondary coils are connected together and the six starts of the secondary windings are connected to the rectifier assembly In addition the main transformer also has eight isolat ed secondary windings There are three 32 VAC wind ings which provide power and timing to the firing board The 115 VAC winding powers the fan motor and provides the user with up to 20 amps of 115 VAC auxiliary power at the receptacle or 14 pin MS type connector The 42 VAC winding provides up to 10 amps at the 14 pin MS type connector Three other isolated coils are used to power the optional digital meter PC board One winding is rated at 42 VAC and the other two are each rated at 10 VAC NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC DC 655 LINCOLN 5 Return to Section TOC Return to Master TOC
15. Section Safety Precautions a rete esu sr D 2 5 General 2 General Component D 3 Return to Master TOC o 0 Return to Master IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC O o Fle S PEN Ge 1 Return to Section Return to Master TOC Return to Master TOC MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK kill e Only qualified personnel should per form this maintenance e Turn 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 fan motor has sealed bearings which require no service 2 extremely dusty locations dirt may restrict the cooling air causing the welder to run hot with pre mature tripping of thermal protection Blow ou the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on inter nal parts 3 Periodically check the welding cables Inspect for any slits or punctures Also make sure that all connections are tight IDEALARC DC 655 LINCO
16. o 5 B Return to Section Return to Master TOC o 52 5 20 20 TROUBLESHOOTING amp REPAIR FIGURE 5 14 PIN RECEPTACLE K 42 B GND C 2 D 4 7 Connect a jumper wire from pin C lead 2 to pin D lead 4 at the 14 pin receptacle See Figure F 5 Or put the Output Terminal 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 Table F1 i LED 10 does not glow when leads 2 and 4 are con nected together perform the Internal Trigger Test The firing board may be faulty 8 Locate LEDs 1 to 6 on the firing board See Figure F 4 Each LED should glow with equal brightness NOTE LEDs 1 through 6 indicate that the SCR gate firing signals are being generated by the firing board 9 Set the Output Control Switch SW3 in the Output Control at DC 655 local position 10 Set the Mode Switch SW2 in a constant voltage CV position IDEALARC DC 655 LINCOLN 5 Hz21 G 75 Rotate the Output Control Potentiometer R1 As the pot is turned clockwise LEDs 1 through 6 should get brighter As the pot is turned counter clockwise the LEDs should get dimmer If the LEDs glow and change in brightness equally as the pot is turned and the prob lem continues the SCR bridge may be faulty
17. oc wa 08 V mak mm 7 mi 2 POINT sD 5 zs 7168 392 ru TRIGGER e e O BEER R189 E LED7 5 ne OPEN en 4 5 2 102v 16V Y gt Vor 61s 1 RISZ 10v nm 10 10 0K lt ARC FOR HI 50 on NN R7 NEXT 8 SOK POT XS a amp I 1 10 0K 12 25 R194 vaco 4 88 Wa R3 aH i e lt L e n aw 104 7 RE cape 1696 Ja i m 5 574 tow Ss C34 10 0K V 45 R206 Le x 322 157 6 TEST aye Trig g m gw 07 1 o 5 22 doe 8 ase 8 J caz e 8 S 20 0K g a s LIT TEST 4 lt 7 9 8 ELI 222 2 RW V MOUNTED 0 ml zT A S 267K 104 2 RIO eu 10 0K 7 CONTROL PANEL V 35V OUTPUT STUD 9 Q V lh i e 515 1 Xi 0v Fer r V ror 4 o Logs 20 6 2v ray T R154 4 Vo POINT 15 2 e CC CU a S 4 Ref 7 10v 2 VFB 75 EM V 4 153 e ni56 e DX 12k BUFFER 15v x xA RM2 10 Eas 10 06 Ld xe 20 0K Y 5 8 25K 5 2184 8196 5 T s HLS CONTROL 2 62 Leon AT m RI26 bd m MODE AMPLIFIER Ae 100K 222 S
18. 6 Indicates the fan motor should be running LED 6 should be illuminated and the fan running when any of the following LEDs are lit LED 2 LED 3 LED 4 or LED 5 Ojo O10 5 5 2 2 EIS 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN 5 F 42 F 42 TROUBLESHOOTING amp REPAIR olo CONTROL BOARD LED CHART 8 8 LED LED FUNCTIONS AND INDICATIONS 5 Machine is olo 1 Indicates that the mode switch SW2 is the CC mode When LED 1 is on LED 6 should also be illuminated 2 Indicates that feedback voltage is present This informa tion is used when the machine is in a CV mode This LED should get brighter as the output voltage is increased 3 Indicates an input shutdown The normally closed relay CR2 will activate causing input contactor CR1 to open ats 8 See Remote Control Leads Fault Protection amp s Shutdown Shorted Rectifier Fault Protection and 2 2 Shutdown Timer in the Operation Section 8 2 4 Indicates an over current shutdown cc Protection Shutdown in the Operation Section 5 Indicates output current is present 6 Indicates that the machine is in the CC mode LED 6 should be on whenever LED 1 is lit 7 Indicates that the 16 VDC power supply is functioning olo This circuitry is located on the control board
19. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS Return to Master TOC o D Return to Master TOC FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting D
20. 2 5 5 Return to Section Return to Master TOC Return to Master TOC C 2 ACCESSORIES FIELD INSTALLED OPTIONS K1482 1 Digital Ammeter Voltmeter Kit Installs easily to the front control panel and provides digital display of actual welding voltage and amperage while welding Installation instructions are included with the kit K1483 1 Analog Ammeter Voltmeter Kit Installs easily to the front control panel and provides analog display of actual welding voltage and amperage while welding Installation instructions are included with the kit K1484 1 Dual Feeder Kit This kit replaces the 14 Pin MS receptacle panel on the lower case front of the DC 655 It provides two 14 Pin MS receptacles and a built in transfer circuit for connecting and operating two like polarity wire feeders European DC 655 mod els can only use 42V feeders with this kit Installation instructions are included with the kit K1485 1 Cable Hanger Bracket Mounts over stan dard lift bale of the DC 655 and provides a cable hanger on both sides of the power source each side capable of holding up to 100 ft of weld cable Installation instructions are included with the kit K1486 1 Air Filter Kit Removable metal filter easily slides in and out of a bracket which mounts to the front of the DC 655 Filter is designed to trap 8096 of entering particles which are 5 microns or larger in size Instal
21. Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source IDEALARC DC 655 LINCOLN amp Return to Master Return to Master TOC Q 7 Return to Master SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on meta
22. C 4 5 5 Set the MODE switch to a CV constant voltage position 6 6 Adjust wire feed speed at the LN 8 or LN 9 and set the welding voltage with the WIRE FEEDER VOLTAGE CONTROL Place the OUTPUT CONTROL switch in the Remote position and the OUTPUT TERMINALS switch in the Remote position and duty cycle of the application Connect the DH 10 input cable between the 14 pin MS receptacle on the DC 655 and the input cable plug on the DH 10 See Figure C 5 Set the MODE switch to a CV constant voltage position Adjust wire feed speed at the DH 10 and set the welding voltage with the WIRE FEEDER VOLTAGE CONTROL Set the DIP switches on the DH 10 for DC 655 See the DH 10 Operator s Manual Place the OUTPUT CONTROL switch in the Remote position and the OUTPUT TERMINALS switch in the Remote position FIGURE C 5 IDEALARC DC 655 DH 10 CONNECTION DH 10 LINCOLN CV 655 WIRE POWER SOURCE FEEDER SP a AMPHENOL AMPHENOL EN S ELECTRODE CABLE 2 0 ae TO WORK ASSEMBLY IDEALARC DC 655 LINCOLN P 5 IDEALARC DC 655 LINCOLN E 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE gt 5
23. 2 5 Return to Section Return to Master TOC o 7 52 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The output control potentiometer does not function when the output control switch SW3 is the Local position The DC 655 operates normally when controlled remotely The remote output control unit does not function properly when the output control switch SW3 is in the Remote position The DC 655 operates normally when con trolled locally from the machine s output control potentiometer POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS The output control switch SW3 may be defective The remote control unit or con necting cable may be defective Check or replace TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The output control potentiome ter or associated wiring may be faulty See the Wiring Diagram The output control switch SW3 may be defective Check or replace See the Wiring Diagram Check the remote control leads 75 76 and 77 at plug P15 the terminal strip and the 14 pin MS type connector Check for loose or faulty connections See the Wiring Diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tac
24. 4 82 5K 33074A 33074A 33074A DIGITAL METER PCB _ c24 a SNUBBER PCB V 8 ele CV FEEDBACK 1200A AVO 8 681K E 7 7 gt gt 1 004 T FOR CV 655 START _ R45 TRIG LATCH COMPATIBILITY e E 2 4 4 ES OVER ii E x 5 CURRENT J 2 am p de gt 2 00 6 5 22552 8 PROTECTION p se 5 V SWITCH di R55 Hisl POINT 2 5 940 Bs e cy 5 CV CURRENT LIMITING E s mS 44 2 SHUT 10 4 REFERENCE 2528 T OWN 4 lo lt RIG4 ggv 4 he 9 CONTROL Oa 5 AVS REFERENCE MT pa PEAK Y Lene vus REMOTE 619 2 18 16 5 68 50v CURRENT 10V gt z i 06201 s AlZla kVs gt PROTECTION I 45368 8 5 e r7 C FAULT FEEDBACK z 032 1 0 K 3 V MuR 14 le 4 T V E LOIA 0 5 2 d Mounted 100K 3 x TP RIS 04 V to RD Ae 5 g 10 0 4 R78 20 0K gt e pe DLE ZERO Y Ms 10 2 AUN R104 R109 13 7K lt 12 RI3 55 5 555 10 0K 15 0K Ico 4 LS 1020 T 222 REFERENCE 522 REFERENCE 8162 8 ak x7 O CONTROL E GENERAL INFORMATION OUTPUT 13443 z 5 7 POT CIRCUIT T TN amp GENERAL INEGRMATIUN wer ausen 54 1 S
25. Electrical Code and the manufacturer s recommendations IDEALARC DC 655 LINCOLN Return to Master Return to Master TOC Q 0 Return to Master SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter tou jours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants Secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un planch er metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le cable de soudage la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir e jamais toucher simultan ment les parties sous ten sion des porte lectrodes connect s deux machines s
26. TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The 115 VAC receptacle is not working The machine s welding output is normal POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS The circuit breaker may be tripped Reset if necessary Make sure the 115 VAC plug and load is in good working condition TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The circuit breaker may be defective Check associated wiring See the Wiring Diagram Check for 115 VAC at terminals 31 and 32 on the terminal strip If 115 VAC is present at the terminal strip check the wiring between the terminal stirp the circuit breaker and the 115 VAC receptacle If 115 VAC is NOT present at the terminal strip perform the Transformer Test 3 The 115 VAC receptacle may be defective When not welding for a period of time the machine shuts down 1 This may be a normal condition See the Idle Shut Down Timer A CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5
27. j 8 Indicates the control signal is being generated to control 8 2 the firing of the output SCRs This signal is sent to the firing board This LED should get dimmer as the output 8 8 voltage is increased This LED will normally be off when the machine is the constant current mode at open ajg circuit 9 Indicates that the 10 VDC power supply is functioning This circuitry is located on the control board 10 Indicates that 42 VAC is being supplied to the control board from the control board T3 transformer 11 Indicates that feedback voltage is present This informa tion is used when the machine is in the CC mode This LED should get brighter as the output voltage is increased o 5 5 0 15 2 2 IDEALARC DC 655 LINCOLN 5 F 43 F 43 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE NO LOAD Return to Section TOC Return to Master TOC 0 volts Return to Section TOC Return to Master TOC 50 volts 2ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal divi sion represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to ne
28. position and increase typically to no more than 7 as necessary to prevent stubbing or pop outs while welding This higher arc force is recommended especially for low end 6010 stick welding VOLTS 4 OCV Max Arc Force Hot Start Low Hi Setting CC OUTPUT CC MODE HOT START Hot start is built in for CC mode stick and carbon arc starting Hot Start provides an extra weld current boost at the arc strike which increases with higher current settings This Hot Start level exponentially decays to the weld current setting in a few seconds Adjustment of the Hot Start shouldn t be necessary but an unsealed trimmer R81 is provided on the DC 655 Control PC Board to adjust hot start Full counter clockwise adjustment will reduce Hot Start to zero Switch 3 is for test purposes Keep down DIP Switch as shown CC Hot Start 21 2 3 24 B E D AP Switch 4 Hi CV Current Limit as shown Note See Machine Shutdown section for use of switch 1 and 2 DC 655 Control PC Board CC MODE ARC GOUGING The DC 655 is rated for air carbon arc gouging with up to 3 8 10mm diameter carbons CC mode gouging is often preferred over CV mode for cutting
29. 1 305 gt 41 BRASS TERMINAL SECONDARY 4 N a 41 273 CHOKE LEAD THERMOSTAT 76 77 OUTPUT NE OR OUTPUT t CONTROL 202 lt 7 10K 201 lt 6 210 5 315 4 215 3 317 lt 2 222 1 SW3 e 8 CONTROL x air 201 Ike 6 210 ke5 315 lt 4 215 44 3 317 K 2 222 orl e 6 7 lt e 8 9 282 lt lt 10 61 62 2 G3 ke 3 G4 4 G5 5 96 6 6 1 4 5 C K e 6 ATA 22M 41 3 2 301 4 2 5922208 621207 206 8 gt gt 205 9 gt 4 10 gt 310 11 9 309 1222 1 215 182 gt 231 142 214 1521 203 16223 1 204 e 11 238 2 12 ConTROL 1 P C BOARD LI lt 202 21 201 2 210 OPTIONAL ANALOG METERS 222 1 620 336 dl 334 J12 4 gt gt 333 J13 3922 22 LL M Hun S9NIONI OPTIONAL DIGITAL MERES OPTIONS 341 lt gt 5 2158 344 32 263 D 1 7 A ke 8 26 D 36 202 FIRING CIRCUIT LI P C BOARD 445 fUv x 2 32 K 300 tes pH G2 4 AX Gi k G4 5 lt ___ G5 lt AG 2 Al lt ek G6 222 er 4
30. 145 710 13 12 11 10 6 9 420 8 7 9 6 5 4 3 2 1 2 J8 1 Au eom 11 55 4315 222 318 i 817 der 41 5 2 314 gt 301 821 305 117 319 2 2 316 5 51 05 4 gt G4 3 gt G3 2 5 G2 12 G1 THERMAL FAN SNUBBER P C BOARD 1 319 THERMAL FAN NTC THERMISTOR 316 OUTPUT CHOKE 222 222 OUTPUT SHUNT 50 MV 800 AMPS 320V 160J H ALL 3 210 05MFD 600V ALL 3 ARC FORCE OUTPUT MODE SWITCH SHOWN IN CC POSITION FOR OPTIONAL PARALLELING KIT G 2 OUTPUT RECTIFIER ASSEMBLY 6 11 8 13 JUMPER PLUG NOTES J7 J10 J12 J14 J3 TO J16 1 3 1 4 1 5 5 8 6 10 N A LEADS 4 THRU 9 ARE NOT PRESENT ON 380 500V AND SINGLE VOLTAGES OVER 345V MACHINES N D TAPE UP SEPARATELY TO PROVIDE AT LEAST 32 gt GREEN 19 600V INSULATION gt L J1 J9 J15 J16 43 4 JENN N E PLUG amp LEAD ASSEMBLY GOES TO EITHER J12 OPTIONAL DIGITAL METERS BD OR J14 IN LINE CONNECTOR FOR ANALOG METERS 31 N F LOCATED IN SECONDARY COIL WINDING t 76 BN N G STANDARD 14 PIN RECEPTACLE PLUGS INTO J16 ON STANDARD 252005 CONNECTOR CAVITY NUMBERING SEQUENCE MACHINES AN
31. Install the six transformer secondary leads to the heat sink assembly See the Wiring Diagram Connect lead 222 to the high inductance output terminal Install plugs J9 and J20 onto the thermal fan snubber board Replace any cable ties cut at disassembly Install the case top and sides Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN P F 54 F 54 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main transformer and choke for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Wrench 7 16 Wrench 9 16 Wrench Wire cutters Soldering
32. v s 160 Rer V 750 ES TO CVS a B 267 Ref 031 CIRCUIT ie TO CASE Jl cvs cu CVS MODE SWITCH OUTPUT GROUND lt lt 76 E E 342 355 9 MOUNTED ret EA x8 5 2 2 1 110 CONTRO x V e C zz LEDS CIRCUIT po MEL 28 CURRENT 038 pe 25 uj PARAL ELAR V 160J Y SWITCH 035 N S oae TE lorc CS SHUTDOWN ae 6 2 EA SIK J21 TO OPTIONAL ls p 843 e e DIGITAL METER lp 500 Y he r 2 22 ES lt 5 cal TO MODE 8 28 0K xl OUO X13 EB x2 Le t R133 SWITCH CURRENT FEED BACK m 5 320740 0 201 330740 330740 390740 oo ga mar CV SUBA 8 E 7 i om P RDI 200 n 4 M 4 2 21K x9 for 4 230 V 5 4 4 z 1 d x9 99 e R79 R96 Ref m 2 3 V 16V TO SHUNT 2 da aK ET sex o M oy HOD yw 5 mV e 80 0 WV oU CURRENT xe 5 SHU m o o AMPLIFIER ue n at a DOWN E 182K V 1 c2 TS 4 a 4 C 2 0 0 5 5 yi 3 98 R49 Y 7 B 26 7K 3 058 10 0K v 4 V 10 00 B xia t27 X7 X6 lt Le 34 ae TO OPTIONAL TO THERMAL FAN d Velcv
33. 56 27 50 067615 6 662710 006 51 96 0672 LS 9 QLO SLO VLO ELO SLO ELO gt JAM 007 QAN 8970 89 6111 8 60 80 90 90 70 20 2010 Q 1 R NOILVOIJILN3QI ONIHVd 0 038 WALI DOL J91Se N 901 01 901 01 901 J91Se N 01 DOL uonoes DOL uonoes uumeg 901 uonoes DOL uonoes NOTES DC 655 LINCOLN B 901 01 901 01 901 01 901 J91Se N 01 DOL uonoes o3 uumeg DOL uonoes uumeg 901 uonoes uumeg DOL uonoes uumeg
