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TROUBLESHOOTING & REPAIR

F-46

F-46

CV-655

This is NOT the typical DC open circuit voltage
waveform generated from a properly operating
machine. The output capacitors have been
disconnected. Note that each vertical division
represents 20 volts and that each horizontal
division represents 2 milliseconds in time.

Note: Scope probes connected at machine
output terminals: (+) probe to positive High
Inductance terminal, (-) probe to negative
terminal.

SCOPE SETTINGS

Volts/Div.....................20V/Div.
Horizontal Sweep.....2 ms/Div.
Coupling ............................DC
Trigger .........................Internal

ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

MAXIMUM OUTPUT SETTING - NO LOAD

OUTPUT CAPACITORS DISCONNECTED

0 volts

2 ms

20 volts

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Summary of Contents for CV-655

Page 1: ...per 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 SERVICE MANUAL For use with machine code number 10120 thru 10129 CV 655 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 119...

Page 2: ...INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy o...

Page 3: ...work or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of...

Page 4: ...a 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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent haza...

Page 5: ...imité au soudage à l aide d écrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans...

Page 6: ...ols and Settings B 4 Case Back Connections B 6 Auxiliary Power B 6 Machine Protection B 6 Accessories Section C Maintenance Section D Safety Precautions D 2 General Maintenance D 2 General Component Locations D 3 Theory of Operation Section E Troubleshooting and Repair Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting Guide F 4 Test Procedures F...

Page 7: ...ng Plate A 3 Safety Precautions A 4 Select Suitable Location A 4 Stacking A 4 Tilting A 4 Electrical Input Connections A 4 Fuse and Wire Sizes A 4 Ground Connection A 4 Input Power Supply Connections A 5 Reconnect Procedure A 5 Output Connections A 6 Electrode and Work Cables A 6 Auxiliary Power and Control Connections A 7 Auxiliary Power Table A 7 115VAC Duplex Receptacle A 7 230V Receptacle A 7 ...

Page 8: ...5 60 230 400 50 60 380 500 50 60 440 50 60 200 400 50 60 415 50 60 Code Number 10120 10121 10122 10123 10124 10125 10126 10127 10128 10129 100 Duty Cycle 94 47 94 47 38 104 52 47 38 94 54 56 43 49 107 54 52 60 Duty Cycle 116 58 116 58 47 128 64 58 47 116 67 69 53 60 132 67 64 Input Current at Rated Output RATED OUTPUT INPUT VOLTAGE FREQUENCY 208 230 416 460 575 200 230 380 400 415 440 500 TYPE 75 ...

Page 9: ... ON RATING PLATE LOCATED ON CASE BACK Constant Voltage Output Characteristics R NEMA EW 1 100 Designates welder complies with International Electrotechnical Commission requirements 974 1 European Models IEC 974 1 Designates welder complies with low voltage directive and with EMC directive European models CE Designates welder can be used in environments with increased hazard of electric shock Europ...

Page 10: ... and frequency as specified on the welder nameplate Use input wire sizes that meet local electrical codes or see the Technical Specifications page 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 t...

Page 11: ...electrically live parts Only qualified persons should install use or service this equipment Do not operate with covers removed Disconnect input power before LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN TRANSF CONTROL TRANSF CONTROL 3 CONNECT L1 L2 L3 INPUT SUPPLY LINES AND H1 H3 CONTROL TRANSFORMER CONNECTION FOR HIGHEST RATING PLATE VOLTAGE servicing M18225 INPUT CONTACTOR CONNECTION FOR LOW...

Page 12: ...4 Work Sense lead 21 from the 14 Pin MS recepta cle must be connected to 21 on the terminal strip Note This is how the CV 655 is shipped from the factory 5 Replace the terminal strip access cover panel For Negative Polarity 1 Connect the work cable to either the low inductance terminal marked or the high induc tance terminal marked See OPERATION section Positive Output Terminals for an explanation...

