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Lincoln Electric SVM188-A manual

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Table of contents for the manual

  • Page 1

    SVM188-A October , 2008 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. Howe ver , your o verall saf ety can be increased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANU AL AND THE SAFETY [...]

  • Page 2

    SAFETY i i Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FOR ENGINE powered equipment. 1.a. T ur n the engine off before troub leshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v [...]

  • Page 3

    SAFETY ii ii Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FUMES AND GASES can be dangerous. 5.a. Welding ma y produce fumes and gases hazardous to health. Av oid breathing these fumes and gases.When welding, k eep your head out of the fume . Use enough ventilation and/or e xhaust at the arc to keep fume[...]

  • Page 4

    SAFETY iii iii Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Jan ‘07 FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U .S. National Electrical Code, all local co[...]

  • Page 5

    SAFETY iv iv Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Mar ‘93 PRÉCA UTIONS DE SÛRETÉ Po u r votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- a[...]

  • Page 6

    SAFETY v v Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Electroma gnetic Compatibility (EMC) Conf ormance Products displa ying the CE mark are in conformity with European Community Council Directiv e of 3 Ma y 1989 on the appro ximation of the laws of the Member States relating to electromagnetic compat[...]

  • Page 7

    SAFETY vi vi Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Electroma gnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may e xtend beyond the boundaries of the premises[...]

  • Page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I DC-600 RETURN T O MAIN INDEX P age S a f e t y ........................................................................... i - i v I n s t a l l a t i o n ................................................................. S e c t i o n A O p e r a t i o n ............................................[...]

  • Page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 I n s t a l l a t i o n ............................................................................. A - 1 T e c h n i c a l S p e c i f i c a t i o n s ..............................................[...]

  • Page 10

    INST ALLA TION A-2 A-2 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 60% Duty Cycle 122/61 122/61/49 61 49 128/74/64 74/56 64 140/70 68 TECHNICAL SPECIFICA TIONS – DC-600 V olts at Rated Amperes 44 44 44[...]

  • Page 11

    INST ALLA TION A-3 A-3 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SAFETY PRECA UTIONS Read entire Installation Section bef ore installing the DC-600. ELECTRIC SHOCK CAN KILL. • Only qualified per sonn[...]

  • Page 12

    ELECTRICAL INPUT CONNECTIONS Bef ore installing the machine check that the input sup- ply v oltage, phase , and frequency are the same as the voltage , phase, and frequency as specified on the welder Rating Plate located on the Case Bac k Assembly . Input power supply entry is through the hole in the Case Back Assemb ly . See Figure A.2 for the loc[...]

  • Page 13

    INST ALLA TION A-5 A-5 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC RECONNECT PR OCEDURE Multiple v oltage machines are shipped connected to the highest input v oltage listed on the machine’ s rating pl[...]

  • Page 14

    INST ALLA TION A-6 A-6 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC CONNECTION FOR 380 VOL TS, 50 OR 60 HZ. CONNECTION FOR 440 VOL TS 50 OR 60 HZ. (460V 60HZ) 1. TURN OFF THE INPUT POWER USING THE DISCONN[...]

  • Page 15

    INST ALLA TION A-7 A-7 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FIGURE A.7-Reconnect P anel Board P ositions for Single V oltage Machines L3 L2 L1 LINES INPUT GND SEE MACHINE RA TING PLA TE FOR REQUIR[...]

  • Page 16

    INST ALLA TION A-8 A-8 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC OUTPUT CONNECTIONS See T able A.1 f or recommended DC-600 cable sizes f or combined lengths of electrode and work cables. T ABLE A.1 DC-[...]

  • Page 17

    INST ALLA TION A-9 A-9 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC TERMINAL STRIPS T erminal str ips are av ailable behind the cov er on the case front to connect wire f eeder control cables that do not [...]

  • Page 18

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES A-10 A-10 DC-600[...]