34. D40 041 042 043 046 049 5 Sy 044 045 047 048 4 TI12189 2 184007 gt 2 t LOC 021 072 2 T12702 27 1N4740 x yc UA 2 4 g aid px DZ3 1 T12702 33 1N53478 9 224 024 1 T12702 30 IN52258 e fea 853 3 DZ5 1 T12702 23 1 5352 12 5 gt N 1191 Jt 1 518248 14 HEADER 20 0 BE 4 4 12 1 518248 12 HEADER o HL r5 Jeah 4 1 S18248 10 HEADER gt i e 4 52 tout 4 cu J21 1 S18248 16 EADER S 4 yout 45 pere SIE 1 4 228 LEO 1 LED2 LED3 LED4 LEDS 11 13 57 2 REO LEO 4 sa LED6 LED7 LEDS LEDS LED 10 os 0 9 1 eit LED S 2 5 2 Z S oci 1 1 15000 8 ISOLATOR E SB ef 9 01 03 2 71270468 284401 o as 02 1 18105 4 imm Tem 9 9 8 ga et Ri R2 R42 R104 R105 8106 12 19400 1372 13 7K 174W U a 4 R107 R 108 109 152 8 184 lt c oO c 2 TEL e 4 R196 Q A gt 814318 LH 9 R3 R134 145 3 519400 1212 12 IK 1 4W gt TT T Haru 4 R4 R5 R7 13 R 15 R28 52 519400 1002 10K 1 4 2 5 D 4 R37 R38 R39 R40 R4 1 R44 gt 184 Jao 1 R57 R70 R7 1 R72
35. EIS 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN F 36 F 36 TROUBLESHOOTING amp REPAIR STATIC SCR TEST continued FIGURE F 14 THERMAL FAN SNUBBER BOARD AND FIRING BOARD PLUG LOCATIONS Return to Master TOC Return to Master TOC o o o v z o TEST PROCEDURE 1 Disconnect the main AC input power to the 4 Test for high or infinite resistance from the DC 655 machine anode to the cathode of SCR1 See Figure 2 Locate and disconnect plug J9 from the F15 Use an analog ohmmeter multimeter thermal fan snubber board and plug J5 from 5 Test for high or infinite resistance from the the firing board See Figure F 14 cathode to the anode of SCR1 by reversing Fi 15 3 Remove the red insulating paint from the the meter leads f fox heat sink test points See Figure 15 DO NOT DISASSEMBLE THE HEAT SINKS Return to Master TOC IDEALARC DC 655 LINCOLN 37 F 37 TROUBLESHOOTING amp REPAIR STATIC SCR TEST continued FIGURE 15 HEAT SINK TEST POINTS Return to Section TOC Return to Master TOC ANODE CATHODE REMOVE INSULATING PAINT Return to Section TOC Return to Master TOC 6 high or infinite resistance is indica
36. Output Duty Cycle Rating s Output Voltage Rating s Output Current Rating s Return to Section Return to Master TOC Return to Section TOC o Fle S PEN Ge 1 Return to Section Return to Master TOC Return to Master TOC A 4 A 4 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING e ELECTRIC SHOCK can kill Only qualified personnel should perform this installation e Turn the input power OFF at the disconnect switch or fuse box before working on this equipment e Turn the Power Switch on the DC 655 OFF before connecting or disconnecting output cables wire feeder or remote connections or other equipment Do not touch electrically hot parts Always connect the Idealarc DC 655 grounding ter minal located on the welder near the reconnect panel to a good electrical earth ground SELECT SUITABLE LOCATION Place the welder where clean cooling air can freely cir culate in through the front louvers and out through the rear louvers Dirt dust or any foreign material that can be drawn into the welder should be kept at a mini mum Failure to observe these precautions can result in excessive operating temperatures and nuisance shut downs STACKING The DC 655 may be stacked three high provided the bottom machine is on a stable hard level surface Be sure that the
37. Perform the SCR Output Bridge If one or two lights stay bright or dim and the others change this could indicate an open or shorted gate lead or faulty snubber board Perform the SCR Output Bridge If the Output Bridge and associated gate leads are OK the firing board may be faulty If all of LEDs 1 through 6 do not glow or do not change in brightness equally as the output control is rotated go to step 12 21 F 21 TROUBLESHOOTING amp REPAIR 12 Test for 9 5 VDC to 11 0 VDC between 13 Test for approximately 5 5 VDC between Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q o 5 Return to Section Return to Master TOC o 5 leads 231 215 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 from pin C lead 2 to pin D lead 4 at the 14 pin receptacle Or put the Output Terminal Switch in the ON position This should initiate machine output at the welding terminals Rotate the Output Control R1 clockwise and counter clockwise The DC voltage between leads 231 and 215 should vary from 9 5 VDC to 11 0 VDC as the control is turned from minimum to maximum If the voltage varies a
38. pired timer is reset with each weld The idle mode timer is activated by setting Switch 1 left most of the DIP Switch located on the lower cen ter of the DC 655 Control PC board from the down Off position to the up On position Setting Switch 2 of the DIP switch to up On sets the shutdown time to 2 hours Setting Switch 2 of the DIP switch to down Off sets the shutdown time to 1 2 hour Shutdown is reset by turning the DC 655 input power off then on Switch 1 Timer On Off UP ON Down OFF 1 2 3 4 m DIP Switch m f Switch 2 Time selection UP 2 hours Down 1 2 hour Note See Weld Performance section for use of switch 3 and 4 IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o Fle 5 5 gt Ge 2 1 Return to Section Return to Master TOC B 8 OPERATION WELDING PERFORMANCE LOW INDUCTANCE TERMINAL The inside right Negative terminal is lower choke inductance and presently is only recommended for welding with NR203Ni 1 procedures other processes are to be welded using the outside right Negative terminal with higher choke inductance CV MODE CURRENT LIMITING CV MIG and CV Sub Arc modes employ electronic current limiting to limit excessive short circuit output current which can result in und
39. 8 25 o 27 TRIGGER CIRCUIT RIGG i 8 4 e e 9 J5 619 NB lt 1 a7 4 3 8145 o 1N4007 BEES ow if ne T 8 pes 19 0K 108V 4 R37 R43 4 75 15W baa 9 1 4207 519 022 gt mezle 0213 b Lo Pa 45 2 7 144007 0712 1 5K 144004 c 028 9 15V 15W 10v 144007 wa 078 M 5w 5 150 S 150K 515 4 5 8 5 21 2 2 AS E D m 1N4007 rr e R233 Ze 392 p R89 e6 6 6 6 6 12 3 017 Re8 184007 SCRI R58 5 R87 c a 5 R46 R58 68 1k 1 L 9 9 9 0 e 0 0 9 9 9 9 400 R86 2 4 064 aS 023 gt vg 144007 885 100v 031 032 THERMOSTATIC FAN 20V R 2 00K 144004 SNUBBER 51V 526 B 6 s 19 5 2 55 2 5 5258 amp 332 144004 TO CONTROL BOARD e E oz _ 2 2 amp 4 CLOSURE 1 5 v nis vut CONTROL SIGNAL z 09 6 6 6 0 0 9 09 09 0 Nix 7 10 gt A 033 v ACTIVATOR 144004 kid 158 7 5 3 C ce 2 100 c5 100 E 152 RI R36 909 ohms r eo 5 55 158 267 iy 267 4 8 8 33 le 33 25 y 150 8 8 Ei 5 v A 50v 2 a 013 R232 10 3 CNY17 3 Je 219 e e e e o o o e e e 027 392 1N4004 y 5 c2 P e e qo o o o O O Ja 5 DRIVE
40. LINCOLN 5 Apply the correct three phase input power to the DC 655 and turn the power switch SW1 to the ON position Carefully check for 42 VAC at the secondary leads 281 to 282 If 42 VAC is present the control board transformer 3 is good If 42 VAC is missing or low proceed to the next step Carefully check for 115 VAC at the primary leads 255 and 256 If the 115 VAC is present but the secondary voltage 42 VAC is missing or low the T3 transformer may be faulty Replace If the 115 VAC is NOT present at the prima ry leads check the associated switch SW1 and wiring See the Wiring Diagram Perform the Control Transformer T2 Test Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC Q 7 5 F 32 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable
41. Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo E 2 a gt 23 mlt 5 5 Aic a Return to Section Return to Master TOC E 3 THEORY OF OPERATION FIGURE E 3 CONTROL BOARD FIRING BOARD SNUBBER FAN BOARD AND RECTIFICATION CONTROL TRANSFORMER domzzoormum 28 CONTACTOR CR1 TO OPTIONAL METER BOARD CONTROL BOARD FIRING BOARD SNUBBER FAN BOARD AND RECTIFICATION The neutrals of the welding secondary windings in the main transformer are connected together and the Six starts are connected to the six Silicon Controlled Rectifier SCR assemblies to form a six phase output This six phase AC output from the main transformer secondary is rectified and controlled through the SCR bridge A portion of the firing board is a three phase circuit Each phase provides two firing pulses one for each of the two SCRs controlled by that phase When a gate firing enable signal is received the firing circuit sup plies the proper amount of energy to the gates of the power SCRs When this gate firing signal is applied at the correct time through the snubber fan board the SCR will turn ON The amount of ON time versus OFF time determines the output of the machine See SCR At this time the latching resistor is brought into the machine s output circuit The latching resistor provides a pre load for the SCR bridge The control board
42. SYMPTOMS The arc is variable or sluggish POSSIBLE AREAS OF MISADJUSTMENT S 4 WELDING PROBLEMS Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel configuration Make sure the machine s set tings are correct for the welding process Check the welding cables for loose or faulty connections Also make sure cables are sized correctly for the welding cur rent See CV Mode Current TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the weld mode switch SW2 and associated leads for proper operation or loose or faulty connections See the Wiring Diagram Perform the Firing Board Test 3 Perform the SCR Bridge Test 4 Perform the Main Transformer 5 The control board may be faulty See the Control Board LED Chart The Arc Force Control R4 has no effect on the arc The Arc Force Control is active only in the CC Stick mode The effect of the Arc Force Control will be less noticeable at high welding currents Weld at low currents less than 150 amps and check the Arc Force control function The control Check the Arc Force Control potentiometer R4 for the cor rect resistance and proper operation Normal resistance is 10 000 ohms Check the continuity of leads 321 322 and 328 from the Arc Force Control to the control board See the Wiring Diag
43. Section Return to Master TOC Return to Master TOC F 40 F 40 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE 17 HEAT SINK TEST POINTS swi R2 6 VOLT R1 4 ohms 10 watts LANTERN R2 3 ohms 10 watts BATTERY To test SCRs construct the circuit outlined above Resistor values are plus or minus ten precent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC 4 Construct the circuit shown in Figure F 17 b If the voltage is 3 6 volts only when the One 6 volt lantern battery can be used Set switch is closed or there is no voltage the voltmeter scale low at approximately 0 when the switch is closed the SCR is 5 volts or 0 10 volts defective a Test the voltage level of the battery NOTE Be sure the battery is functioning Short leads A and C Close switch properly A low battery can affect the SW 1 Battery voltage should be 4 5 results of the test Repeat the battery volts or higher If lower replace the bat test procedure in Step 4 if needed tery 10 Open switch SW 1 11 Reconnect the Tester leads See Figure 17 a Connect Tester lead to the cathode b Connect Tester lead C to the anode c Disconnect Test lead G from the gate 12 Close switch SW 1 13 Read the meter for zero voltage a f the voltage is zero the SCR is func 5 Connect the Tester to SCR 1 as shown in Figure F 17 a Connect Tester lead A to the ano
44. Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b IDEALARC DC 655 LINCOLN amp Return to Master Return to Master TOC Q 7 Return to Master WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and c
45. This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into three main categories Output Problems Function Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Content
46. VOLTAGE WAVEFORM CONSTANT VOLTAGE MIG MINIMUM OUTPUT SETTING NO LOAD Return to Section TOC Return to Master TOC 0 volts 20 volts 2ms Return to Section TOC Return to Master TOC This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative high inductance terminal 5 5 gt 218 5 2 SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN 5 F 46 F 46 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CONSTANT VOLTAGE MIG MODE Return to Section TOC Return to Master TOC BREE Et 0 volts Return to Section TOC Return to Master TOC 20 volts 2ms This is the typical DC open circuit voltage wave form generated from a properly operating machine Note that each vertical division repre sents 20 volts and that each horizontal division r
47. a protective cover to prevent acciden tal contact and is a Schuko type The circuit is pro tected by a 2 amp circuit breaker also located on the rear panel This circuit is electrically isolated from all other circuits but on the European Models one line is connected to chassis ground 14 PIN MS TYPE RECEPTACLE For MS3106A 20 27PX Plug L E C Part 512020 32 Refer to the Figure A 4 for the available circuits in the 14 pin receptacle 42 VAC is available at receptacle pins and K A 10 amp circuit breaker protects this circuit 115 VAC is available at receptacle pins A and J Domestic Canadian and Export Models This circuit is protected by a circuit breaker see Auxiliary Power Table Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other However on the European model one line of the 115 VAC is connected to chassis ground FIGURE A 4 FRONT VIEW OF 14 PIN CONNECTOR RECEPTACLE FUNCTION 115 VAC Chassis Connection Trigger Circuit Trigger Circuit Output Control Output Control Output Control Work Sense Connection 42 VAC 115 42 D E F G H K L M N 415VAC circuit is not present in the 14 pin connector on IEC 974 1 European models As shipped from the factory Lead 21 from the 14 pin connector is connected to 21 on the terminal strip This is the configuration for positive welding If welding negative polarity connect
48. amp 219 515 ply oO a Return to Section Return to Master TOC G 5 ELECTRICAL DIAGRAMS G 5 Thermal Fan Snubber Board Schematic L10123 LINCOLN P NOTE J8 J8 48 J8 1 o 63 3 d 63 65 5 18 59 d GATE DRIVE TO GATE SCRI GATE DRIVE TO GATE SCR3 GATE DRIVE TO GATE SCRS FROM FIRING PCB 24 di FROM FIRING PCB J4 3 J9 FROM FIRING PCB J4 5 25 Al 277 A3
49. as it is rotated clockwise The CV mode voltage range of control is 13 to 44V The CC mode current range of control is 50 to 815A OUTPUT TERMINALS ON REMOTE When this switch is in the REMOTE A position the DC 655 s output terminals will be electrically cold until a remote device such as a wire feeder closes the 2 and 4 circuit in the MS receptacle or terminal strip When this switch is in the ON position the machine s output terminals will be electrically energized all the time 5 LOCAL REMOTE CONTROL SWITCH When this switch is set to the LOCAL position con trol of the output voltage is via the output control on the DC 655 s control panel When this switch is set to the remote position control is through a remote source such as a wire feeder via the 75 76 and 77 leads in the MS receptacle or termi nal strip 6 CC STICK CV SUBARC CV MIG MODE SWITCH This switch selects the proper welding characteris tics for the process being used CC Stick provides a constant current output characteristic through the 50 to 815 amp range The current is adjusted within this range by the Output Control dial The open circuit no load voltage will be about 68 volts in this mode This mode is used for stick welding SMAW and CC air carbon arc gouging and employs a Hot Start feature and an Arc Force Control IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Sect
50. by short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard PN junc tion between gate and cathode the voltage between these terminals must be slightly greater than 0 6V Once the SCR has fired it is not necessary to contin ue the flow of gate current As long as current contin ues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC sup ply voltage passes through zero into the negative por tion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output IDEALARC DC 655 LINCOLN 5 IDEALARC DC 655 LINCOLN E 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Return to Master Return to Master TOC Q 7 5 Return to Master TOC Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section 242 4 4 4 1 Section F How to Use Troubleshooting Guide
51. cle must be connected to 21 on the terminal strip Note This is how the DC 655 is shipped from the factory Replace the terminal strip access cover panel For Negative Polarity 1 Connect the electrode cable to the appropriate hig inductance terminal marked WYW or to the low inductance terminal marked if using NR203Ni 1 electrode Connect the work cable to the positive terminal marked Remove the terminal strip access cover panel on the lower case front Refer to Figure A 3 for the location Work Sense lead 21 from the 14 Pin MS recepta cle must be connected to 21 the terminal strip Replace the terminal strip access cover panel 14 PIN MS RECEPTACLE POSITIVE OUTPUT TERMINAL TERMINAL STRIP COVER PANEL LOW INDUCTANCE NEGATIVE OUTPUT TERMINAL HIGH INDUCTANCE NEGATIVE OUTPUT TERMINAL FIGURE A 3 OUTPUT CONNECTIONS IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Fle 5 PEN 2 1 Return to Section Return to Master TOC Return to Master TOC A 7 INSTALLATION AUXILIARY POWER AND CONTROL CONNECTIONS Located at the lower front of the welder behind a hinged door is a 115 VAC duplex receptacle for auxil iary power Domestic and Canadi