Page 13: ...g L E C Part S12020 32 Refer to the Figure A 4 for the available circuits in the 14 pin receptacle 42 VAC is available at receptacle pins I 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 elec...

Page 14: ...ead of the control cable to 21 when welding positive polarity or to 21 when welding negative polarity TERMINAL STRIP 1 T S 1 TERMINAL STRIP 2 T S 2 INSTALLATION A 8 A 8 CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Lead No Function 75 Output Control 76 Output Control...

Page 15: ...ecautions B 2 General Description B 3 Recommended Processes and Equipment B 3 Design Features and Advantages B 3 Welding Capability B 3 Controls and Settings B 4 Lower case front control conections B 5 Case Back Connections B 6 220 VAC Auxiliary Receptacle B 6 220 VAC 2 Amp Circuit Breaker B 6 Auxiliary Power B 6 Thermal Fan Control B 6 Overload Protection B 6 Fan Motor Fuse B 6 ...

Page 16: ...can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not cut containers that have hel...

Page 17: ...lot light and thermostat tripped indicator light Full range output voltage control for easy operation Panel switches for remote or local output control and out put on or remote selection Hinged cover to protect output terminals and auxiliary con nections 42 VAC 10 amp auxiliary power available for the wire feeder circuit breaker protected DESIGN FEATURES AND ADVANTAGES CONT D 115 VAC auxiliary pow...

Page 18: ...ls 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 control of the output voltage is via the output voltage control on the ...

Page 19: ...n about the circuits 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 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 NEGATIVE OUTPUT TERMINAL This output ter minal is for connecting a welding cable T...

Page 20: ... ___________________________________________ CAUTION 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 requiring air flow cooling as determined by electronic monitoring of several thermal sensors and the welding current of the machine The fan may remain off until welding begins but once the fan is activa...

Page 21: ... Wire Feeders C 3 NA 3 or LT 7 Terminal Strip C 3 NA 5 or NA 5R Terminal Strip C 4 Semiautomatic Wire Feeders C 6 LN 7 14 Pin MS Receptacle C 6 LN 7 Terminal Strip C 7 LN 8 or LN 9 Terminal Strip C 8 LN 8 or LN 9 14 Pin MS Receptacle C 9 DH 10 14 Pin MS Receptacle C 9 Section C 1 Section C 1 CV 655 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 22: ...gned to trap 80 of enter ing particles which are 5 microns or larger in size Installation instructions are included with the kit NOTE A dirty air filter may cause the thermal protec tion of the CV 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 CV 655 is designed f...

Page 23: ...ip as shown in Figure C 1 4 Connect the wire feeder control cable ground lead to the frame terminal marked NOTE The CV 655 must be properly grounded FIGURE C 1 NA 3 OR LT 7 WIRE FEEDER CONNECTION TO THE CV 655 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 the bolted connec tion with...

Page 24: ...0 position 2 Disconnect main AC input power to the CV 655 3 Connect the wire feeder control cable leads to the CV 655 terminal strip as shown in Figure C 2 FIGURE C 2 NA 5 5R WIRE FEEDER CONNECTION TO THE CV 655 4 Connect the wire feeder control cable ground lead to the frame terminal marked NOTE The CV 655 must be properly grounded 5 Extend wire feeder control cable lead 21 so it can be connected...

Page 25: ...ded 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 CV 655 OUTPUT CONTROL switch to the Remote position and the OUTPUT TERM...

Page 26: ... the LN 7 See Figure C 3 5 Place the output terminals switch in the Remote position 6 Adjust wire feed speed at the LN 7 and set the welding voltage with the output CONTROL NOTE If optional remote control is used place the OUTPUT CONTROL switch and the OUTPUT TERMINALS switch in the Remote position ACCESSORIES C 6 C 6 CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return ...

Page 27: ...he work piece are secure then wire feeder control cable lead 21 can be connected directly to the CV 655 terminal strip 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 NOTE The connection diagram shown in Figure C 3 shows the electrode co...