  • Page 19

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 O p e r a t i o n .............................................................................. B - 1 S a f e t y P r e c a u t i o n s ...................................................................[...]

  • Page 20

    OPERA TION B-2 B-2 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the mac hine. ELECTRIC SHOCK can kill. • Do not tou[...]

  • Page 21

    OPERA TION B-3 B-3 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC GENERAL DESCRIPTION The DC-600 is an SCR controlled three phase welding and cutting power source . It uses a single range poten- tiometer to[...]

  • Page 22

    OPERA TION B-4 B-4 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WELDING CAP ABILITY The DC-600 has the f ollowing Output and Duty Cycle based on operation f or a 10 minute period: 600 Amps, 44 V olts at 1[...]

  • Page 23

    OPERA TION B-5 B-5 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC CONTR OLS AND SETTINGS All operator controls and adjustments are located on the Case F ront Assembly of the DC-600. See Figure B.1 f or the [...]

  • Page 24

    OPERA TION B-6 B-6 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 3. OUTPUT CONTROL This control provides contin uous control of the machine’ s output voltage and current from minimum to maximum (typical [...]

  • Page 25

    OPERA TION B-7 B-7 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC REMO TE CONTROL OF MA CHINE OPERA TION The toggle s witch on the control panel labeled “Remote - P anel” giv es the operator the option [...]

  • Page 26

    OPERA TION B-8 B-8 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 4. Connect the electrode cables to ter minal polarity to be used. 5. Connect the #21 work lead (on T .S.2) to the same polarity as the work [...]

  • Page 27

    OPERA TION B-9 B-9 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 2. Connect the LN-8 or LN-9 Control Cable to the 14 pin Amphenol of the DC-600. 3. Connect the #21 work lead (on T .S.2) to the same polarit[...]

  • Page 28

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NO TES B-10 B-10 DC-600[...]

  • Page 29

    T ABLE OF CONTENTS - A CCESSORIES SECTION C-1 C-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 A c c e s s o r i e s............................................................................ C - 1 F a c t o r y I n s t a l l e dE q u i p m e n t .................................................[...]

  • Page 30

    A CCESSORIES C-2 C-2 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WIRE FEEDERS AND TRA CT ORS The DC-600 can be used to power an y of the follo wing Lincoln Wire Feeders and T ractors: Semi-A utomatic Wir[...]

  • Page 31

    A CCESSORIES C-3 C-3 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC The MUL TI-PROCESS SWITCH has two sets of output ter minals . Y ou connect the wire f eeder unit cables to the set of ter minals on the le[...]

  • Page 32

    A CCESSORIES C-4 C-4 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 12. Connect stick or air/carbon arc electrode and work cable . See Figure C.2 . • Inser t the electrode and work cables through the stra[...]

  • Page 33

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 M a i n t e n a n c e ........................................................................... D - 1 S a f e t y P r e c a u t i o n s .................................................................[...]

  • Page 34

    MAINTENANCE D-2 D-2 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC R OUTINE AND PERIODIC MAINTENANCE 1. Disconnect input AC pow er supply lines to the machine bef ore perf orming per iodic maintenance, tigh[...]

  • Page 35

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 T h e o r y o f O p e r a t i o n ..................................................................... E - 1 G e n e r a l D e s c r i p t i o n .................................................[...]

  • Page 36

    THEOR Y OF OPERA TION E-2 E-2 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC GENERAL DESCRIPTION The DC-600 is a three-phase, SCR controlled DC power source . It is capable of either constant current or con[...]

  • Page 37

    THEOR Y OF OPERA TION E-3 E-3 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FIRING CIRCUIT , CONTR OL CIR- CUIT AND RECTIFICA TION RECTIFICA TION The “neutrals” of the welding secondar y windings in th[...]

  • Page 38

    THEOR Y OF OPERA TION E-4 E-4 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PROTECTIVE DEVICES AND SHUTDOWN CIRCUITS THERMAL PROTECTION This welder has thermostatic protection from excessiv e duty cycles, [...]