52. lead 21 to the 21 connection point on the terminal strip IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC ojo 5 5 PEN 5 gje 2 1 Return to Section Return to Master TOC Return to Master TOC INSTALLATION TERMINAL STRIPS Terminal strips are available behind the cover panel on the lower case front to connect wire 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 Terminal Strip charts See Auxiliary Power Table for rating of circuit breaker in 115 VAC cir cuit Remove a plug button from the terminal strip cover and install an appropriate strain relief clamp for the cable being used NOTE There are two work sense lead connection points on the terminal strip Connect both the work sense lead 21 from the 14 pin connector and 21 lead of the control cable to 21 when welding positive polarity or to 21 when weld ing negative polarity TERMINAL STRIP 1 T S 1 Output Control Output Control Output Control Work Connection Work Connection 42 VAC Trigger Circuit Trigger Circuit 42 VAC 115 115 115 circuit is also present on IEC 974 1 European models connecting a feeder cable directly to the terminal strip Lead 21 from th
53. not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below 50287 01 99 LINCOLN 5 Return to Master Return to Master TOC Q 0 5 Return to Master ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section G Wiring Diagram 60 Hz Domestic 633481 G 2 Control Board Schmatic 6334 G 3 Firing Board Schmatic 02792 a nenne nnne nnne G 4 Thermal Fan Snubber P C Board Schematic 110123 G 5 Control Board Eayout 3385 1 G 6 Firing Board Layout 02699 2 G 7 Thermal Fan Snubber Board Layout 110124 G 8 DC 655 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC elo o GIS gle JE 2 a Return to Master G 2 Wiring Diagram G3348 1 TO GROUND PER NATIONAL ELECTRIC
54. ojo CODES GND H2 e 5 MOUNT THE LINKS IN THE POSITIONS SHOWN DOUBLE OR TRIPLE STACK THE LINKS 5 99 THREE POSITIONS LOOP THE FLEX LEAD IN THE POSITION SHOWN POSITIONING conrRoL THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS INSTALL AND TIGHTEN LINKS TRANSF ALL OF THE HEX NUTS CONNECTION FOR LOWEST RATING PLATE VOLTAGE 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX cri 2 DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE L3 LEAST 600 VOLT INSULATION INPUT 12 ams Y 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H2 CONTROL TRANSFORMER LINES CONTACTOR NS LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN L1 0 Qe 4 CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC 2 7 CODES GND H2 H3 e 5 MOUNT THE LINKS IN THE POSITIONS SHOWN CONNECT THE FLEX LEAD AS SHOWN POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS oo pass INSTALL AND TIGHTEN ALL OF THE HEX NUTS LINKS D UF THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A M18225 FIGURE A 2 DUAL VOLTAGE MACHINE RECONNECTION PROCEDURE Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Fle 5 PEN 8 2 1 Return to Section
55. receives current feedback informa 42VAC 115VAC CONTROL BOARD TRANSFORMER CR2 O FAULT PROTECTION BE 115 3 OUTPUT m NOL ASEE FIRI NG CONTROL SIGNAL E E a G s aye N ema CONTROL BOARD MODE SWITCH GATE SIGNAL D B A POSITIVE TERMINAL o o SHUNT LATCHING D RESISTOR B SCR BRIDGE A HIGH 5 TERMINAL LOW tion from the shunt and voltage feedback information from the choke and welding output terminals This feedback information is processed on the control board The control compares the commands of the mode switch the output control potentiometer or remote control device and the arc force control with the feedback information and sends the appropriate output control signal to the firing board In the event of a fault condition the control board activates the fault relay CR2 See Protective Devices and Shut A tapped output choke is connected between the neu tral connection of the main transformer secondaries and the two negative output terminals This large inductor stores energy which provides current filtering for the welding output of the DC 655 Two negative output terminals are provided One is connected to the tap lead in the choke thus providing a lower induc tance The other utilizes the entire choke for higher inductance arc characteristics The snubber fan board furnishes protection
56. requiring air flow cooling as determined by electronic monitoring of several thermal sensors and the welding current of the machine Depending upon the operating temperature of the machine the fan may remain off while welding but once the fan is activated it will remain on for at least 5 minutes to assure proper cooling This feature saves energy and also minimizes the amount of dirt and other air borne particles being drawn into the machine FAN MOTOR FUSE European Model A 10 amp slow blow fuse protects the fan motor cir cuit This fuse is located inside the DC 655 mounted on the fan motor bracket MACHINE SHUTDOWN The DC 655 provides shutdown modes for thermal over heating excessive load currents and faults It also provides an idle timer shutdown feature for addi tional operating economy IDEALARC DC 655 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC o Fle 5 5 lt Ge cc 1 Return to Section Return to Master TOC Return to Master TOC B 7 OPERATION THERMAL SHUTDOWN This welder has thermostatic protection from 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 front see Figure B 1 Th
57. skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves 3 FUMES AND GASES can be dangerous Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone DE CUTTING SPARKS can cause fire or explosion Keep flammable material away e Do not cut containers that have held combustibles E 4 ARC RAYS can burn e Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC 5 5 gt 2 2 1 Return to Section Return to Master TOC Return to Master TOC B 3 B 3 OPERATION GENERAL DESCRIPTION The DC 655 is an energy efficient constant voltage DC power source that produces 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 Hertz models CE qualified and rated for IEC 974 1 Export 50 60 Hertz models NEMA Class 1 rated RECOMMENDED PROCESSES AND EQUIPMENT The DC 655 is designed for CV or CC processes CV processes include GMAW MIG and FCAW flux cored welding plus the capabili
58. switch SW3 or associated wiring may be defective See the Wiring Diagram 2 Perform the Firing Board Test 3 Perform the SCR Output Bridge Test 4 The control board may be faulty See the Control Board LED Chart The machine does not have maxi mum output Check the three phase input lines at the DC 655 Make cer tain the input voltages match the machine s rating and recon nect panel configuration Put the output control switch SW3 in the Local control position If the problem is resolved the remote unit or wire feeder may be defective The output control potentiome ter output control switch SW3 or associated wiring may be defective See the Wiring Diagram Perform the Main Transformer 3 Perform the Firing Board Test Perform the SCR Bridge Test 5 The control board may be faulty See the Control Board LED Chart A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC Q 7 52 5
59. the work cable to the d NOTE If optional remote control is used place the OUTPUT CONTROL and the OUTPUT TERMI NALS switch in the Remote position IDEALARC DC 655 LINCOLN P Return to Section Return to Master TOC Return to Section TOC ojo 5 5 PEN 5 2 2 1 Return to Section Return to Master TOC Return to Master TOC C 7 ACCESSORIES 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 control cable leads to the Idealarc DC 655 terminal strip as shown in Figure 4 Connect the wire feeder control cable ground lead to the frame terminal marked 777 NOTE The lIdealarc DC 655 must be properly grounded 5 PERFORM THIS STEP ONLY IF THE LN 7 IS EQUIPPED WITH A METER KIT 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 NOTE If the work cable length is less than 25 feet and the connections to the work piece are secure then wire feeder control cable lead 21 be connected directly to the DC 655 terminal strip b An S 16586 X remote voltage sensing work lead is available for this purpose c
60. to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the input contactor is receiving the correct coil voltage and if the contacts are functioning correctly MATERIALS NEEDED Volt ohmmeter Multimeter 3 8 Nut driver DC 655 Wiring Diagram External 120 VAC supply IDEALARC DC 655 LINCOLN P F 32 33 33 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F 12 INPUT CONTACTOR CONNECTIONS X1 256 Return to Section TOC Return to Master TOC elg 5 8 9 2 255A 0 2 2 2 518 2 TEST PROCEDURE 1 Disconnect the main input supply power to 5 Apply the correct three phase input power the machine to the DC 655 and turn the power switch 2 With the 3 8 nut driver remove the case top SW se the ON pesnion and input access cover 6 Check for 120 VAC at the contactor coil leads 3 Locate the three leads connected to the olo input contactor coil X1 256 and 255 7 Ifthe 120 VAC is NOT present with the input e e See Figure F 12 power switch SW1 on check the switch associated circuitry See the Wiring 518 Diagram Also see the Control Board LED 5 Relay CR2 be faulty See the WARNING Wir
61. two pins in the roof fit into the slots in the base of the DC 655 above it TILTING Do not place the machine on a surface that is inclined enough to create a risk of the machine falling over ELECTRICAL INPUT CONNECTIONS Before installing the machine check that the input sup ply voltage phase and frequency are the same as the voltage phase and frequency as specified on the welder nameplate INPUT CONTACTOR CR1 INPUT POWER SUPPLY CABLE WITH BUSHING OR BOX CONNECTOR RECONNECT PANEL ASSEMBL Y L3 a o 1 12 NN ND IS L1 le FIGURE ELECTRICAL INPUT CONNECTIONS Use input wire sizes that meet local electrical codes or see the Technical Specifications in this manual Input power supply entry is through the hole in the Case Back Assembly See Figure A 1 for the location of the machine s input cable entry opening Input Contactor CR1 and reconnect panel FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Technical iSpacincatons of this manual for the machine being used They are also called inverse time or ther mal magnetic circuit breakers DO NOT use fuses or circuit breakers with a lower amp rating than recommended This can result in nui sance tripping caused by inrush current even when machine is not being used for welding at high output currents GROUND CONNECTION Ground the frame o
62. understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 tc Return to Section TOC Return to Master TOC Q B 5 5 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The input contactor chatters The machine is dead the input contactor does not operate The pilot light is lit POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel configuration Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel configuration Turn the machine off and then back on to reset the fault pro tection circuit See the Control TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check for loose or faulty wiring between the input power switch SW1 the fault protec tion relay CR2 and the input contactor See the Wiring Diagram The fault protec
63. wrench 3 8 Wrench 1 2 Wrench 9 16 Wrench O10 515 2 2 5 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN o i 0 iv g he 5 Return to Master TOC F 52 F 52 TROUBLESHOOTING amp REPAIR 1 Remove the input power to the DC 655 machine the Thermal Fan Snubber Board See Figure F 19 3 SCR RECTIFIER BRIDGE REMOVAL AND 2 REPLACEMENT PROCEDURE continued 5 FIGURE F 19 THERMAL FAN SNUBBER BOARD PLUG LOCATIONS 3 THERMAL SNUBBER L10124 LED2 LED6 LED5 LED4 5 LED1 8 2 LED3 5 PLUG J20 PLUG 9 4 44 DICT PROCEDURE Disconnect lead 222 from the negative high inductance output terminal This lead runs from plug J9 to the negative high inductance 2 Using the 3 8 wrench remove the case top output terminal Cut necessary cable and sides T ties See the Wiring Diagram 3 Locate and remove plugs J9 and J20 from IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Q B 5 53 SCR Shen BRIDGE F 53 TROUBLESHOOTING amp REPAIR SCR REC
64. 1 2 7 CLOCK INH o 2 45368 26338 LM224 8 9 COMMON CONNECTION lt H Vss 13 V 45368 M 8 7 D 11 7 FRAME CONNECTION 2 L EARTH GROUND CONNECTION V 5 wena V gt 57 57 5 16 97 NOTES 70 110123 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine SQUARE L10123 5 16 97A WAVE TIG 275 ii ELECTRICAL DIAGRAMS em
65. 29 ADDE 5088 _ cu 50 TO ANODE SCRI tn E ANODE SCR3 _ 15 o 2 5 o T 222v Sw T 200v Tow 208v tl C5 7 68 1 68 SN 68 400V 400 400 38 18 18 x 2 TO GATE SCR 54 x 2 95 Y cE ATE DRIVE SEES S GATE DRIVE TO GATE SCR4 GATE DRIVE TO GATE SCR6 FROM FIRING PCB 44 2 18 FROM FIRING PCB J4 4 ja FROM FIRING PCB J4 6 ja 12 50 ANODE SCR2 Ci4 50 TO ANODE 5 4 skis 50 TO ANODE SCR6 2 5 lt lt 15 200v s 200v 2001 2 C4 C6 2 68 68 2 68 400 400V 400 Ja lt lt amp common 68 58 CURRENT SENSE 16V 400v Bit g 04 R42 2500 a 017 25 sy E sw P el ne 100K 4 16V ZEE Jo 015 SA 853 gt x4 pe 09 R24 222 2 cae L 4 1500 357 TO OUTPUT CHOKE 1006 2 m Troe R23 R30 3 324 V S 15 0K 20V o TO Li L50K is J1 57 34 6 R41 FLEN 0 12 5 39 2 TO CONTROL 15 06 C35 V A h 019 Bis C26 2 AW B kent 2 4 WA m N L50K a LED2 g 4 ey 57 Ium 23 57 47 5k 07 EMPERATURE PTh 1 400v dog ACTIVATOR Ve 150 Ji 38 R34 828 45 1 gt 2 D TO FAN MOTOR 08 _ R THERMAL FAN 16 5 Mj 2 00K THERMISTOR A Vv i200 CIRCUIT V 16V 012 L A 4 10 0K 267K dee 7 R19 R35 36 2 R51 020 16 1 00K
66. 513490 66 47 35 8157 1 __ 519400 432 1 4 32 1 44 C5 CB CB C10 C11 C12 28 S16668 5 022 50 o i B1 1 519400 1080 1 44 C15 18 C 19 C21 C22 C24 a Ri 1 619400 2210 221 174W C25 C27 C29 C31 C35 C38 oo R 1 14648 19 1K SW C38 C40 C4 1 C43 C44 C46 C47 R 1 T14648 23 20 SW 1 513490 42 1 0735 RI 2 519400 2001 2 0 1 4W 3 513490 25 4 7 38 Q 5 8204 1 519400 4750 475 OHM 174W 2 711577 38 02 600 R207 1 519400 5110 511 1 4 2 13490 49 47 50 51 1 519869 24 SLIDE SWITCH SPDT 1 513490 39 18715 tc TP 1 2 3 __ 113640 18 150 C26 C28 C37 3 711677 32 017200 5 2 5 C32 C42 2 513490 93 27 35 2 X4 X7 10 X13 9 515128 18 33074A 1 13490 130 27 50 QUAD GH PERF C34 1 S13490 99 0277200 gt 5 1 515018 13 16 PIN I 55 cae 1 513490 138 12007100 5 o 1 515128 16 1C LT1014 LINEAR 45 1 si34g0 63 47 50 INTEGRATED CIRCUIT C48 1 S16668 9 150 100 0 X16 2 618018 11 CMOS ANALOG SWI TCH 01 02 03 D4 05 06 07 08 09 43 12199 1 1N4004 1 59 010 011 012 013 014 015 20 X12 X14 2__ s15128 10 431 VOLTAGE REF 016 017 018 019 020 021 Loo 022 025 026 027 028 029 5 5 030 031 032 033 034 035 l c ERN 036 037 038 039
67. 6 R73 R 114 3 S19400 3011 3 01K 174w 827 832 2 519400 3982 39 2 1 44 S8 2 gt T asm eea P cer 1 B acu R23 Rb 1 R63 R112 1136 5 519400 8252 82 5K 1 4W Go esta 1 b 1 R31 R131 R132 R169 4 19400 2211 2 21K 1 4W EES esta ag R32 1 519400 6191 6 19K 1 4W D 2914 4 R33 R80 2 519400 2672 26 7 1 4W Eoo R34 267 R171 3 519400 6190 819 1 4W er oO R43 R186 R 187 R 188 R 189 10 519400 9091 9 09 1 4 D S gt 25 R190 R 181 R 192 193 R 194 o o R46 1 19400 1301 1 3K 1 4W 2 b 847 151 R176 3 19400 8251 B 25K 1 4W 5 9 b R50 R160 2 19400 6192 6 CN c R53 R165 8178 3 519400 6811 6 81K 1 4W c R54 1 519400 2432 24 3K 1 4W S 865 1 519400 2801 2 8K 1 4W 5 T R67 1 S19400 2212 22 1 1 4W OS D a R68 168 2 519400 7501 7 5K 1 4V Tye R81 1 T10812 41 10K 1 2W TRIMMER 2818 t a 2 R85 R201 2 _ 519400 1003 __100 1 44 a u 2 ep R93 R I2 1 8138 3 sS19400 1001 1 1748 gt emnmr R94 1 519400 3322 33 2 174w ram eer R100 1 519400 4752 47 5K 1 4 oot cm E R102 i S 19400 1000 100 1 4W m 8103 1 518380 1 THERMISTOR RNO 1 19400 2000 200 174w 5 R111 135 8139 3 519400 1622 1
68. 8 c33 ELECTRICAL SYMBOLS PER E1537 kee 18 ms sa 0 267 C22 8 267 le 8 15 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED C 43 QU 3 SCR 7 E 158 33 S B T igav RESISTORS Ohms 1 40 UNLESS OTHERWISE SPECIFIED LABELS D 71 07 18 001 IN E 50 Ao cs 5e DIODES 14 4000 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET 51 e e e e oo oo e e e oo e o e e 219 oureut POWER SUPPLY SOURCE POINT 25 RECTIFIER CATHODE gt 760 57 COMMON CONNECTION o 9 V FRAME CONNECTION 7 DRIVE Ja 7 97 GATE DRIVE E Je FILE 62792_20 EARTH GROUND CONNECTION 9 2 5 62792 4 7 17 98 5 2 62792 5 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not avail LINCOLN able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine DC 655 7 17 98A Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Fr G
69. 8 2K 1 4W 2g 8 R123 1 T10812 62 500 1728 TRIMMER t R127 1 519400 1821 1 82 1 4W o R137 1 19400 7500 750 1 4W R147 1 19400 1023 102K 1 4W olL R149 R 187 R170 3 519400 1501 1 5 1 44 O RISO 1 19400 2670 267 1 44 925 Er r ler 1 2 9 2 5 919 E CAPACITORS MFD VOLTS SEO F RESISTORS 5 1 4 WATT UNLESS OTHERWISE SPECIFIED San c 918 n o u ct olg sge 5 C RW Sga G3385 1 egt olo Sis E 5 E 5 DC 655 LINCOLN 5 LELECTRIC NOTE 3385 1 C RW ud ELECTRICAL DIAGRAMS Firing Board Layout G2699 2 it Board Return to Section Return to Master TOC DESCRIPTION 1022751 0576000 25 12193 2 144007 12704 73 12707 4 Return to Master TOC Return to Section TOC 1002 10K 1 4W 13 19400 150 50 174W 5 519400 100 1720 3 28 200 1 4W G2699 2 267 174W FIRING BOARD 500