Page 28: ...e Control board See LN 9 Operator s Manual NOTE The connection diagram shown in Figure C 4 shows the electrode connected for positive polarity To change polarity a Set the CV 655 POWER toggle switch to the OFF 0 position b Move the electrode cable to the negative output terminal c Move the work cable to the positive output terminal High inductance or low inductance as needed d Connect control cabl...

Page 29: ...si tion 2 Disconnect main AC input power to the CV 655 3 Connect the electrode cable from the DH 10 to the terminal of the welder High inductance or low inductance as needed Connect the work cable to the terminal of the welder Reverse this hookup for negative polarity NOTE Welding cable must be sized for the current and duty cycle of the application 4 Connect the DH 10 input cable between the 14 p...

Page 30: ...NOTES CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 31: ...eturn to Master TOC Return to Master TOC Return to Master TOC Section D 1 Section D 1 CV 655 TABLE OF CONTENTS MAINTENANCE Maintenance Section D Safety Precautions D 2 General Maintenance D 2 General Component Locations D 3 ...

Page 32: ...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 MAINTENANCE D 2 D 2 CV 655 Return to Section TOC R...

Page 33: ... MAINTENANCE D 3 D 3 CV 655 4 8 3 6 14 5 13 7 9 11 10 2 1 15 12 3 FIGURE D 1 GENERAL COMPONENT LOCATIONS 1 CASE FRONT 2 OUTPUT TERMINALS 3 CASE SIDES 4 CASE TOP 5 RECONNECT PANEL LOCATION 6 INPUT CONTACTOR LOCATION 7 CONTROL TRANSFORMER LOCATION 8 CASE BACK 9 FAN ASSEMBLY 10 CONTROL PANEL 11 PC BOARDS LOCATION 12 CHOKE 13 MAIN TRANSFORMER 14 BASE 15 SCR RECTIFIER BRIDGE ...

Page 34: ...NOTES CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 35: ...ation E 5 TABLE OF CONTENTS THEORY OF OPERATION SECTION CONTROL TRANSFORMER R E C O N N E C T CONTACTOR 115VAC MAIN TRANSFORMER CONTROL BOARD SHUNT OUTPUT CONTROL SWITCH POSITIVE TERMINAL NEGATIVE TERMINAL F E E D B A C K F E E D B A C K SCR BRIDGE 42VAC 115VAC 42VAC T E R M I N A L S T R I P TO OPTIONAL METER BOARD LOW FIRING BOARD SNUBBER FAN BOARD CONTROL BOARD TRANSFORMER CR1 CHOKE 14 pin Amph...

Page 36: ... secondary windings There are three 32 VAC windings which provide power and timing to the fir ing 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 m...

Page 37: ... the feedback information and sends the appropriate output control signal to the firing board A tapped output choke is connected to the two posi tive output terminals This large inductor stores ener gy which provides current filtering for the welding out put of the CV 655 Two positive output terminals are provided One is connected to the tap lead in the choke thus providing a lower inductance The ...

Page 38: ... run but the welding output will be disabled until the machine cools and the Thermostatic Protection Light is out OVER CURRENT PROTECTION The CV 655 also has over current protection When the load exceeds a threshold current about 900 amps overcurrent shutdown will occur after a period of time that shortens as the current increases beyond this threshold If the current reaches about 1000 amps the ou...

Page 39: ... Gate An SCR is fired by a 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 catho...

Page 40: ...NOTES CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 41: ...35 Active SCR Test F 38 Thermal Fan Snubber Board LED Chart F 41 Control Board LED Chart F 42 Oscilloscope Waveforms Normal Open Circuit Voltage Waveform Maximum Output Setting F 43 Typical Output Voltage Waveform Machine Loaded F 44 Abnormal Open Circuit Voltage Waveform One Output SCR Not Functioning F 45 Abnormal Open Circuit Voltage Waveform Maximum Output Setting No Load F 46 Typical SCR Gate...

Page 42: ...S 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 s...