  • Page 39

    THEOR Y OF OPERA TION E-5 E-5 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SCR OPERA TION A silicon controlled rectifier (SCR) is a three-terminal de vice used to control rather large currents to a load. An SCR [...]

  • Page 40

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NO TES E-6 E-6 DC-600[...]

  • Page 41

    T ABLE OF CONTENTS - TROUBLESHOO TING AND REP AIR F-1 F-1 Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 T r o u b l e s h o o t i n g a n d R e p a i r .............................................................. F - 1 H o w t o U s eT r o u b l e s h o o t i n g G u i d e ......................[...]

  • Page 42

    TR OUBLESHOO TING AND REP AIR F-2 F-2 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC This T roubleshooting Guide is provided to help you locate and repair possib le machine malfunctions. Simply follow the t[...]

  • Page 43

    TR OUBLESHOO TING AND REP AIR F-3 F-3 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Sometimes machine f ailures appear to be due to PC board f ailures. These problems can sometimes be traced to poor electr[...]

  • Page 44

    OUTPUT PROBLEMS Obser v e Saf ety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact the Lincoln Electric Ser vice Depar tment f or techn[...]

  • Page 45

    OUTPUT PROBLEMS Obser v e Saf ety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact the Lincoln Electric Ser vice Depar tment f or techn[...]

  • Page 46

    OUTPUT PROBLEMS Obser v e Saf ety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact the Lincoln Electric Ser vice Depar tment f or techn[...]

  • Page 47

    OUTPUT PROBLEMS Obser v e Saf ety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact the Lincoln Electric Ser vice Depar tment f or techn[...]

  • Page 48

    OUTPUT PROBLEMS Obser v e Saf ety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact the Lincoln Electric Ser vice Depar tment f or techn[...]

  • Page 49

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 50

    FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8 (206) 7 (207) 6 (208) 5 4 3 2 1 16 (204) 15 (203) 14 13 (231) 12 (215) 11 10 9 FIGURE F .1 – FIRING BO ARD LEDs PC BO ARD TR OUBLESHOO TING GUIDE (continued) FIRING BO ARD 1. With DC-600 set for the T est Conditions all ten LEDs on the Firing Board sh[...]

  • Page 51

    DC600 CONT ROL G3409-1 LED1 LED5 LED2 LED3 LED4 LED6 J2 J3 J1 2 (256) (290) 7 (291) 8 1 (222)12 1 (210) 5 (231) (255) 6 1 FIGURE F .2 – CONTROL BO ARD LEDs PC BO ARD TR OUBLESHOO TING GUIDE (continued) CONTROL BO ARD 1. With the DC-600 set for the T est Conditions , all the LEDs e xcept LED 4 should be lit. 2. LED 1 indicates the 120v ac input to[...]

  • Page 52

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NO TES F-12 F-12 DC-600[...]

  • Page 53

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 54

    FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8 (206) 7 (207) 6 (208) 5 4 3 2 1 16 (204) 15 (203) 14 13 (231) 12 (215) 11 10 9 FIGURE F .3 – FIRING BO ARD INTERNAL TRIGGER CIRCUIT TEST (continued) PROCEDURE 1. With the correct input power applied to the DC-600 and the trigger circuit not activated,[...]

  • Page 55

    1 2 3 4 5 6 7 8 9 10 DC-600 21- 21+ 41 4 2 31 32 75 76 77 TS 2 TS 1 F=76 G=75 H=21 I=41 J=31 K=42 A=32 B=GND C=2 D=4 E=77 LN M 14 PIN CONNECTOR 10 AMP CIRCUIT BREAKER OUTPUT TERMINALS SWIT CH FIGURE F .4 - TERMINAL STRIPS AND AMPHENOL INTERNAL TRIGGER CIRCUIT TEST (continued) TR OUBLESHOO TING AND REP AIR F-15 F-15 DC-600 Return to Section T OC Ret[...]