70. 874 R75 ow 4 zv3 8 eset ae R76 R77 R78 RBZ R84 R95 R97 R98 199 R101 R113 R116 0 4 2 R117 R118 122 109191 4 23 R126 R 128 R 129 R 13 D 1 c 8153 8154 8162 R164 aj R177 R179 R180 R182 R183 E 1211 baa 5 12 R195 5 4 RY R30 R58 R59 R60 R61 R62 14 519400 5111 5 11K 1 4W 4 viu 4 216 R73 R88 R89 R90 91 R96 o 1g sco JeF a TT Qd geo 868 648 4 OIE pr R10 R12 21 R23 R24 R35 23 519400 2002 20K 174 5 1 ze Mea Ier 23 18 R36 R52 R55 R65 R69 R LIS D iu is 4 E 0 J sp e 4 k 4 R141 8142 8144 8148 8158 in 4 scm Ee Seu abt 1 F R159 8163 173 R174 R185 D Is E Oo f Leu s 4 La R200 Tia 5037 ol poo RIL R48 R205 3 519400 3921 3 92 1 4 gi snum ag 2 R14 R19 25 R45 R49 856 8 519400 1004 1M 1 4W 8 4 13 R64 R83 S 4 R16 R86 1161 R 166 4 519400 1502 15K 1 4W 17 115 120 3 519400 1652 16 5 1 4W d ac DA H R18 R133 2 519400 68 12 68 IK 1 4W oO EAC TZ 258 Geza b _ R20 R181 R202 3 si9400 2802 28 0 1 4W o2 5 2619 seol DETIN R22 R146 2 619400 5112 1 44 eelu 3 R2
71. AL CODE TO GROUND PER NATIONAL ELECTRICAL CODE N D H3 TO SUPPLY LINES L3 L2 L1 DUAL EXCEPT 380 500V amp 230 400V amp SINGLE VOLTAGE UNDER 346 VOLTS SHOWN CONNECTED FOR LOW VOLTAGE RECONNECT PANEL TO PRIMARY COILS SINGLE VOLTAGE OVER 345 VOLTS N D H2 RH TILES TO SUPPLY LINES L3 L2 L1 RECONNECT PANEL TO PRIMARY COILS STANDARD 14 PIN RECEPTACLE FRONT VIEW DUAL FEEDER P C BOARD A et aa gt L GREEN gt 2 4 77 gt 31 gt 76 nr 75 21 REA gt 42 0045 3000V 3 5 TO RECONNECT 2 PANEL CONNECT OR INSULATE AS SHOWN ON INPUT CONNECTION DIAGRAM H4 Ho a 9 211 X1 X2 T2 CONTROL TRANSFORMER MAIN TRANSFORMER ELECTRICAL DIAGRAMS 10A 42V Cl IT BREAKER 424 0 0 42 20A 32 115V RECEPTACLE 32A gt SWI POWER SWITCH d 115V CIRCUIT BREAKER 32A THERI 5 75 75 yyy 76 gt H Y pum n gt 210 gt 210 32A gt 4 4 gt 41 32A 1 41 41 u Y 402a 42 gt 13 gt 42 7 222 sp 14 222 TERMINAL SWITCH MAL PROTECTION 41 LIGHT
72. ATE DRIVE e e 1 NB o gt e 06 051 L t c 144007 5 5 c30 D R239 sce zx im tc N4007 B cw R240 S y 065 055 619 2 lt 4007 4007 gt 14400 T 1400 45 v 058 066 See 184007 lt gt 144207 200 D56 R225 1500 85 NOTES R224 400 amp 062 SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE 1N4007 0223 282 e WITHOUT AFFECTING THE INTERCHANCEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY e 200 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE 4A R222 053 e R216 qe a 231 NUMBER Y 200 05 o gt 267K 09 J5 FIRING SIGNAL N B 16 IS USED TO CONNECT THE FIRING PCBS IN TWO LIKE MACHINES 184007 R220 en 1 IN4004 nj FROM CONTROL PCB TO PARALLEL THEIR OUTPUTS D49 625 J7 REMAINS IN THE MASTER FIRING PCB V 246027 J7 18 REMOVED FROM THE SLAVE FIRING PCB C26 c23 TY 475 B 392K 2 S 1 4 L 9 i 100 10 0 20 Be R207 o m e sv 48 p o B 10K 267 7 M g we FIRING CIRCUIT 5 CNY17 3 10 0 5 51 5 bs 5 ES i d 5 ENABLE 999 7134 309 ohms tao UT S s c28 iov E xm d GENERAL INFORMATION HE le 5 oe 02
73. D 15 REPLACED BY DUAL FEEDER OPTION IF USED 0 VIEWED FROM COMPONENT SIDE OF BOARD 5 Return to Section Return to Master TOC 4 LOCATED ON OUTPUT RECTIFIER FLAT HEAT SINK ae ELECTRICAL SYMBOLS PER E1537 AS SHIPPED ONLY SWITCH 4 IS ON UP SEE INSTRUCTION MANUAL G3348 1 G3348 1 NOTE This diagram is for reference only It may not be accurate for machines covered by this manual The wiring diagram specific to your code is pasted inside of the enclo LINCOLN 5 sure panels of your machine DC 655 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 o 2 2 Return to Section 5 Return to Master G 3 ELECTRICAL DIAGRAMS G 3 Control Board Schematic G3384
74. ECTION DIAGRAM 14 PIN RECEPTACLE POWER SOURCE CONTROL CABLE ry FOR CONTROL CABLE WITH 14 PIN 5 i PLUG CONNECTOR LN 7 TO INPUT CABLE PLUG R 1 LN 7 CONTROL i CABLE E our FOR CONTROL CABLE Return to Section TOC Return to Master TOC 3 WITH TERMINAL STRIP LEAD CONNECTORS ELECTRODE CABLE TO WIRE FEED UNIT TO WORK s VOLTAGE SENSING LEAD Return to Master TOC o 2 3 SEMIAUTOMATIC WIRE FEEDERS CONNECTING THE LN 7 TO THE IDEALARC DC 655 14 PIN MS RECEPTACLE Return to Section TOC Return to Master TOC terminal of the welder High inductance or low inductance as needed Reverse this hookup for negative polarity NOTE Welding cable must be sized for the current and duty cycle of the application e Q Set the POWER toggle switch to the OFF 0 posi 4 Connect control cable between the DC 655 and tion the LN 7 See Figure C 3 8 Disconnect main input power to the Idealarc 5 Set the MODE switch to a CV constant voltage a 4 DC 655 position at the welder 8 9 Connect the electrode cable from the control 6 Adjust wire feed speed at the LN 7 and set the cable to the terminal of the welder and to the welding voltage with the output CONTROL 2 2 LN 7 wire feeder Connect
75. GATE DRIVE d8 CHOKE e e 2 NB THERMOSTAT 214 CONNECTED TO R3 30 OHM 100 WATT LATCHING RESISTOR ON DC 655 35 o 035 24 24 164 09 gt l R63 184007 o z R62 55 7 022 2 4 208 REQ e gt e nis2 2 4 o o Ix R59 042 619 184007 e e e R58 100K R193 8 10 0 1N4Q07 067 R57 912 R258 3 5 R56 025 m 32 vac 45 45 gt 20v E 1N4007 600v 84 041 N 09K a tt 144007 200 N 068 100 681 2 e 180 5 a 8 158 gt 75202 8 N Don 228 SCR4 179 200 184007 285 15 200 4 RI78 222 a R82 e RU2 Fog 400V 28 4009 R 184007 200 z SCR3 RUL 8176 ope gt e R80 46 R170 208 043 063 R79 08 400v 222 2 144004 9 18 pa dL R78 144007 mea 228 5 2510 V 3775 R77 D29 030 100v al SI 332 GU2 P R76 cia cia 5 33 246027 gt lt R75 e jc e jc e 8 475 332k e 8 R74 100 02 aa LED3 LED4 2 p 9 SCR7 9 100K oS lo 2 6397 ale 2 LATCHING R47 R82 909 ohms 1 00 cis 100v RESISTOR 150 9 267 ae 150 267 QU ENABLE Ej 158 5 33 133 4 4 O El 8 5 v Ao 8 50 O e e e e o oo e e e e V 54 7 LS gt o c J4 DRIVE J4 G
76. IGNAL POT FAULT Raz UDA EA A R 207 0 3 LED lI 226 lt s CL e ras e Rize BUFFER TP UE aet PROTECTION GB CAPACITORS MEDI 822 50 UNLESS OTHERWISE SPECIFIED C 45 45 TP 3 15 0K 108K 4 19 0 m 10 0K 10v 10V RESISTORS Ohms 1 44 UNLESS OTHERWISE SPECIFIED LABELS 0 50 02 5 0061 1 9 5 HD 2 25Vs E wheresthilO 10V 1004 M DIODES 16 400V UNLESS OTHERWISE SPECIFIED CIS 200v PEL 21 Ico 30Vset hij POWER SUPPLY SOURCE POINT bow zen Ref LO 1 50Vs 51 4 Ref 4 19 4 5 100 329 310 57 COMMON CONNECTION E e 4 7 Ico 28Vset TO FROM Enni id 025 500 2 Current FIRING FANG FILENAMES casai 1 7 FRAME CONNECTION LOCAL 2 20 0 2 EARTH GROUND CONNECTION LEA 29 eS gt mE 5 Lm NOTES CLOSED IF 2 4 1S CLOSED let GHI 788 TRIM op SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 75 m 208 V WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BDARD THIS DIACRAM MAY 200V NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE V NUMBER A G3384 G3384 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual
77. IN TRANSFORMER IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 Return to Section Return to Master TOC Q 7 5 TROUBLESHOOTING amp REPAIR FIRING BOARD TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine whether or not the firing board is receiving the correct volt ages and signals The LEDs Light Emitting Diodes will help determine if the firing board is generating gate signals for the main SCRs MATERIALS NEEDED Volt ohmmeter Multimeter DC 655 wiring diagram and firing board schematic drawing IDEALARC DC 655 LINCOLN 5 F 17 18 18 TROUBLESHOOTING REPAIR
78. Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 221 lead to work cable for ease of use NOTE The connection diagram shown in Figure 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 induc tance as needed c Move the work cable to the positive output terminal d Connect control cable lead 21 to 21 on the terminal strip IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC o 5 5 gt 2 2 1 Return to Section Return to Master TOC Return to Master TOC ACCESSORIES FIGURE C 4 LN 8 OR LN 9 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 1 2 TOLN 8OR LN 9 i INPUT CABLE PLUG R i 1 CONTROL CABLE FOR CONTROL CABLE WITH TERMINAL STRIP Por LEAD CONNECTORS 1 1 p A PLI jue j i N 5 0 NEGATIVE positive 1 2 nm bm VOLTAGE SENSING LEAD CONNECTING THE LN 8 OR LN 9 TO THE 6 Connect LN 9 wire feeder control jumpe
79. LN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 PEN 15 2 2 21 Return to Section Return to Master TOC eee OMNE aron oOo MAINTENANCE FIGURE D 1 GENERAL COMPONENT LOCATIONS CASE FRONT OUTPUT TERMINALS CASE SIDES CASE TOP RECONNECT PANEL LOCATION INPUT CONTACTOR LOCATION CONTROL TRANSFORMER LOCATION CASE BACK FAN ASSEMBLY CONTROL PANEL PC BOARDS LOCATION CHOKE MAIN TRANSFORMER BASE SCR RECTIFIER BRIDGE IDEALARC DC 655 LINCOLN 5 D 3 5 IDEALARC DC 655 LINCOLN E 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH 901 J91Se N 01 UuunjeH DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg Section E 1 Section E 1 TABLE OF CONTENTS O OF OPERATION SECTION 5 o Theory of Operation Section 9 General DescriptlOn nter ur 2 3 Input Line Voltage Contactor Reconnect Fault Protection Main and Control
80. N Check feedback leads 222 210 201 and 202 for loose or faulty connections See the Wiring Diagram The optional digital meter PC board may be faulty Check feedback leads 222 210 201 and 202 for loose or faulty connections See the Wiring Diagram The meter s may be defective A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q pe 2 5 Return to Section Return to Master TOC Q B 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Poor arc characteristics Check the three phase input Check the weld mode switch processes line voltage at the machine SW2 and associated leads for The input voltage must match proper operation or loose or the rating plate and reconnect faulty connections See the panel Wiring Diagram Check the welding cables for 2 Perform the Firing B
81. NCOLN 2 2 THEORY OPERATION FIGURE E 2 INPUT LINE VOLTAGE CONTACTOR RECONNECT FAULT PROTECTION MAIN AND CONTROL TRANSFORMERS Return to Section TOC Return to Master TOC olo o Fle S8 o PEN 9 gt 212 5 5 1 TRANSFORMER 42 115 CONTROL BOARD TRANSFORMER CR2 FAULT PROTECTION 32VAC Fan Motor OUTPUT CONTROL SIGNAL FIRING 32VAC BOARD NEU 115VAC GATE SIGNAL ARC FORCE GONIROL CONTROL n AR TS Anal L 523 or CONTROL BOARD MODE wW MAIN TRANSFORMER TO OPTIONAL METER BOARD GENERAL DESCRIPTION The DC 655 is a three phase SCR controlled DC power source It is capable of either constant current or constant voltage output It is rated at 650 amps 100 duty cycle with outstanding arc characteristics for multiple welding processes INPUT LINE CONTACTOR RECONNECT FAULT PROTECTION AND TRANSFORMERS The desired three phase input power is connected to the DC 655 through an input contactor located in the input box at the rear of the machine Two phases of the input line are also connected to the control trans former The secondary of the control transformer sup plies 115 VAC power to the control board transformer and to the input contactor through the fault protection relay The control board transformer supplies 42 VAC to the control board
82. NCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC Q 7 5 C 9 C 9 ACCESSORIES CONNECTING THE LN 8 OR LN 9 TO THE CONNECTING THE DH 10 TO THE IDEALARC DC 655 14 PIN MS RECEPTACLE IDEALARC DC 655 14 PIN MS RECEPTACLE 1 Setthe POWER toggle switch to the OFF 0 posi 15 tion 2 Disconnect main AC input power to the Idealarc 2 DC 655 3 Connect the electrode cable from the LN 8 or 3 LN 9 to the terminal of the welder Connect the work cable to the terminal of the welder High inductance or low inductance as needed Reverse this hookup for negative polarity See Set the POWER toggle switch to the OFF 0 posi tion Disconnect main AC input power to the Idealarc DC 655 Connect the electrode cable from the DH 10 to the terminal of the welder Connect the work cable to the terminal of the welder High induc tance or low inductance as needed Reverse this hookup for negative polarity Figure C4 NOTE Welding cable must be sized for the current NOTE Welding cable must be sized for the current and duty cycle of the application 4 4 Connect the control cable between the 14 MS receptacle on the DC 655 and the input cable plug on the LN 8 or LN 9
83. OHMS 15 RESISTOR 68 IK 174W es resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ojo o FEE 2 2 9 5 5 Aic a RIMMER 1 5183 1 CAPACITORS MFD VOLTS 7 17 98A RESISTORS OHMS 2699 2 Lincoln Electric assumes no responsibility for liabl Return to Section TOC Return to Master TOC DC 655 LINCOLN 0 G2699 2 7 17 98A NOTE Ta 1 o eutuoeui y ur pjnoo
84. Printed Circuit Board Components are not avai able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine DC 655 6 4 ELECTRICAL DIAGRAMS G 4 Firing Board Schematic G2792
85. Return to Master TOC Return to Master TOC A 6 A 6 INSTALLATION OUTPUT CONNECTIONS ELECTRODE AND WORK CABLES Use the shortest possible cable lengths See Table 1 for recommended cable sizes based on length TABLE A 1 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable Cable Length Parallel Cables Cable Size ft m 0 0 to 100 30 4 2 2 0 70mm 100 30 4 to 200 60 8 2 3 0 95mm 200 60 8 to 250 76 2 2 4 0 120mm The output terminals are located at the lower front of the welder behind a hinged door Refer to Figure A 3 Route the welding cables through the slotted strain reliefs of the base to the welding terminals LOW INDUCTANCE TERMINAL On the DC 655 the inside right Negative output ter minal is lower choke inductance This terminal is presently only recommended for CV mode welding with NR203Ni 196 negative polarity procedures All other processes are to be welded using the outside right Negative output terminal with higher choke inductance mode processes must use high inductance For Positive Polarity 1 Connect the work cable to the high inductance terminal marked Connect the electrode cable to the positive terminal marked Remove the terminal strip access cover panel on the lower case front location Refer to Figure A 3 for the Work Sense lead 21 from the 14 Pin MS recepta
86. SVM142 A September 2002 IDEALARL DC 655 For use with machine code number 10501 thru 10510 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info 9 gt o gt ET SERVICE MANUAL is 7 P o 9 3 tc NCOLN Copyright 2002 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC View Safety Info SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
87. TIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 20 SCR RECTIFIER BRIDGE ASSEMBLY DETAILS LEG ASSEMBLY MOUNTING BRACKETS 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 With the 9 16 wrench remove the shunt from the left side of the heat sink assembly 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 While supporting the heat sink assembly remove the left side horizontal mounting bracket from the left side leg assembly See Figure F 20 Carefully slide the rectifier heat sink assem bly from the machine Clear all leads MAIN TRANSFORMER SECONDARY LEADS REASSEMBLY 1 Upon reassembly apply a thin coating of Dow Corning 340 Heat Sink Compound to all bolted connections With the left side horizontal mounting brack et removed slide the heat sink assembly into the machine 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 Attach the shunt to the left side of the heat sink assembly
88. TOC Q 7 5 F 49 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in inspecting cleaning and replacing the input contactor MATERIALS NEEDED Phillips head screw driver 5 16 Socket wrench Flat head screw driver Low pressure air source Allen head type wrench IDEALARC DC 655 LINCOLN 5 F 49 Return to Section Return to Master TOC Return to Section TOC Ojo O10 5 5 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC F 50 F 50 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT continued FIGURE F 18 INPUT CONTAC
89. TOR CLEANING AND REMOVAL C T ALS 112 B T1 C OO J J e J Jd V amp J INPUT SUPPLY LINE INPUT CONTACTOR CR1 RECONNECT PANEL CLEANING PROCEDURE 1 Remove the main input supply power to the machine Locate and get access to the input contac tor CR1 in the input box See Figure F 18 Remove the input contactor cover plate using a phillips head screwdriver A WARNING e Do not apply input power to the machine with the input contactor cover plate re moved Blow out any dirt or dust in or around the contacts with a low pressure air stream Inspect the contacts for signs of excessive wear pitting or contacts fused stuck together a any of these conditions are present replace the input contactor assembly Replace the input contactor cover plate CONTACTOR REPLACEMENT PROCEDURE 1 Disconnect main input supply power to the machine 2 Locate and get access to the input contac tor CR1 in the input box See Figure F 18 3 Disconnect the main input supply power leads L1 L2 and L3 to the input contactor Remove the control transformer primary leads H1 H2 or H3 dependent on input volt age from the L1 and L3 terminals on the input side of the contactor 4 Disconnect the output leads T1 T2 and T3 from the input contactor 5 Identify and label the leads connected to the input con