Page 43: ...ment Do not touch electrically hot parts 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 c...

Page 44: ...er switch S1 is in the ON position 2 Check for blown or missing fuses in the input lines 3 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...

Page 45: ...se or faulty wiring between the input power switch SW1 and the input contactor See the Wiring Diagram 2 The control board may be defective See the Control Board LED Chart 3 The input contactor may be faulty The machine is dead the input contactor does not operate The pilot light is lit 1 Check the three phase input line voltage at the machine The input voltage must match the rating plate and recon...

Page 46: ...Test 4 Perform the Control Trans former Test 5 The control board may be faulty See the Control Board LED Chart The machine does not have maxi mum output 1 Check the three phase input lines at the CV 655 Make cer tain the input voltages match the machine s rating and recon nect panel configuration 2 Put the output control switch SW3 in the Local control position If the problem is resolved the remot...

Page 47: ...ary 2 Make sure the 115 VAC plug and load is in good working condition 1 The circuit breaker may be defective Check associated wiring See the Wiring Diagram 2 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 s...

Page 48: ...ssociated wiring may be faulty See the Wiring Diagram The remote output control unit does not function properly when the output control switch SW3 is in the Remote position The CV 655 operates normally when con trolled locally from the machine s output control potentiometer 1 The remote control unit or con necting cable may be defective Check or replace 1 The output control switch SW3 may be defec...

Page 49: ...e fan runs continuously 1 Note The fan is thermal con trolled Under normal condi tions it does not continuously run 1 The Thermal Fan Thermistor may be faulty See the Wiring Diagram 2 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 1 Check for loose plugs P13 and P12 at the digital meter PC boar...

Page 50: ...o make sure plug P3 is securely plugged into the con trol board 1 Check feedback leads 222 210 201 and 202 for loose or faulty connections See the Wiring Diagram 2 The optional digital meter PC board may be faulty The analog meters are not reading correctly 1 Make sure plug P3 is securely plugged into the control board and plug J14 is securely seated in the plug assembly from the control board 1 C...

Page 51: ...e capacitor bank may be faulty Check or Replace WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body 2 Perform the Firing Board Test 3 Perform the SCR Bridge Test 4 Perform the Main Transformer Test 5 The control board may be faulty See the Control Board LED Chart 6 Check the reactor for shorts or opens Poor arc striking with semiauto matic or au...

Page 52: ... The input voltage must match the rating plate and reconnect panel configuration 2 Make sure the machine s set tings are correct for the welding process 3 Check the welding cables for loose or faulty connections Also make sure cables are sized correctly for the welding cur rent 1 Perform the Firing Board Test 2 Perform the SCR Bridge Test 3 Perform the Main Transformer Test 4 The control board may...

Page 53: ...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 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the wirin...

Page 54: ...he wiring and circuitry to the firing board is good Perform the Firing Board Test and see the Control Board LED Chart See the Simplified Trigger Diagram NOTE LED 10 should not be lit if the trigger circuit is not activated 2 If LED 10 does not light when the trigger cir cuit is activated proceed with the following voltage and continuity checks 3 Check the 10 Amp circuit breaker It is the one close...

Page 55: ...nd plugs 8 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 and Figures F 1 and F 2 If a resistance of any value is indicated check the associated wires and plugs TROUBLESHOOTING REPAIR F 15 F 15 CV 655 Return to Section TOC Return to Section TOC Return to Section TO...

Page 56: ...TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 2 4 C D P16 2 4 TERMINAL STRIP 42A 13 P15 5 9 41 11 10 2 4 TO 41 AT MAIN TRANSFORMER TO 42 AT MAIN TRANSFORMER 273 N C SECONDARY THERMOSTAT 41 N C CHOKE LEAD THERMOSTAT 4 41 9J5 1J5 11J5 10J5 309 310 TO CONTROL BOARD OUTPUT TERMINAL SWITCH 14 PIN RECEPTACLE 10AMP CIRC...