  • Page 56

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NO TES F-16 F-16 DC-600[...]

  • Page 57

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 58

    FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8 (206) 7 (207) 6 (208) 5 4 3 2 1 16 (204) 15 (203) 14 13 (231) 12 (215) 11 10 9 FIGURE F .6 FIRING BO ARD FIRING BO ARD TEST (contin ued) PROCEDURE ELECTRIC SHOCK can kill. • Do not touch electrically hot par ts. 1. Disconnect the AC input pow er to th[...]

  • Page 59

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 60

    DC600 CONT ROL G3409-1 LED1 LED5 LED2 LED3 LED4 LED6 J2 J3 J1 2 (256) (290) 7 (291) 8 1 (222)12 1 (210) 5 (231) (255) 6 1 FIGURE F .7 CONTROL BO ARD CONTR OL BO ARD TEST (continued) PROCEDURE ELECTRIC SHOCK can kill. • Do not touch electrically hot par ts. 1. T ur n the POWER Switch ON. LEDs 1 and 3 should tur n ON. 2. If LED 1 does not come ON, [...]

  • Page 61

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 62

    L3 T3 L2 T2 L1 T1 FIGURE F .8 - INPUT CONT ACT OR AND RECONNECT P ANEL MAIN TRANSFORMER V OL T A GE TEST (contin ued) PROCEDURE 1. Disconnect the main input power from the DC-600. 2. Inspect the input contactor , reconnect panel and primar y leads to the main transf or mer f or loose or f aulty connections. See Figure F .8. 3. Confir m that the rec[...]

  • Page 63

    A A A SECONDAR Y LEADS (6 PLACES) COMMON BUSS FIGURE F .9 – TRANSFORMER SECONDARIES MAIN TRANSFORMER V OL T A GE TEST (contin ued) PROCEDURE 9. T est with an AC v oltmeter f or appro ximately 55 V A C from each of the six main transf or mer secondar y leads to the common bus connected to the output choke . See Figure F .9. NO TE: All of the secon[...]

  • Page 64

    FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8 (206) 7 (207) 6 (208) 5 4 3 2 1 16 (204) 15 (203) 14 13 (231) 12 (215) 11 10 9 FIGURE F .11 – FIRING BO ARD MAIN TRANSFORMER V OL T A GE TEST (contin ued) PROCEDURE ELECTRIC SHOCK can kill. • Do not touch electrically hot par ts. 13. Remove the inpu[...]

  • Page 65

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 66

    A Power Switch Secondary Thermostat Control T ransformer L3 T3 L2 T2 L1 T1 H2, H3 or H4 (see Input Diagram) H1 FIGURE F .12 - CONTROL TRANSFORMER CONTR OL TRANSFORMER TEST (continued) PROCEDURE 1. With the Input P ower OFF , remov e the case top , right side panel and the input access door . The Control T ransf or mer is located on the back of the [...]

  • Page 67

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 68

    L3 T3 L2 T2 L1 T1 W (L3) T3 U (L1) V T2 (L2) T1 CR 1 Contactor Coil T erminals Apply External 120vac Here 272 271 Cover Plate Screws FIGURE F .13 – INPUT CONT ACT OR INPUT CONT A CT OR TEST (continued) PROCEDURE V OL T A GE TEST 1. Disconnect the input power and remov e the Input Access P anel from the rear of the machine 2. Connect an AC v oltme[...]

  • Page 69

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate your f actor y warranty . For y our safety and to a void electrical shock, please observe all saf ety notes and precaution[...]

  • Page 70

    ANODE CA THODE REMOVE INSULA TING PA I N T FIGURE F .14 – SCR BRIDGE ASSEMBL Y SCR BRIDGE TEST(continued) PROCEDURE ST A TIC TEST 1. Disconnect the input power from the DC-600. 2. Remove the top and side panels and drop the nameplate to access the PC Boards. 3. Unplug the Molex connectors from both the Control Board and the Firing Board. 4. Scrat[...]