90. _ 634 47 5K DI T 013 7 OPEN 28 0 2 28 0 7 212 S TO CONTROL THERMISTOR V PCB PROTECTION V V 13 06 05 10 06 16V 2 28 Di Ria ra 10 0K 5 2 00K ta lt 2 00 D B 4 64 858 538 8 E 2 TO THERMAL Hei CONTROL PROTECTION LIGHT 071 8 25K 102 D23 10 0K am 021 16v PCB AND 42VAC ACORN V Leos VE 57 1W2K pf _ C22 Lo V 2 n A 5 Wr 305 8 R54 5 TO THERMAL 322 1 17 3 5 m PROTECTION LIGHT VE 9 J10 Aus A THERMAL 232 mw 21 ZND C33 HN pu V TO CONTROL fed x3 414 9 10V PCB J10 a 100K ACTIVATOR d a 7 R55 03 TO FIRING 342 3 16 V 10 0K PCB x2 1 A 5 2 e R47 4 100K 182K 4 So c 2 000 25 V 16V E 35V lt 10 0K i 16 RIG 100K SET Vdd gt GENERAL INFORMATION LAST NETED 10 0K aoe Er RESE pra mm 0 1 OSC INH ELECTRICAL SYMBOLS PER E1537 R 60 X 4 18 6 15 0K LED5 Z 4 a ar 6 14 4 4 CAPACITORS MFDI 022 50V UNLESS OTHERWISE SPECIFIED 36 9 1 oci 2 C sr 1 DECODE _ RESISTORS Ohms 1 44 UNLESS OTHERWISE SPECIFIED LABELS 0 23 07 1 Vi 5 our 2 202 g 3 C29 c28 x4 C27 DIODES 14 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET R45 5 a 58 16V x3 1 XL O POWER SUPPLY SOURCE POINT
91. age is evident POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact the Lincoln Electric Service Dept 1 800 833 9353 TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION The machine is dead the input contactor does not operate The pilot light is not lit The power switch S1 is in the ON position Check for blown or missing fuses in the input lines Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel 1 Check the power switch S1 and associated leads and con nections See the Wiring Diagram 2 Perform the Control Trans former Test The input contactor operates but no welding output The 115 VAC auxiliary supply is present at the receptacle Check the electrode and work cables for loose or faulty con nections If the Thermal Protection Light is ON the machine is overheat ed Wait for the machine to cool and remedy the cause of the overheating problem See the Fan Snubber Board LED Make certain either the output terminals switch is in the ON position or the external gun trigger circuit is functioning properly 1 Perform the Internal Trigger Circuit Test 2 Perform the Firing Board Test 3 Perform thelMain Transformer 4 Perform the SCR Output Bridge Test 5 The control board may be faulty See Control Board LED CAUTION If for any reason you do not
92. an Models only and a 14 pin MS type receptacle for connection of auxiliary equipment such as wire feeders Also terminal strips with 115 VAC and connections for auxiliary equipment are located behind the access panel on the lower case of the welder A 220 VAC receptacle for a water cooler European and Export Models only is located on the case back AUXILIARY POWER TABLE Voltage and Circuit Breaker Ratings at Auxiliary Power Connections for Various Models Auxiliary Domestic Canadian European Power Models Model Models Models Connections 60Hz _ 230 460 575 60 Hz 50 60 Hz 50 60 Hz At Duplex 115V 20A 115V 15A No Duplex No Duplex Receptacle 115V 20A 115V 15A 115V 15A 115V 20A 115V 15A Open Circuit 42V 10A 42V 10A 42V 10A 42N 10A 220V 2A Export Terminal strip terminals 31 amp 32 MS Receptacle pins A amp J MS Receptacle pins amp At 220V Receptacle No Receptacle aad cod 220V 2A 115 VAC DUPLEX RECEPTACLE DOMESTIC AND CANADIAN MODELS ONLY The 115 VAC duplex receptacle is protected by a cir cuit breaker located below the receptacle see Auxiliary Power Table Receptacle is a NEMA 5 20R protected by a 20 amp breaker on Domestic Models and a NEMA 5 15R protected by a 15 amp breaker on Canadian Models 230 VAC RECEPTACLE EUROPEAN AND EXPORT MODELS ONLY A Continental European receptacle is located on the rear panel for supplying 220 VAC to a water cooler The receptacle has
93. arc force control with built in adjustable Hot Start High efficiency output and selectable sleep mode idle mode timer which shuts down input power if not used for extra energy conservation Fan as needed F A N Solid state thermally con trolled fan operates cooling fan only when required Minimizes power consumption operating noise and dust intake Hinged cover to protect output terminals and auxil iary connections Electronic and thermostatic protection for current overload and excessive temperatures 42 VAC 10 amp auxiliary power available for the wire feeder circuit breaker protected e 115 VAC auxiliary power available for the wire feed er circuit breaker protected 20 amp breaker on Domestic model and 15 amp breaker on Canadian European and Export Models e115 VAC duplex plug receptacle available on Domestic and Canadian Models 20 amp breaker on Domestic Models and 15 amp breaker on Canadian Model e 220 VAC receptacle on European and Export models for connecting to a water cooler Protected by 2 amp breaker Single MS type 14 pin connection for wire feeder Optional Field Installed Digital or Analog Voltmeter Ammeter kits are available Optional dual feeder kit for like polarity connection of two wire feeders Easy panel installation e Optional Dual Process Switch for two processes with polarity change and electrical isolation WELDING CAPABILITY The DC 655 has
94. ary windings of the main transformer The secondary windings the auxiliary windings and the phase angle windings will also be checked Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Multimeter DC 655 Wiring Diagram O10 515 218 5 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Return to Section TOC Return to Master TOC Q 7 B 5 23 23 TROUBLESHOOTING REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 6 INPUT CONTACTOR AND PRIMARY LEADS TEST PROCEDURE 1 Disconnect the main input power from the DC 655 Inspect the input contactor reconnect panel and primary leads to the main trans former for loose or faulty connections See Figure Remove the case sides Confirm that the reconnect panel is config ured correctly for the three phase AC input power supplied to the DC 655 See the connection diagram located on the inside of the input box assembly Connect the correct AC three phase input power to the DC 655 machine A WARNING ELECTRIC SHOCK can kill 0 Do not touch electrically hot parts 5 Turn the pow
95. control but some Arc Force may be required to avoid carbon stub bing IDEALARC DC 655 LINCOLN P Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES 5 Section Field Installed Options cs ssssscssscsscssecssecseesseesseessecssusscusecesesseecsesseessecssucsserececeraterserseesseecsaseess 2 5 Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders C 3 Automatic Wiro Feeders ener terrre x R 3 or LT 7 Terminal Strip C 3 NA 5 or NA 5R Terminal Strip C 4 Semiautomatic Wire Feeders 24 4 C 6 LN 7 14 Pin MS nennen nnne nnne nnns C 6 LN 7 Terminal C 7 LN 8 or LN 9 Terminal Strip rerit eerte ennt in nikon ne Ron n ea eda C 8 LN 8 or LN 9 14 Pin MS Receptacle essen eene C 9 DH 10 14 Pin MS Receptacle sess C 9 Return to Master TOC Q 7 5 Return to Master IDEALARC DC 655 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Ee 1 a gt
96. d P16 connectors and thermostats to the firing board The technician will also be able to determine if the 42 VAC trigger supply voltage is present MATERIALS NEEDED Ohmmeter Multimeter DC 655 Wiring Diagram Simplified Trigger Diagram IDEALARC DC 655 LINCOLN 5 F 13 TROUBLESHOOTING amp REPAIR o INTERNAL TRIGGER CIRCUIT TEST continued Olo z FIGURE F 1 FIRING BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS ge LED7 LED8 LED9 2 3 8 2 6 5 LED1 LED2 G2699 2 LED10 J6 518 fie Flr 5 5 LED3 LED4 U7 z 5 o 9 ele 518 Tu LED6 J4 FIRING BOARD 2 If LED 10 does not light when the trigger cir A WARNING cuit is activated proceed with the following voltage and continuity checks ELECTRIC SHOCK can 3 Check the 10 Amp circuit breaker It is the Do not touch electrically hot one closest to the 115V duplex receptacle parts Reset if tripped o 5 5 PEN 2 TEST PROCEDURE 1 With the correct input power applied to the DC 655 and the trigger circuit activated LED 10 on the firing board should be lit See Figure 1 If LED 10 lights when the trigger is activated the wiring and circuitry t
97. d power will be present until the power switch is turned off IDEALARC DC 655 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Fle 5 PEN Ge 2 1 Return to Section Return to Master TOC Return to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 4 SCR OPERATION CATHODE 2 AS THE GATE ANODE e PULSE 15 APPLIED SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large 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 from anode to cathode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cathode Thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes current only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more pos itive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state The amount of time spent in the ON state is controlled by the Gate LATER IN THE CYCLE THE SCR OUTPUT 15 DECREASED An SCR is fired
98. de b Connect Tester lead C to the cathode c Connect Tester lead G to the gate 6 Close switch SW 1 NOTE Switch SW 2 should be open 7 Read the meter for zero voltage a If the voltage reading is higher than zero tioning b If the voltage is higher than zero the Close or keep closed switch SW 1 SCR is shorted Close switch SW 2 for 2 seconds and 14 Perform the Active Test Procedure outlined release and read the meter in Steps 5 13 for SCRs 2 6 a f the voltage is 3 6 volts while the Switch is closed and after the switch is open the SCR is functioning 15 Replace all SCR assemblies that do not pass the above tests 16 Plug J9 onto the thermal fan snubber board and plug J5 into the firing board IDEALARC DC 655 LINCOLN 5 F 41 TROUBLESHOOTING amp REPAIR The thermal protection light should also be illuminated 8 THERMAL FAN SNUBBER BOARD LED CHART 812 2 E E LED LED FUNCTIONS AND INDICATIONS IE Machine is ON 1 1 Indicates fan should be running 2 Indicates welding current is greater than 200 amps 3 Indicates fan should be running due to heating of main SCRs 4 Indicates open thermal fan thermistor an open o nection between the thermistor and the thermal fan snub sis ber board See the Wiring Diagram leads 319 and 8 316 9 9 5 Indicates a thermostat choke or secondary has opened
99. ds 203 and 204 connected to the phase angle winding in the Main Transformer Normal is 32 VAC LED 7 is not lit or is dimmer than The proper AC voltage may not be the other LEDs reaching the firing board Check for loose or faulty connections Perform the Main Transformer Test LED 8 is ON 32 VAC power is being supplied to the firing board from leads 205 and 206 connected to the phase angle winding in the Main Transformer LED 8 is not lit or is dimmer than The proper AC power may not be the other LEDs reaching the firing board Check for loose or faulty connections Perform the Main Transformer Test Return to Section TOC Return to Master TOC LED 9 is ON 32 VAC power is being supplied to the firing board from leads 207 and 208 connected to the phase angle winding in Transformer LED 9 is not lit or is dimmer than The proper AC power may not be the other LEDs reaching the firing board Check for loose or faulty connections Perform the Main Transformer Test LED 10 is ON This indicates the trigger circuit is activated at the 14 pin receptacle or the terminal strip or that the Output Terminal Switch SW5 is closed Ojo O10 E 515 gt 2 2 5 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
100. e la 4 Garder tous les couvercles et dispostifis de s ret leur 7 Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie 8 S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de la faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent 9 Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fum es toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment roxique ou autres produits irritants PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFOR MATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece soud
101. e cable is connected to 21 on the terminal strip for positive welding If welding negative polarity connect lead 21 to the 21 connection point on the terminal strip IDEALARC DC 655 LINCOLN A 8 Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION 2 gt danasdanuudecnestevesasuvancunee Section Safety Precautlors uii mi ee redet int 2 5 Generali DSS Crit OEY B 3 E Recommended Processes and Equipment B 3 Design Features and B 3 Welding Capability m tete cies 3 Controls and Settings aa ede aie B 4 Case Back Connections rane enge e ea ea sents B 6 T 220 VAC Auxiliary RBeceptacle 1a eec et ere uci B 6 e 220 VAG 2 Amp Circuit tota inen randa inane Renee ee B 6 5 AUXINARY IPOWGR E heehee B 6 Machine o ue 6
102. e fan will continue to run to cool the power source No welding is possible until the machine is allowed to cool and the Thermostatic Protection Light goes out OVER CURRENT PROTECTION SHUTDOWN Average Current Shutdown To protect the SCR s the DC 655 will shut down to essentially no output if the output current averages over 900 amps for about 5 6 seconds and in less than 0 3 seconds if averaging over 1200 amps shorter time for higher current Control PC board LED4 shutdown light will turn on This average current shut down can only be reset by opening the feeder gun trigger or switching the DC 655 Output Remote switch out of the position Peak Current Shutdown To protect the SCRs the DC 655 will shut down imme diately to essentially no output if the peak output cur rent exceeds 2500 amps about 1800A average Control PC board LED4 shutdown light will turn on This peak current shut down can be reset by turning the DC 655 input power off then on REMOTE CONTROL LEADS FAULT PROTECTION SHUTDOWN The remote control leads from the 14 pin receptacle or terminal strip are protected against high voltage faults to the electrode circuit or auxiliary voltage supplies If such a fault occurs the DC 655 will shut down the input primary voltage to the transformer to prevent the fault output Control PC board LEDS input shutdown light turns on If this input shutdown occurs the input power pilot light remains
103. e is not tripped or faulty Also check the the 20 amp circuit breaker is not tripped or wiring between the main transformer the faulty Also check the wiring between the terminal strip and the circuit breaker See main transformer the terminal strip the cir the Wiring Diagram cuit breaker and the receptacle See the Wiring Diagram 13 Remove the AC input power to the DC 655 Remove the screws from the control 11 If 115 VAC is NOT present and the wiring box cover and carefully lower the cover and circuit breaker are good the main transformer may be defective 14 Locate the firing board on the left side of the control box IDEALARC DC 655 LINCOLN F 26 F 26 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER 1 VOLTAGE TEST continued S FIGURE F 9 FIRING BOARD PLUG J5 PINS OJo 5 98 LED7 LED8 LED9 ilz 205 8 1 16 204 2 206 7 1 45 203 207 6 14 208 5 37 13 231 LED LED2 2699 2 21 10 1 C LED10 98 FP 55 LED3 LED4 7 5 5 o 9 ele 518 LED6 J4 FIRING BOARD 15 Locate plug J5 on the firing board See 17 Locate plug J13 on the optional digital Figure 9 meter board If a digital meter board is not 9 place plug J13 will not be used but will be pres
104. e thermostat bly 4 Using the 9 16 wrench remove the flexible 9 Carefully lift the choke from the DC 655 transformer secondary lead and the 222A machine lead from the top lead of the output choke See Figure F 21 5 Using the 9 16 wrench remove the low inductance output lead from the center tap of the choke See Figure F 21 IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Q B 5 56 F 56 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT PROCEDURE continued MAIN TRANSFORMER REMOVAL 10 11 12 13 14 15 16 With the 1 2 wrench remove the six trans former secondary leads from the SCR heat sink assembly Remove the transformer primary leads from the reconnect panel Label for reassembly Carefully label and unsolder the following leads from the transformer windings Cut any necessary cable ties See the Wiring Diagram 335 203 31 336 204 32 g 331 205 0 41 332 206 1 42 333 1 207 04 thermostat 334 1 208 Using rope sling and hoist support the iron coil assembly See Figure 21 With the 9 16 wrench remove the four bolts washers and nuts holding the iron coil assembly to the frame assemb
105. ee A 4 TEE 4 He 4 Electrical Input GConrnectloris eg innen tren REE 4 Fuso and 1268 thei 4 Ground LLL 4 Input Power Supply Connections 1 5 Reconnect nd oro ro U MERECE A 5 9 RR 6 Electrode and Work A 6 2 Auxiliary Power and Control Connections natin an aaa aiaa aaa A 7 Auxiliary Power Table rec ach Y KENEN OLTE ee und 7 T45VAGC Duplex Receptacle a diera Eng ness A 7 230V Receptacle essene en araa E a M Ld 7 14 Pin MS Typ Receptacle e temen A 7 SER 8 Q 7 Return to Master IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Fle 515 gt Ge 1 Return to Section Return to Master TOC INSTALLATION TECHNICAL SPECIFICATIONS DC 655 INPUT THREE PHASE ONLY Standard Input Curren