Page 57: ...y 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 1 800 833 9353 WELD TEST DESCRIPTION This test will help determi...

Page 58: ...4 LED5 LED6 LED10 J5 J6 J7 J4 TEST PROCEDURE 1 Disconnect the AC input power to the CV 655 machine 2 Locate the firing board on the left side of the control box 3 Perform a visual inspection on the firing board to see if there are any loose or faulty connections or physical damage 4 Connect the correct AC input power to the CV 655 ELECTRIC SHOCK can kill Do not touch electrically hot parts 5 Turn ...

Page 59: ...ower 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 LED 9 is ON 32 VAC power is being supplied to the firing board from leads 207 and 208 connecte...

Page 60: ...d 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 Perform the SCR Output Bridge Test If one or two lights stay bright or dim and the others change this could indicate an open or shorted gate lead or faulty sn...

Page 61: ...ockwise 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 and 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 may be faulty See the Wiring Diagram TROUBLESHOOTING R...

Page 62: ... perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltages are being applied to the primary windings of the main transformer The secondary windings the auxiliary windings and the phase angle windings will also be checked MATE...

Page 63: ...CV 655 See the connection diagram located on the inside of the input box assembly 4 Connect the correct AC three phase input power to the CV 655 machine ELECTRIC SHOCK can kill Do not touch electrically hot parts 5 Turn the power switch SW1 to the ON position 6 Make sure the input contactor CR1 ener gizes 7 Test with an AC voltmeter for the proper main AC input voltages applied to the line side of...

Page 64: ...COMMON BUS VOLTAGE CHECK 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 F 7 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 connections See the Wiring Diagram If the leads and c...

Page 65: ...g Diagram 11 If 115 VAC is NOT present and the wiring and circuit breaker are good the main transformer may be defective 12 Test for 42 VAC between leads 41 and 2 on the terminal strip The terminal strip can be accessed by removing the small panel at the lower portion of the case front See Figure F 8 If the correct voltage is not pre sent make sure the 10 amp circuit breaker is not tripped or faul...

Page 66: ...eter board If a digital meter board is not in place plug J13 will not be used but will be present in the harness Check the fol lowing voltages at the appropriate leads and pin locations 10 VAC Plug J13 pin 1 lead 331 to pin 2 lead 332 10 VAC Plug J13 pin 4 lead 333 to pin 5 lead 334 42 VAC Plug J13 pin 3 lead 335 to pin 6 lead 336 18 If the correct primary voltages are applied to the main transfor...

Page 67: ...nable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 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 MATERIALS NEEDED V...

Page 68: ...T continued FIGURE F 10 CONTROL TRANSFORMER TEST PROCEDURE 1 Disconnect the main AC input voltage to the CV 655 2 Remove the case top and sides 3 Locate the control transformer T2 on the left side of the input box facing the back of the machine See Figure F 10 4 Locate the control transformer primary leads H1 H2 H3 etc See the Wiring Diagram NOTE Unused leads should be insulated and taped Inspect ...

Page 69: ...5 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 7 If approximately 115 VAC is present at leads X1 to X2 the control transformer is function ing properly 8 If approximately 115 VAC is NOT present at leads X1 to X2 make certain the correct input voltage is being applied to the primary...

Page 70: ...le to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test 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...

Page 71: ...ill Do not touch electrically hot parts 5 Apply the correct three phase input power to the CV 655 and turn the power switch SW1 to the ON position 6 Carefully check for 42 VAC at the secondary leads 281 to 282 If 42 VAC is present the control board transformer T3 is good If 42 VAC is missing or low proceed to the next step 7 Carefully check for 115 VAC at the primary leads 255 and 256 If the 115 V...

Page 72: ...e unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 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 CV 655 Wir...

Page 73: ...oil X1 256 and 255A See Figure F 12 4 Connect an AC voltmeter to the leads ELECTRIC SHOCK can kill Do not touch electrically hot parts 5 Apply the correct three phase input power to the CV 655 and turn the power switch SW1 to the ON position 6 Check for 120 VAC at the contactor coil leads 7 If the 120 VAC is NOT present with the input power switch SW1 on check the switch and associated circuitry S...

Page 74: ...ontacts 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 5 When the contactor is NOT activated the resistance should be infinite or very high across the contacts If the resistance is low the input contactor is faulty Replace the input contactor TROUBLESHOOTING REPAIR F 34 F 34 CV 655 Return to Section TOC...

Page 75: ...or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 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 MATERIALS NEEDED Analog ohmmeter Multime...

Page 76: ...D9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 TEST PROCEDURE 1 Disconnect the main AC input power to the CV 655 machine 2 Locate and disconnect plug J9 from the thermal fan snubber board and plug J5 from the firing board See Figure F 14 3 Remove the red insulating paint from the heat sink test points See Figure F 15 DO NOT DISASSEMBLE THE HEAT SINKS 4 Test for high or infinite resistance from...

Page 77: ... to isolate the defective SCR s See the Wiring Diagram 8 Replace plug J9 into the thermal fan snub ber board and plug J5 into the firing board NOTE To further check the SCRs functions use an SCR tester and proceed to the Active SCR Test TROUBLESHOOTING REPAIR F 37 F 37 CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mast...

Page 78: ...st 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 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 CV 655 Wi...

Page 79: ...FIRING BOARD PLUG LOCATIONS THERMAL FAN SNUBBER LED5 LED1 LED2 LED3 LED4 LED6 PLUG J9 L10124 FIRING BOARD G2699 LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 PLUG J20 TEST PROCEDURE 1 Disconnect the main AC input power to the machine 2 Locate and disconnect plug J9 from the thermal fan snubber board and plug J5 from the firing board See Figure F 16 3 Remove the red insulating pain...

Page 80: ...y A low battery can affect the results of the test Repeat the battery test procedure in Step 4 if needed 10 Open switch SW 1 11 Reconnect the Tester leads See Figure F 17 a Connect Tester lead A 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 If the voltage is zero the SCR is func tioning b If the ...

Page 81: ...tes welding current is greater than 50 amps 3 Indicates fan should be running due to heating of main SCRs 4 Indicates an open thermal fan thermistor or an open con nection between the thermistor and the thermal fan snub ber board See the Wiring Diagram leads 319 and 316 5 Indicates a thermostat choke or secondary has opened The thermal protection light should also be illuminated 6 Indicates the fa...

Page 82: ... Closing the trigger circuit and turning the CONTROL POT towards maximum LED 5 should dim and then go out Replace the control P C board if LED 5 does not go ON 6 LED 6 Indicates trigger condition LED 6 ON indicates trigger is CLOSED LED 6 OFF indicates trigger is OPEN If LED 6 does not come ON look for open connections in the 2 4 circuit 7 LED 7 Indicates welder output voltage is being sensed on t...

Page 83: ...enerated 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 High Inductance terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT V...

Page 84: ...hine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 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 output terminals probe to positive High Inductance terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2...

Page 85: ...t SCR is NOT Functioning Note the GAP in the wave form Note that each vertical division represents 20 volts and that each horizontal division represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive High Inductance terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal ABNORMAL O...

Page 86: ...chine The output capacitors have been disconnected Note that each vertical division represents 20 volts and that each horizontal division represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive High Inductance terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal ABNORMAL OPEN ...

Page 87: ...veform The machine was in an open circuit condition no load and operating properly Note that each vertical division represents 2 volts and that each horizontal division repre sents 5 milliseconds in time Note Scope probes connected at SCR gate and cathode probe to gate probe to cathode SCOPE SETTINGS Volts Div 2V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TYPICAL SCR GATE VOLTAGE W...

Page 88: ...NOTES F 48 F 48 CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 89: ...ocedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 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 ...

Page 90: ...OCEDURE 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...