106. ent the harness Check the fol rir cls A WARNING lowing voltages at the appropriate leads pin locations 518 ELECTRIC SHOCK can kill 2 10 VAC Plug J13 1 lead 331 to 2 e e not touch electrically hot lead 332 E E parts ala 10 VAC Plug J13 pin 4 lead 333 to pin 5 Qu lead 334 42 VAC Plug J13 pin 3 lead 335 to pin 6 lead 336 16 Turn on the DC 655 and check for approx 18 If the correct primary voltages are applied imately 32 VAC at the following leads and to the main transformer and any of the sec pins at plug J5 These are the phase angle ondary voltages are missing or not correct winding voltages See Fig F 9 the transformer may be faulty olo Plug J5 pin 15 lead 203 to pin 16 lead NOTE Always check the wiring between B 204 the transformer windings and the test cls points before replacing the transformer a 45 Plug J5 8 lead 205 to pin 7 lead 8 206 919 Plug 5 pin 6 lead 207 to pin 5 lead 208 515 dc IDEALARC DC 655 LINCOLN 27 27 TROUBLESHOOTING REPAIR CONTROL TRANSFORMER T2 TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please obser
107. epresents 2 milliseconds in time The machine was loaded with a resistance grid bank The grid bank meters read 650 amps at 44 VDC Note Scope probes connected at machine out put terminals probe to positive terminal probe to negative high inductance terminal O10 5 5 gt 218 5 2 SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling ies DC Meg Internal Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN F 47 F 47 TROUBLESHOOTING amp REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM CONSTANT VOLTAGE MIG MAXIMUM OUTPUT SETTING NO LOAD Return to Section TOC Return to Master TOC 0 volts 2 volts 5ms Return to Section TOC Return to Master TOC This is the typical DC open circuit voltage wave form The machine was in an open circuit con dition no load and operating properly Note that each vertical division represents 2 volts and that each horizontal division represents 5 milli seconds in time Note Scope probes connected at SCR gate and cathode probe to gate probe to cathode O10 5 5 gt 218 5 2 SCOPE SETTINGS Volts Div 2V Div Horizontal Sweep 5 ms Div Coupling DC Trigger
108. er doit tre branch une bonne mise la terre seront effectu s par un lectricien qualifi debrancher l interrupteur la boite de fusibles place IDEALARC DC 655 LINCOLN MASTER TABLE CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety sc i iv Installations Section 2 2 alely Precautloris 4 Select Suitable Location Stacking Tilting Lifting A 4 Electrical Input Connections aa A 4 Recontnect Procedure is Fen erit 5 Output CornnectlOns 6 ea Precautlons adii B 2 General DESC MOM erc B 3 Controls and icio diserti B 4 enne t B 6 PEDIS B 6 Machine Protection oti E 6 Weldi
109. er switch SW1 to the ON position 6 IDEALARC DC 655 LINCOLN Make sure the input contactor CR1 ener gizes Test with an AC voltmeter for the proper main AC input voltages applied to the line side of the input contactor CR1 See the Wiring Diagram If the correct voltages are not present at the line side of the input contactor check the input fuses and leads a L1 to L2 b L2 toL3 L1 to L3 Test with an AC voltmeter for the proper AC input voltages at the output side of the input contactor CR1 See the Wiring Diagram If the correct voltages are not present perform the Contactor a T1 to T2 b T2 to T3 T1 to Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 5 5 0 2 2 5 2 Return to Section Return to Master TOC F 24 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 7 MAIN TRANSFORMER SECONDARY LEADS TO COMMON BUS VOLTAGE CHECK SECONDARY LEADS 6 9 Test with an AC voltmeter for approximately 55 VAC from each of the six main trans former secondary leads to the common bus connected to the output choke See Figure ET F 24 CHOKE MAIN TRANSFORMER NOTE The secondary voltages will vary if the input line voltages vary If any one or more of the voltage checks are incorrect check for loose or faulty connectio
110. esirable arc character istics or nuisance over current protection shutdown see Machine Protection section As shipped the DC 655 is set for Hi current limiting which maintains constant voltage until the welding current exceeds a level proportional to the voltage set ting then falls off linearly at about 10 volts per 100 amps to a limited short circuit current Lo current limiting provides the same short circuit current but the arc voltage begins to linearly fall off at lower current at about 5 volts per 100 amps Hi is recommended for all CV processes especially for CV subarc and CV arc gouging but Lo tends to soften the arc more when welding NR203Ni 1 on the Low Inductance terminal If Lo is desired switch 4 right most of the DIP switch located on the lower center of the DC 655 Control PC board needs to be switched from up Hi position to down Lo posi tion VOLTS 4 High lt Setting EM HI Current Limit Lo Current Limit P d Low Setting 5 CV OUTPUT CC MODE ARC FORCE Arc Force provides extra weld current which linearly increases as the welding voltage decreases below a level determined by the constant current setting The Arc Force control knob located behind the latched cover adjust Arc Force from Min no current increase to Max about 9A V increase As a general guideline for CC welding set Arc Force to Mid
111. f the machine A ground terminal marked with the symbol is located inside the case back of the machine near the input contactor Access to the input box assembly is at the upper rear of the machine See your local and national electrical codes for proper grounding methods Use grounding wire sizes that meet local electrical codes or see the Technical Specifications page in this manual IDEALARC DC 655 LINCOLN 5 5 INSTALLATION INPUT POWER SUPPLY CONNECTIONS RECONNECT PROCEDURE A qualified electrician should connect the input power WARNING supply leads Electric Shock Can Kill 1 Follow all national and local electrical codes s Disconnect input power before per 2 Use a three phase line forming this procedure Return to Section TOC Return to Master TOC 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 Multiple voltage machines are shipped connected to the highest input voltage listed on the machine s rating 5 Connect the three phase AC power supply leads plate Before installing the machine check that the L1 2 L3 to the input contactor reconnect panel in the input box assembly is connect terminals in the input box assembly See Figure ed for the proper voltage CAUTION Failure to follow these instructions can cause immedi ate failure of components within the machine To rec
112. from the T1 transformer windings Perform the Check the wiring between Plug J13 and the associated leads at the main transformer See the Wiring Diagram The digital meter PC board may be faulty A CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC Q 0 52 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The optional digital meter is not working properly and or the dis play is erratic The analog meters are not reading correctly POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make certain plugs P12 and P13 are securely plugged into the digital meter PC board Also make sure plug is securely plugged into the con trol board Make sure plug is securely plugged into the control board and plug J14 is securely seated in the plug assembly from the control board TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTIO
113. g ative high inductance terminal Ojo O10 E 5 5 gt 2 2 5 2 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN F 44 F 44 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE MIG MAXIMUM OUTPUT SETTING NO LOAD Return to Section TOC Return to Master TOC HEH HH 0 volts Return to Section TOC Return to Master TOC 50 volts 2ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal divi sion represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative high inductance terminal Ojo O10 E 5 5 gt 2 2 5 2 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN F 45 F 45 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT
114. he 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 IDEALARC DC 655 LINCOLN P Return to Section Return to Master TOC Return to Section TOC E 5 5 gt 2 2 1 Return to Section Return to Master TOC Return to Master TOC 4 ACCESSORIES NOTE The connection diagram shown in Figure 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 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 co
115. hock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Devices Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is des
116. ically separate from the work cable circuit and connection d Tape the 221 lead to work cable for ease of use IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC o 5 5 gt 2 2 1 Return to Section Return to Master TOC Return to Master TOC ACCESSORIES 6 Connect NA 5 5R wire feeder control jumpers on Voltage Control Board See NA 5 5R Operator s Manual NOTE The connection diagram shown in Figure C 2 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 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 NOTE For proper NA 5 operation the electrode cables must be secured under the clamp bar on the left side of the NA 5 Control Box 7 Set the DC 655 OUTPUT CONTROL switch to the Remote position and the OUTPUT TERMINALS switch to the Remote position IDEALARC DC 655 LINCOLN P 6 6 ACCESSORIES FIGURE C 3 IDEALARC DC 655 LN 7 WITH K584 INPUT CABLE ASSEMBLY CONN
117. ing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products
118. ing Diagram Perform the Transformer 2 Test 5 5 ELECTRIC SHOCK can 8 If the 120 VAC IS present and the contactor Do not touch electrically hot parts does NOT activate the input contactor is faulty Replace the input contactor Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q o 5 B tc Return to Section TOC Return to Master TOC o 52 5 F 34 F 34 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE 13 INPUT CONTACTOR TEST CONNECTIONS X1 256 APPLY EXTERNAL 120 VAC HERE a X1 256 AND 255 4 L 255 TEST CONTACT CONTINUITY 1 Disconnect the main input supply power to the DC 655 machine Locate label and remove the three leads connected to the input contactor coil X1 256 and 255A See Figure F 13 WARNING ELECTRIC SHOCK can kill Do not touch electrically hot parts Using the external 120 VAC supply apply 120 VAC to the terminals of the input con tactor coil If the contactor does NOT acti vate the input contactor is faulty IDEALARC DC 655 LINCOLN 5 With the contactor activated check the continuity across the contac
119. ion TOC o Fle 5 gt 8 1 Return to Section Return to Master TOC Return to Master TOC B 5 B 5 OPERATION CC mode may also be used for CC submerged arc with appropriate arc sensing CC VV wire feeders if arc force is set high enough Refer to Welding Performance section CV MIG provides a constant voltage output char acteristic through the 13 to 44 volt range The volt age is adjusted within this range by the Output Control dial The dynamic characteristics of this mode are ideal for open arc processes including MIG MAG GMAW Innershield and other cored wire FCAW processes Faster travel submerged arc processes and CV air carbon arc gouging may also use this mode Refer to the Welding Performance section CV Sub Arc provides the same constant voltage output control range as CV MIG but the dynamic characteristics of this mode make possible improved CV constant wire speed submerged arc welding This improved process is most notice able on high deposition slow travel speed welds Fast travel narrow bead subarc welds will have better performance in CV MIG mode 7 ARC FORCE CONTROL This control is only func tional in CC Stick mode It prevents stubbing of the electrode by providing the extra weld current that linearly increases as the welding voltage decreases below a level determined by the setting of the constant current c
120. irable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 tc Return to Section TOC Return to Master TOC Q 7 B 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam
121. iron and solder 1 2 Socket wrench 9 16 Socket wrench Ojo O10 5 5 2 2 EIS 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Return to Section TOC Return to Master TOC Q B 5 55 55 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 21 OUTPUT CHOKE MAIN TRANSFORMER ASSEMBLY DETAILS CHOKE THERMOSTAT LEADS 273 AND 41A CHOKE FRAME MOUNTING BOLTS 4 TOP LEAD 222A CENTER TAP LOW INDUCTANCE OUTPUT LEAD BOTTOM CHOKE LEAD HIGH INDUCTANCE OUTPUT LEAD IRON COIL MOUNTING BOLTS 4 TRANSFORMER SECONDARY LEADS 6 PROCEDURE 6 Using the 9 16 wrench remove the high inductance output lead from the bottom 1 Remove the input power to the DC 655 choke lead See Figure F 21 machine 5 Bamovelhs case top and sides 7 Support the choke with a crane or hoist 8 Using the 9 16 wrench remove the four OUTPUT CHOKE REMOVAL bolts washers and nuts mounting the choke 3 Label and remove leads 273 and 41A from assembly to the transformer frame assem the chok
122. l structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observ
123. lation instructions are included with the kit Cannot be used with K1528 1 Dual process switch NOTE A dirty air filter may cause the thermal protec tion of the DC 655 to prematurely activate Remove and blow out or wash and dry the filter every two months or less if in extremely dirty conditions Replace if necessary Undercarriage K817P K842 The DC 655 is designed for use with the Lincoln K817P or K842 Undercarriage Complete installation instructions are included with each undercarriage When any of the undercarriages are installed the DC 655 lift bail is no longer functional Do not attempt to lift the machine with the undercarriage attached The undercarriage is designed for moving the machine by hand only Mechanized towing can lead to injury and or damage to the DC 655 STRAIGHT PLUG 14 PIN TO POWER SOURCE REMOTE OUTPUT CONTROL K775 OR K857 WITH K864 ADAPTER An optional remote output control is available This is the same remote control that is used on other Lincoln power sources K775 The K775 consists of a control box with 28 ft 8 5m of four conductor cable This connects to terminals 75 76 and 77 on the terminal strip and the case grounding screw so marked with the symbol 777 on the machine These terminals are locat ed behind the cover panel on the lower connection panel of the DC 655 This control will give the same control as the output control on the machine The K857 has a 6 pin MS style co
124. lit since the power switch is ON and control power is still present Welding output or auxil iary supply output will not be present This input shut down is reset by turning the DC 655 input power off then on If the fault is not corrected however the shutdown will re occur when turning on the input power Note on earlier machines LED4 will turn on and output will be disabled if this fault occurs SHORTED RECTIFIER FAULT PROTECTION If a short occurs across one of the silicon controlled rectifiers of the DC 655 a potentially hazardous AC voltage could appear across the welding output termi nals even in idle mode when no output should be pre sent If such a fault occurs the DC 655 will shut down the input primary voltage to the transformer to prevent the fault output Control PC board LEDS input shut down light turns on If this input shutdown occurs the input power pilot light remains lit since the power switch is ON and control power is still present Welding output or auxil iary supply output will not be present This input shut down is reset by turning the DC 655 input power off then on If the fault is not corrected however the shutdown will re occur when turning on the input power IDLE SHUTDOWN TIMER For additional operating economy the DC 655 can be set up to automatically shut off the primary input power to the main transformer after a selectable time 1 2 or 2 hr has expired without welding The unex
125. ltage Waveform Constant Voltage MIG F 48 Replacement Procedures Input Contactor CR1 Cleaning Replacement F 49 SCR Rectifier Bridge Removal and Replacement F 51 Main Transformer and Choke Removal and F 54 dene Em IU du D LEE EIE F 57 IDEALARC DC 655 LINCOLN Section F 1 Return to Section Return to Master TOC Return to Section TOC O10 515 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS
126. ly Cut or remove any necessary cable ties Using the hoist carefully remove the iron coil assembly from the DC 655 machine Clear all leads REASSEMBLY 1 10 11 Using the rope sling carefully position the iron coil assembly onto the DC 655 Mount it to the frame assembly with four bolts washers and nuts Attach the transformer primary leads to the reconnect panel Attach the six transformer secondary leads to the SCR heat sink assembly Solder the following leads to the transformer windings g 335 1 203 0 31 g 336 1 204 1 32A g 331 1 205 g 41 g 332 0 206 g 42A 3 333 1 207 041 thermostat 3 334 1208 Using crane or hoist carefully place the choke onto the main transformer Attach the high inductance output lead to the bottom choke lead Attach the low inductance output lead to the choke center tap Attach the 222A lead and flexible trans former secondary lead to the top choke lead Attach leads 273 and 41A to the choke thermostat Replace any cable ties cut at disassembly Install the case top and sides Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN 5 57 57 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine s electrical characteristics or if any electrical components are repaired or replaced