Page 91: ...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 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the SCR Rectifier Bridge for main tenance or replacement MATERIALS NEEDED 1 2 Socket wrench 3 8 Wrench...

Page 92: ... wrench remove the case top and sides 3 Locate and remove plugs J9 and J20 from the Thermal Fan Snubber Board See Figure F 19 4 Disconnect lead 222 from the negative output terminal This lead runs from plug J9 to the negative output terminal Cut any necessary cable ties See the Wiring Diagram SCR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE continued THERMAL FAN SNUBBER LED5 LED1 LED2 LED3 L...

Page 93: ...ts Be sure to remove the insulators and take note of placement for reassembly 8 While supporting the heat sink assembly remove the left side horizontal mounting bracket from the left side leg assembly See Figure F 20 9 Carefully slide the rectifier heat sink assem bly from the machine Clear all leads REASSEMBLY 1 Upon reassembly apply a thin coating of Dow Corning 340 Heat Sink Compound to all bol...

Page 94: ...t 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 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main transformer and choke for maintenance or replacement MATERIALS NEEDED 3 8 Wrench 7 16 Wrench 9 16 Wrench Wire cutters Sold...

Page 95: ...op and sides OUTPUT CHOKE REMOVAL 3 Label and remove leads 273 and 41A from the choke thermostat 4 Using the 9 16 wrench remove the flexible 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 6 Using the 9 16 wrench remove the high inductance output lead from the bottom choke lead...

Page 96: ...ary cable ties 18 Using the hoist carefully remove the iron coil assembly from the CV 655 machine Clear all leads REASSEMBLY 1 Using the rope sling carefully position the iron coil assembly onto the CV 655 Mount it to the frame assembly with four bolts washers and nuts 2 Attach the transformer primary leads to the reconnect panel 3 Attach the six transformer secondary leads to the SCR heat sink as...

Page 97: ...se Hertz Maximum Idle Amps Maximum Idle KW 208 3 60 8 8 1 2 230 3 60 8 0 1 2 380 3 60 4 8 1 2 416 3 60 4 4 1 2 460 3 60 4 0 1 2 550 3 60 3 3 1 2 575 3 60 3 2 1 2 200 3 50 14 1 1 5 220 3 50 12 8 1 5 230 3 50 12 2 1 5 380 3 50 7 4 1 5 400 3 50 7 0 1 5 415 3 50 6 8 1 5 440 3 50 6 4 1 5 500 3 50 5 6 1 5 550 3 50 5 1 1 5 MAXIMUM OPEN CIRCUIT VOLTAGES Mode Input Hertz Open Circuit Volts WELD CV 60 48V D...

Page 98: ...NOTES F 58 F 58 CV 655 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 99: ...2 WIRING DIAGRAM CODE 10121 G 3 WIRING DIAGRAM CODE 10125 10126 10127 10128 10129 G 4 CONTROL PC BOARD SCHEMATIC G 5 CONTROL PC BOARD ASSEMBLY G 6 FAN SNUBBER PC BOARD SCHEMATIC G 7 FAN SNUBBER PC BOARD ASSEMBLY G 8 FIRING PC BOARD SCHEMATIC G 9 FIRING PC BOARD ASSEMBLY G 10 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 100: ...9 8 215 7 317 318 6 5 310 4 J1 226 282 J2 5 4 LIGHT W PILOT 255 2 8 J5 4 8 1 J7 J10 J12 J14 1 5 3 7 6 1 J4 J8 J13 4 J1 J9 J15 J16 J6 J11 J17 J18 J19 1 4 1 3 J20 1 6 2 J2 1 J6 9 207 2 208 301 41 J14 9 32A 273 CHOKE LEAD PRI 14 7 F S 204 AUX1 10 GREEN 2 4 76 76 41A 77 11 3 SCR 206 G3 5 SCR 12 G5 208 A2 A3 7 J9 231 R2 316 319 LOW B C2 OUTPUT 4 3 203 SNUBBER P C BOARD THERMAL FAN 4 3 2 1 G3 G6 222 C 2...

Page 101: ...R P C BOARD THERMAL FAN 4 3 2 1 G3 G6 222 C 300 32A 300 1 B 222 42V S F 3 207 S 331 6 9 42A 15 41 F 205 32V F S 45V 332 10V 335 333 332 334 331 FROM T1 AUX WINDINGS 315 336 215 210 ANALOG METERS OPTIONAL 317 201 OPTIONAL DIGITAL 1 METER P C BOARD 222 202 210 222 201 4 202 317 5 6 215 315 210 201 202 1 75 2 3 NATIONAL TO GROUND PER 238 215 10K R1 R3 75 SW3 SWITCH 76 238 77 236 237 237 236 10K 1 2W ...

Page 102: ...T 255 2 8 J5 4 8 1 J7 J10 J12 J14 1 5 3 7 6 1 J4 J8 J13 4 J1 J9 J15 J16 J6 J11 J17 J18 J19 1 4 1 3 J20 1 6 2 J2 1 J6 9 207 2 208 301 41 VIEWED FROM COMPONENT SIDE OF BOARD 31 F 50 MV 800 AMPS 31 CONNECTOR CAVITY NUMBERING SEQUENCE 9 8 14 7 12 MOTOR FAN N J B W N J F1 10A N J N J J14 256 10 11 12 13 14 V U CR 1 L3 CONTACTOR TO SUPPLY 4 32 31 21 41 5 4 6 4 P16 77 77 21 75 11 3 SCR 206 G3 5 SCR 12 G5...

Page 103: ... to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 104: ... 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 ELECTRICAL DIAGRAMS G 6 CV655 PC BOARD ASSEMBLY CONTROL BOARD CV 655 CONTROL P C BOARD AS BLY 20 20 4 40 4 50 8 80 9 00 6 00 5 80 04 04 7 16 99E 0 0 D C B G3037 1 CV 655 CONTROL A E F G H 3037 1D1 G 6 Return to Sect...

Page 105: ...rn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 106: ...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 ELECTRICAL DIAGRAMS G 8 CV655 PC BOARD ASSEMBLY FAN SNUBBER BOARD CV 655 DC 655 THERMAL FAN SNUBBER P C BD AS BLY 10124 2 L CAPACITORS MFD VOLTS 04 IDENTIFICATION PART NO REQ D ITEM RESISTORS OHMS 0 5 75 6 00 25 25 4 50 8 75 9 00 0 2 12 99A THERMAL FA...

Page 107: ...175 200 R179 200 R177 200 R176 200 R178 1W 20V DZ5 10 0 R190 LED4 10 0 R191 1N4004 D38 267 R189 1 50K R199 N B N B B B GATE DRIVE G4 619 R193 4A 400V SCR4 C35 J4 4 32 VAC 203 C3 4A 400V SCR2 619 R165 4A 400V SCR1 1N4007 D2 1N4007 D20 15W 50 R36 LED7 600V 05 C38 D1 A B 200 R88 200 R85 1 00K R92 10 0K R44 600V 05 C39 200 R90 1N4007 D18 C1 41 309 1N4004 T S 2 FIRING CIRCUIT 1N4004 3023 OCI2 1 2 100K ...

Page 108: ...T11577 41 022 400 C30 1 S13490 74 10 150 C32 1 S13490 73 20 50 C38 C39 C40 C41 C42 C43 6 T11577 46 05 600V D1 D4 D7 D11 D12 D14 D15 34 T12199 1 1N4004 D24 D27 D28 D29 D30 D31 D32 D33 D34 D35 D36 D38 D43 D44 D47 D49 D50 D51 D52 D53 D54 D59 D60 D61 D62 D63 D64 D2 D3 D5 D6 D8 D9 D16 D17 26 T12199 2 1N4007 D18 D20 D21 D22 D39 D40 D41 D42 D55 D56 D57 D58 D65 D66 D67 D68 D69 D70 D71 1 T12705 46 1000V 3A...

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