127. m this installation 0 e Turn the input power OFF at the dis connect switch or fuse box before working on this equipment Do not touch electrically hot parts Auxiliary power for wire feeder operation is available at both a 14 pin MS receptacle and at terminal strips with screw type connections located on the front of the machine Refer to the Installation section for pinouts and lead designations The two circuits are isolated and each is protected by a circuit breaker The following descriptions show how to connect the wire feeders using either the 14 pin MS receptacle or the terminal strip C 1 4 Connect the wire feeder control cable ground lead to the frame terminal marked 777 NOTE The Idealarc DC 655 must be properly grounded FIGURE C 1 NA 3 OR LT 7 WIRE FEEDER CONNECTION TO THE IDEALARC DC 655 14 PIN RECEPTACLE CONTROL CABLE FOR CONTROL CABLE WITH 14 PIN MS TYPE TM PLUG CONNECTOR 1 AUTOMATIC 21 i CONTROL BOX 1 i CONTROL CABLE FOR CONTROL CABLE WITH TERMINAL STRIP a LEAD CONNECTORS POWER SOURCE NEGATIVE positive MU ELECTRODE CABLE d TO AUTOMATIC EQUIPMENT TO WORK VOLTAGE SENSING LEAD 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 t
128. n TOC olo o Fle 5 5 PEN 2 21 Return to Section Return to Master TOC Return to Master TOC B 6 B 6 OPERATION 3 42 VAC 10 AMP CIRCUIT BREAKER This breaker protects the 42 VAC auxiliary circuits locat ed in the terminal strip and MS receptacle 4 14 PIN MS RECEPTACLE This connector pro vides easy connection for a wire feeder control cable It provides connections for auxiliary power output switching remote output control wire feed er voltmeter sense lead and ground Refer to in the Installation Section of this manual for information about the cir cuits made available at this receptacle 5 TERMINAL STRIP COVER PANEL Remove this panel to gain access to the circuits made available at the terminal strip and the 4 pin receptacle for the optional paralleling kit This terminal strip contains the same circuits as the 14 pin MS receptacle The cover also provides for installation of cable strain relief clamps 6 POSITIVE OUTPUT TERMINAL This output ter minal is for connecting a welding cable To change welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section of this manual 7 NEGATIVE OUTPUT TERMINALS These output terminals are for connecting a welding cable to either the High Inductance or Low Inductance Terminal for desired arc characteristics To change welding polarity and for proper
129. nd LEDs 1 through 6 do NOT vary in brightness the firing board may be faulty If the voltage does NOT vary the control board control potentiometer or associated leads be faulty See the Wiring Diagram IDEALARC DC 655 LINCOLN 5 leads 231 and 215 on the firing board See Figure 4 Put the Mode Switch SW2 in the constant current CC position Rotate the Output Control R1 clockwise and counter clockwise The DC voltage between leads 231 and 215 should be constant at approximately 5 5 VDC This voltage should not vary when the output control is turned F 22 F 22 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltages are being applied to the prim
130. ng Performance 8 ACCOSSOFIOS aoreet eie ep ricas et iri Gat od su Section C Maintenant EET EPICUREI Section D Dalety PreECAUllONS lee D 2 General RE D 2 General Component D 3 Blaeu Section Troubleshooting Section F How to Use Troubleshooting GUIQO c i retro F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting Guide ini ote eo eoe iic le vertu F 4 Test Procedures m F 13 OSCIIOSCODE Wave lon S nesir F 43 Replacement Procedures eati d re Rea a aaa F 49 F 57 Electrical DiaQraims Section Parts 317 IDEALARC DC 655 LINCOLN P Section 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION o 2 8 ON Section 9 Technical Specifications Idealarc DC 655 A 2 Graphic Symbols that Appear on Rating 1000 A 3 E ron 4 Select Suitable Location Re gor iae
131. nnector The K857 requires a K864 adapter cable which connects to the 14 pin connector on the DC 655 REMOTE CONTROL ADAPTER CABLE K864 CABLE RECEPTACLE 6 SOCKET gt TO K857 REMOTE CONTROL V cable 12 30m long to connect K857 Remote Control 6 pin connector with a wire feeder 14 pin connector and the machine 14 pin connector If a remote control is used alone the wire feeder connec tion is then not used K1528 1 Dual Process Switch Cannot be used with K1486 1 Air Filter Kit The Dual Process Switch mounts easily to the front of the machine and is designed to provide a selection between left and right side output terminals Each pair of output terminals can be switched to either the DC 655 high or low inductance terminals as desired Wire feed unit cables and air carbon arc cables can be connected to either or both sides of the box and with proper connection can provide polarity change with just a switch change Selecting one side only energizes those output studs and opens the other side Installation instructions are included with the switch 000 CABLE RECEPTACLE 14 SOCKET TO LN 7 WIRE FEEDERS K1611 1 Paralleling Kit Provides interconnection of two DC 655 machines in parallel for doubling the cur rent capacity
132. ns See the Wiring Diagram If the leads and connections are OK the main transformer may be faulty IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC Return to Master TOC F 25 F 25 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 8 TERMINAL STRIP 14 PIN MS RECEPTACLE Los INDUCTANCE bi HIGH INDUCTANCE POSITIVE OUTPUT y NEGATIVE OUTPUT NEGATIVE OUTPUT TERMINAL TERMINAL STRIP TERMINAL TERMINAL 2 COVER PANEL 2 1 1 1 21 21 44 4 2 31 32 75 76 77 TERMINAL STRIP 10 Test for 115 VAC between leads 31 and 12 Test for 42 VAC between leads 41 and 2 32 on the terminal strip The terminal strip on the terminal strip The terminal strip can can be accessed by removing the small be accessed by removing the small panel panel at the lower portion of the case front at the lower portion of the case front See See Figure F 8 115 VAC AC should also be Figure F 8 If the correct voltage is not pre present at the 115 VAC receptacle If the sent make sure the 10 amp circuit breaker correct voltage is not present make sur
133. ntrols Only hot starting will be avail able 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 Set the Idealarc DC 655 POWER toggle switch to the OFF 0 position Disconnect main AC input power to the Idealarc DC 655 Connect the wire feeder control cable leads to the Idealarc DC 655 terminal strip as shown in Figure 2 FIGURE C 2 NA 5 5R WIRE FEEDER CONNECTION TO THE IDEALARC DC 655 14 PIN RECEPTACLE CONTROL CABLE POWER SOURCE FOR CONTROL CABLE 14 MS TYPE PLUG CONNECTOR OR FOR CONTROL CABLE WITH TERMINAL STRIP LEAD CONNECTORS TO NA 5 5R INPUT CABLE PLUG CONTROL CABLE NEGATIVE POSI BOLT TO CABLES FROM NA 5 5R WIRE CONTACT AS BLY TO WORI A Rr m VOLTAGE SENSING LEAD Connect the wire feeder control cable ground lead to the frame terminal marked 77 NOTE The lIdealarc DC 655 must be properly grounded 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 5 16586 remote voltage sensing work lead is available for this purpose c Keep the 21 lead electr
134. o not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equip ment 1 6 some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC MAGNETIC FIELDS N may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding
135. o X2 make certain the correct input voltage is being applied to the primary winding of the control transformer and that the correct primary leads H1 H2 etc are being used See the connection infor mation diagram on the input access door If the correct voltage is being applied to the primary of the control transformer and the secondary voltage is incorrect or not pre sent the control transformer may be defec tive Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 Return to Section Return to Master TOC o 7 5 F 30 TROUBLESHOOTING amp REPAIR CONTROL BOARD TRANSFORMER TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This tes
136. o the firing board is good Perform the Firing Board Test and see the Simplified Board LED Chart See the Trigger Diagram NOTE LED 10 should not be lit if the trigger circuit is not activated Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN P Return to Section Return to Master TOC Return to Section TOC OJO 5 5 gt 8 2 EIS 2 Return to Section Return to Master TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR FIGURE F 2 TERMINAL STRIP 14 PIN RECEPTACLE 14 PIN MS RECEPTACLE ee K 42 TR Positive LOW INDUCTANCE HIGH INDUCTANCE N d TERMINAL NEGATIVE OUTPUT NEGATIVE OUTPUT P d TERMINAL STRIP TERMINAL TERMINAL COVER PANEL N 422255222220 21 21 41 4 2 75 76 77 TERMINAL STRIP 4 Check for the presence of 42 VAC at the ter minal strip 2 to 41 See the Simplified Trigger Diagram 5 42 is not present at the terminal strip check the circuit breaker and leads 42A and 41 at the P15 connector See the Also perform Transformer Test 6 Remove the main input supply power to the DC 655 machine 7 Check continuity zero ohms from lead 42A plug P15 13 to lead 2 at the 14 pin receptacle pin C Also check continu it
137. oard Test 3 Perform the SCR Bridge Test Make sure the proper welding 4 Perform the Main Transformer procedures are being used Wire feed speed arc voltage and wire size 5 The control board may be Make sure the negative welding faulty See the Control Board LED Chart Chart cable is connected to the cor rect negative output terminal Low or High inductance Poor arc striking with semiauto Make sure the proper welding Perform the Firing Board Test matic or automatic wire feeders procedures are being used 2 Perform the SCR Bridge Test Wire feed speed arc voltage and wire size 3 The control board may be Check the welding cables for faulty See the Control Board LED Chart Chart loose or faulty connections CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 tc Return to Section TOC Return to Master TOC o 52 5 F 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS
138. of one machine This master and slave connection configuration allows the master to control the balanced output of both machines Individual protection circuits of both machines func tion normally Installation instructions are included with the switch IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC Q 0 5 ACCESSORIES The DC 655 can be used to power any of the following Lincoln Wire feeders SEMI AUTOMATIC WIRE FEEDERS e DH 10 e LN 9 e LN 10 e LN 9 e LN 7 e 23 e LN 742 e 13 25 e LN 7 e LN 8 AUTOMATIC WIRE FEEDERS CONNECTING THE NA 3 OR LT 7 TO THE IDEALARC DC 655 TERMINAL STRIP 1 Set 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 AUTOMATIC WIRE FEEDERS NAS European DC 655 models only provide 115VAC for these feeders at the ter minal strip TS2 NA 5R LT 7 Tractor CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should per for
139. onnect a multiple voltage machine to a different voltage remove input power and follow the input con nection diagram located on the inside of case back input access door 5 2 E Return to Master 1 For dual voltage sample machine reconnect instructions see Figure A 2 ojo 010 A WARNING HIGH VOLTAGE CAN KILL DUAL VOLTAGE MACHINE Do not operate with covers Do not touch electrically live parts INPUT SUPPLY CONNECTION DIAGRAM remove i 5 5 e Disconnect input power before Only qualified persons should install IMPORTANT CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS 15 servicing use or service this equipment NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS CONNECTION FOR HIGHEST RATING PLATE VOLTAGE gt 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT L3 LEAST 600 VOLT INSULATION E INPUT 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H3 CONTROL TRANSFORMER 5 LINES L2 a S LEADS TO THE INPUT SIDE OF 1 AS SHOWN Dlo 41 4 CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
140. ontrol The Arc Force control knob located behind the latched cover adjusts arc force from Min no cur rent increase to higher short circuit current The mid position 5 is recommended for most CC welding Refer to the Welding Performance Section OPTIONAL VOLTMETER amp AMMETER Digital or analog meter kits are available as field installed options Refer to the Accessories Section of this manual THERMAL PROTECTION LIGHT E f the machine overheats due to lack of proper air flow through the machine or due to exceeding the machine s duty cycle thermostats will disable the welding output and this light will illuminate Input power is still applied to the machine and the cool ing fan will continue to run When the machine cools the welding output will resume FIGURE B 2 LOWER CASE FRONT CONTROLS amp CONNECTIONS 1 115 VAC DUPLEX RECEPTACLE Domestic and Canadian Models This receptacle provides up to 20 amps of 115 VAC auxiliary power on the Domestic Models up to 15 amps on the Canadian Model 2 115 VAC CIRCUIT BREAKER 0 This breaker protects the 115 VAC auxiliary circuits located in the duplex receptacle terminal strip and MS receptacle Breaker is rated 20 amps on Domestic Models and 15 amps on all other models IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Sectio
141. ouder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 2 Dans le de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enroule le c ble lectrode autour de n importe quelle partie du corps 3 Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie tincelles 2 Autant que possible l installation et l entretien du poste 3 Avant de faires des travaux l interieur de post
142. process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National
143. ram board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC Q 7 5 TROUBLESHOOTING amp REPAIR INTERNAL TRIGGER CIRCUIT TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the wiring and connections are good from the 14 pin receptacle and terminal strip through the P15 an
144. reate a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode 22584 E if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the
145. rimary leads DC 655 H1 H2 H3 etc See the Wiring Diagram Remove the case top and sides NOTE Unused leads should be insulated and 3 Locate the control transformer T2 on the 2 left side of the input box facing the back of the machine See Figure 10 IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 Return to Section Return to Master TOC o 5 J F 29 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 TEST continued Locate the control transformer secondary leads 10 Lead X1 is con nected to the coil terminal on the CR1 input contactor Lead X2 is spliced into lead 211 which is then connected to the input power switch SW1 A WARNING HIGH VOLTAGE is present at the input leads 6 Apply the correct three phase input power to the DC 655 and check for 115 VAC at leads X1 to X2 NOTE The DC 655 does not have to be ON to perform this test If the main AC input supply voltage varies the control trans former secondary voltage will vary by the same percentage IDEALARC DC 655 LINCOLN 5 If approximately 115 VAC is present at leads X1 to X2 the control transformer is function ing properly If approximately 115 VAC is NOT present at leads X1 t
146. rs on IDEALARC DC 655 TERMINAL STRIP Voltage Control board See LN 9 Operator s 1 Set the Idealarc DC 655 POWER toggle switch to Menus the OFF 0 position NOTE The connection diagram shown in Figure C 4 shows the electrode connected for positive polarity To change polarity a 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 4 b Move the electrode cable to the negative output terminal High inductance or low 4 Connect the wire feeder control cable ground lead inductance as needed to the frame terminal marked 777 c Move the work cable to the positive output 5 Extend wire feeder control cable lead 21 so it can terminal be connected directly to the work piece d Connect control cable lead 21 to 21 on a Make a bolted connection using AWG 14 or the terminal strip larger insulated wire Tape the bolted connec tion with insulating tape 7 Set the OUTPUT CONTROL switch to the Remote position and the OUTPUT TERMINALS b An S 16586 X remote voltage sensing work switch to the Remote position 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 IDEALARC DC 655 LI
147. rstand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION The Active SCR Test will determine if the device is able to be gated ON and conduct current from anode to cathode MATERIALS NEEDED An SCR Tester as specified in this procedure DC 655 Wiring Diagram IDEALARC DC 655 LINCOLN F 38 39 39 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE 16 THERMAL FAN SNUBBER BOARD AND FIRING BOARD PLUG LOCATIONS Return to Master TOC Return to Master TOC o L4 o 9 Ld tc TEST PROCEDURE 1 Disconnect the main AC input power to the 3 Remove the red insulating paint from the machine heat sink test points See Figure 17 DO 2 Locate and disconnect plug J9 from the NOT DISASSEMBLE THE HEATSINKS thermal fan snubber board and plug J5 from the firing board See Figure F 16 Return to Master TOC IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC o E E 5 5 gt 2 2 5 2 Return to
148. s to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN F 2 Return to Section Return to Master TOC Return to Section TOC O10 E E 515 2 5 2 Return to Section Return to Master TOC Return to Master TOC F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can kill Have electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical s
149. t at Rated Output Code Voltage 100 Duty Cycle 60 Duty Cycle Number 230 460 60 122 61 150 75 10501 230 460 575 60 122 61 49 150 75 60 10502 208 416 60 135 67 5 10503 460 60 10504 575 60 10505 230 400 50 60 10506 380 500 50 60 10507 440 50 60 10508 200 400 50 60 10509 415 50 60 10510 RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 100 Duty Cycle 650 44 NEMA Class 100 60 Duty Cycle 815 44 OUTPUT Voltage Range Current Range Maximum Open Circuit Voltage Auxiliary Power 46 CV Mode See the OPERATION section for 13 44 DC 50 815 68 CC Mode Auxiliary Power information by model RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT INPUT 80 C VOLTAGE COPPER WIRE GROUND WIRE SUPER LAG FREQUENCY NAMEPLATE IN CONDUIT IN CONDUIT OR BREAKER AWG IEC MM SIZES AWG IEC MM SIZES SIZE AMPS 40 C 104 F Ambient gt AA ee l MP HEIGHT WEIGHT 27 5 in 01 720 16 699 mm 326 kg European models meet IEC974 1 standards 1Also called inverse time or thermal magnetic circuit breakers circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases IDEALARC DC 655 LINCOLN amp Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o
150. t the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN 9 F 9 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o pe 2 5 tc Return to Section TOC Return to Master TOC Q 7 B 5 The Thermal Protection Light is on but the fan does not run FUNCTION PROBLEMS Check for obstructions that could prevent the fan from turn ing The fan motor could be faulty Check or replace The Thermal Fan Snubber PC Board may be defective See the Thermal Fan Snubber The fan runs continuously Note fan is thermal con trolled Under normal condi tions it does not continuously run The Thermal Fan Thermistor may be faulty See the Wiring Diagram The Thermal Fan Snubber PC Board may be defective See the Thermal Fan Snubber PC Board LED Chart One or both of the optional digital meters are not lit Check for loose plugs P13 and P12 at the digital meter PC board The digital meter board may not be receiving voltages
151. t will determine if the correct voltage is being applied to the primary winding of the control board transformer T3 and also if the correct voltage is being induced upon the sec ondary winding MATERIALS NEEDED Volt ohmmeter Multimeter DC 655 Wiring Diagram IDEALARC DC 655 LINCOLN 5 F 30 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Return to Section TOC Return to Master TOC Q B 5 31 31 TROUBLESHOOTING amp REPAIR CONTROL BOARD TRANSFORMER 3 TEST continued FIGURE F 11 CONTROL BOARD TRANSFORMER LEADS E CONTROL BOARD TRANSFORMER T3 lt m t CONTROL BOX N 9 S 8 8 PRIMARY LEADS SECONDARY LEADS 281 255 AND 256 TEST PROCEDURE 1 Disconnect the main AC input power to the 5 DC 655 machine 2 Remove the case top and sides 3 Locate the control board transformer 3 mounted on the rear of the control box See Figure F 11 4 Locate the transformer T3 primary leads 255 and 256 See Figure F 11 and the Wiring Diagram Also locate the secondary leads 281 and 282 A WARNING lt e ELECTRIC SHOCK can Do not touch electrically hot parts 9 IDEALARC DC 655
152. tactor coil See the Wiring Diagram 6 Disconnect the leads from the input contac tor coil leads X1 256 and 255A See the Wiring Diagram 7 Remove the three self tapping mounting Screws using a 5 16 socket wrench Remove the input contactor 9 Insert the replacement input contactor and install it following the procedures in reverse order NOTE Be sure to reconnect all leads cor rectly IDEALARC DC 655 LINCOLN 5 51 51 TROUBLESHOOTING amp REPAIR SCR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the SCR Rectifier Bridge for main tenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 1 2 Socket
153. ted for 8 Replace plug J9 into the thermal fan snub both steps 4 and 5 SCR1 is not shorted ber board and plug J5 into the firing board Ifa low resistance is indicated in either steps NOTE To further check the SCRs functions use 4 or 5 there is a shorted SCR in the out SCR tester and proceed to the Active SCR 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 rectifier assembly to isolate the defective SCR s See the Wiring Diagram olo OJO 5 5 gt 218 5 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 Return to Section Return to Master TOC Q 7 5 38 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not unde
154. the following Output and Duty Cycle based on operation for a 10 minute period 650 Amps 44 Volts at 10096 815 Amps 44 Volts at 6096 IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC O o Fle S Bjo PEN 2 gr 16 Return to Section Return to Master TOC Return to Master TOC B 4 B 4 OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the DC 655 Refer to Figures B 1 and B 2 and corresponding explanations 3 FIGURE B 1 CONTROL PANEL CONTROLS INPUT POWER ON OFF SWITCH This tog gle switch turns the machine on or off Putting the switch in the ON position energizes the machine s input contactor applying input power to the machine Switching the switch to the OFF position de energizes the input contactor This switch is also used to reset a machine shutdown See Machine Shutdown section PILOT LIGHT When the power switch is in the ON position the machine s white pilot light will illu minate If the input contactor de energizes the machine in a shutdown situation the pilot will still illuminate In this situation it will be necessary to reset the machine by switching the power switch to the OFF then ON position See section OUTPUT CONTROL This control provides continuous control of the machine s output from minimum to maximum
155. the machine must be retested Return to Section TOC Return to Master TOC INPUT IDLE AMPS AND WATTS Input volts Phase Hertz Maximum Idle Amps Maximum Idle KW 208 3 60 230 3 60 380 3 60 416 3 60 460 3 60 550 3 60 ek 575 3 60 200 3 50 220 3 50 230 3 50 380 3 50 400 3 50 415 3 50 440 3 50 500 3 50 550 3 50 Return to Section Return to Master TOC kk CO MAXIMUM OPEN CIRCUIT VOLTAGES _____ Open Circuit Volts CC Stick 66 70 CV MIG 44 47 Auxiliary Output 31 32 122 128 VAC O10 5 5 218 5 2 fe e Auxiliary Output 41 42 44 48 VAC MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT SETTINGS Mode Control Settings Load CC Stick Output Control at Maximum 815 Amps 44 0 Volts Min Arc Force Control at Minimum CV MIG Output Control at Maximum 815 Amps 44 0 Volts Min Auxiliary Output 31 32 N A 5 Amps 120 126 VAC Min Auxiliary Output 41 42 N A 5 Amps 41 45 VAC Min Return to Section TOC Return to Master TOC IDEALARC DC 655 LINCOLN 5 SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We 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
156. tion relay CR2 may have defective contacts Check or replace The control board may be defective See the Board LED Chart The input contactor may be faulty Check the wiring between the fault protection relay CR2 and the input contactor The fault protection relay CR2 may have defective contacts Check or replace The input contactor may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 IDEALARC DC 655 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q pe 2 5 tc Return to Section TOC Return to Master TOC Q 7 B 5 F 6 F 6 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine has welding output but no control Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the output control switch SW3 for proper setting If a remote control cable is used make certain the cable and connections are good RECOMMENDED COURSE OF ACTION 1 The output control potentiome ter output control
157. to the SCR bridge from the transient voltages It also moni tors the thermal sensor and activates the fan motor when cooling is necessary NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC DC 655 LINCOLN P Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC Q 7 5 THEORY OPERATION PROTECTIVE DEVICES AND SHUTDOWN CIRCUITS THERMAL PROTECTION Two thermostats protect the DC 655 from excessive operating temperatures Excessive operating temper atures may be caused by a lack of cooling air or oper ating the machine beyond the duty cycle and output rating If excessive operating temperatures should occur a thermostat will open This condition will be indicated by the illumination of the yellow Thermostatic Protection Light located on the case front The fan should continue to run but the welding output will be disabled until the machine cools and the Thermostatic Protection Light is out OVER CURRENT PROTECTION If the average output current exceeds 900 amps for five to six seconds the welding output will be dis abled The control board LED 4 shutdown light will turn on The higher the current the quicker the DC 655 will shut down If the average current exceeds 1200 amps the sh
158. ts Zero ohms or very low resistance is normal See Figure F 13 If the resistance is high the input contactor is faulty Replace the input contactor When the contactor is NOT activated the resistance should be infinite or very high across the contacts f the resistance is low the input contactor is faulty Replace the input contactor 35 35 TROUBLESHOOTING amp REPAIR STATIC SCR TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION The test is used to quickly determine if an SCR is shorted or leaky See the Oscilloscope Waveform Section in this manual for normal and abnormal SCR waveforms Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog ohmmeter Multimeter DC 655 Wiring Diagram O10 515 gt 2 2
159. ty of CV submerged arc welding and air carbon arc gouging It produces outstanding welding performance with a single range full output control knob CC processes include stick welding CC submerged arc and superior air carbon arc gouging with up to 3 8 10 mm diameter carbons The same single range full output control knob is used and paralleling capability is provided The DC 655 is recommended for use with Lincoln s DH 10 or LN 10 as well as the LN 7 LN 7 LN 742 LN 8 LN 9 LN 9 GMA LN 23P and LN 25 semiautomatic wire feeders It is also recommended for use with the NA 3 NA 5 and NA 5R automatic feeders Cold starting for sub arc or across arc touch sensing can be used The 14 pin MS receptacle on the European models does not provide 115 VAC for these feeders 115 VAC must be obtained from terminal strip Two DC 655 s may be paralleled in a master and slave interconnection using the K1611 1 Paralleling kit DESIGN FEATURES AND ADVANTAGES e Separate output terminals for selecting high or low inductance as recommended for the welding process Power on off switch with pilot light and thermostat tripped indicator light Full range output voltage CV mode and current CC mode control for easy operation e Panel switches behind a latched front panel for remote or local output control output on or remote selection and CC CV Sub arc or CV MIG mode selection Panel knob settable CC
160. utdown will occur in 0 3 seconds The over current shutdown circuit can be reset by opening the feeder gun trigger or switching the DC 655 output terminal switch to the OFF position PEAK CURRENT PROTECTION If the peak current exceeds 2500 amps the welding output will be disabled and the control board LED 4 shutdown light will turn on The peak current shut down circuit can be reset by turning the DC 655 input switch off REMOTE CONTROL FAULT PROTECTION The remote control leads from the 14 pin receptacles or terminal strip are protected against voltage faults to the electrode circuit or auxiliary voltage supplies If a fault should occur the welding output will be disabled and the control board LED 4 shutdown light will turn on This fault protection shutdown circuit can be reset by opening the feeder gun trigger or switching the DC 655 output terminal switch to the OFF position On later production machines LED 3 input shutdown light will turn on and the input contactor will open SHORTED OUTPUT RECTIFIER FAULT PROTECTION If a short should occur across one of the SCRs a potentially hazardous AC voltage could appear across the welding output terminals If such a fault should occur the input contactor will open and remove the input power to the primary of the main transformer Also the control board LED 3 input shutdown light will turn on Welding and auxiliary output will not be pre sent but the pilot light and control boar
161. ve all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of the con trol transformer and also if the correct voltage is being induced upon the secondary winding Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Multimeter DC 655 Wiring Diagram O10 515 218 5 2 Return to Section Return to Master TOC IDEALARC DC 655 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 218 5 2 Return to Section Return to Master TOC F 28 F 28 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 TEST continued FIGURE F 10 CONTROL TRANSFORMER LEAD X1 CONNECTION INPUT CONTACTOR CR1 CONTROL TRANSFORMER T2 LEAD X2 CONNECTION SPLICED TO LEAD 211 TEST PROCEDURE 1 Disconnect the main AC input voltage to the 4 Locate the control transformer p
162. welding cable size refer to Electrode and Work Cables the Installation Section of this manual CASE BACK CONNECTIONS 220 VAC AUXILIARY RECEPTACLE European and Export Models This receptacle provides up to 2 amps of 220 VAC auxiliary power for a water cooler 220 VAC 2 AMP CIRCUIT BREAKER European and Export Models This breaker protects the 220 VAC auxiliary circuit located in the 220 VAC receptacle AUXILIARY POWER 42 volt AC auxiliary power as required for some wire feeders is available through the wire feeder recepta cle A 10 amp circuit breaker protects the 42 volt cir cuit from overloads DC 655 machines can also supply 115 volt AC auxil iary power through the wire feeder receptacle A 20 amp circuit breaker on the Domestic model and a 15 amp on the Canadian and Export models protects the 115 volt circuit from overloads 115 VAC is not avail able in the MS receptacle on the European models CAUTION Note that some types of equipment especially pumps and large motors have starting currents which are sig nificantly higher than their running current These high er starting currents may cause the circuit breaker to open If this situation occurs the user should refrain from using the DC 655 auxiliary power for that equip ment MACHINE PROTECTION THERMAL FAN CONTROL The machine s cooling fan remains off when the tem perature of the rectifiers and windings inside the machine are below that
163. x E lt MIL 927 09 7 007615 054 Cis 2 198 0298 006 LS 628 S X d 1 091 0091 0076 LS 804 PEDS WO 2 1081 00618 0Gu 92u G2H 2 E 1 0792 2082 007615 N My L ASH 2051 007615 919 5 lt 92821 1281 00615 Mv t 001 5001 00618 9 ESH 2 C1 l WS Ir 2547 007615 2 u 011 tc 098 87 N L MOL 2001 007615 6 9rd eru Lod eLd oLg oLd 6H L e 40191534 WHO 0092 MS 6 870711 2 2 O 5 MS 52 ld a c2 o MG 09 00 8797 1 9 9u cu ru eu cu Ld C12 o gt 89 70721 ID L 6 831401020140 21 000915 2100 l 1 1051 0140 01 000915 HOO id zu LL pun Q31 dau 2 189611 9 SQq317031 031 2031 1031 2 6 u30V3H 2 872815 oer ee o u3avaH 7802816 ur 0 103 00 8 875815 T i m 1 870815 6r dii C4 9 870815 8r g 29 0020 1 120 5 01 eza zza sw 5 2242 RS C5 Iz o 7007 1 1 66 1511 2 2 ra b oi C15 MA 02 66 01 06915 920 7 09 1 11 899918 00 1 0 19 1191 2 900 20 n6 LL 960 80 960 060 C6 05 000 9 899915 01 6820820720920 00810 C16
164. y to the output terminal switch See the If a resistance of any value is indicated check the associ ated wires and plugs IDEALARC DC 655 LINCOLN 5 Check continuity zero ohms from pin D lead 4 at the 14 pin receptacle to the out put terminal switch and also to plug J5 pin 9 at the firing board See the Simplified Trigger Diagram Figures F 1 and F 2 If a resistance of any value is indicated check the associated wires and plugs Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o E E 5 5 2 2 5 2 Return to Section Return to Master TOC F 16 F 16 TROUBLESHOOTING amp REPAIR 9 Check continuity zero ohms from lead 41 plug P15 pin 10 to plug J5 pin 1 at the fir ing board See the Simplified Trigger Diagram and Figure F 1 If a resistance of any value is indicated check the associat ed wires plugs and thermostats FIGURE F 3 SIMPLIFIED TRIGGER DIAGRAM 10AMP CIRCUIT BREAKER 42 AT MAIN TRANSFORMER 42 FIRING BOARD TERMINAL STRIP 14 PIN 11J5 309 RECEPTACLE CONTROL OUTPUT gt 2 2 TERMINAL LEDAO gt SWITCH x La 0J5 310 ger ye _________ 9J5 gy RESISTOR ENABLE 273 4115 FIRING N C NC SECONDARY CHOKE LEAD CIRCUIT THERMOSTAT THERMOSTAT ENABLE TO 41 AT MA

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