  • Page 71

    FIGURE F .15 – ACTIVE SCR TEST SCR BRIDGE TEST(continued) PROCEDURE A CTIVE TEST 1. With the circuit shown in Figure F .17. One 6-volt lantern batter y can be used. Set the voltmeter scale low , at approximately 0-5 v olts or 0-10 volts. a. T est the voltage le v el of the batter y . Shor t leads (A) and (C). Close switch SW -1. Batter y voltage [...]

  • Page 72

    This is the typical DC open circuit v oltage wa v ef or m generated from a properly operating machine. Note that each vertical division represents 50 v olts and that each horizontal divi- sion represents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to positiv e ter minal, (-) probe to nega- tiv e high [...]

  • Page 73

    This is the typical DC open circuit v oltage wa v ef or m generated from a properly operating machine. Note that each v er tical division represents 50 v olts and that each horizontal divi- sion represents 2 milliseconds in time. Note: Scope probes connected at machine output ter minals: (+) probe to positive terminal, (-) probe to nega- tiv e high[...]

  • Page 74

    This is the typical DC open circuit v oltage wa v ef or m generated from a properly operating machine. Note that each vertical division represents 20 v olts and that each horizontal divi- sion represents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to positiv e ter minal, (-) probe to nega- tiv e high [...]

  • Page 75

    This is the typical DC open circuit v oltage wa v ef or m generated from a properly operating machine. Note that each v er tical division represents 20 v olts 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 con[...]

  • Page 76

    This is the typical DC open circuit v oltage wa v ef or m. The machine was in an open circuit condition (no load) and operating properly . Note that each v er tical division represents 2 v olts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at SCR gate and cathode: (+) probe to gate, (-) probe to c[...]

  • Page 77

    This is NO T the typical DC open cir- cuit v oltage wa v ef or m. One output SCR is not functioning. Note the “gap” in the wav eform. One SCR gate is disconnected to simulate an open or non-functioning output SCR. Each v er tical division represents 20 v olts and each horizontal division rep- resents 2 milliseconds in time. Note: Scope probes c[...]

  • Page 78

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES F-38 F-38 DC-600[...]

  • Page 79

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid electrical shock, please observe all saf ety notes and precaution[...]

  • Page 80

    L3 T3 L2 T2 L1 T1 W (L3) T3 U (L1) V T2 (L2) T1 CR 1 Contactor Coil T erminals Apply External 120vac Here 272 271 Cover Plate Screws FIGURE F .16 – CONT ACT OR INPUT CONT A CT OR CLEANING/REPLA CEMENT PROCEDURE (contin ued) TR OUBLESHOO TING AND REP AIR F-40 F-40 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return [...]

  • Page 81

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid electrical shock, please observe all saf ety notes and precaution[...]

  • Page 82

    "C" LEAD, RED (6 PLACES) "A" LE AD, W HITE (6 PL ACES) GA TE LEAD CONNECTOR OUTPUT SNUBBER A A A A A A A A A A A A A A A A LEFT SIDE OF CHOKE TO LEFT SIDE OF CHOKE OUTPUT SHUNT 210 215 MOUNTING BOL TS (4) SECONDARY LEAD (6 PLACES) BUSHING CONNECTION STRAP FIGURE F .17 – RECTIFIER ASSEMBL Y SCR RECTIFIER BRIDGE REMO V AL AND RE[...]

  • Page 83

    Thread Forming Screw Plain Washer Insulator Insulator Insulator Plain Washer Lock Washer 5/16-18 Hex Nut Rectifer Mounting Bracket Bridge Mounting Bracket Fig. 18 ‘A ’ Fig. 18 ‘B’ Transformer Secondary Lead ‘A ’ Lead from Snubber Heat Sink Negative Output Lead Output Snubber Lead Choke Lead Lock Washer 3/8-16 Hex Nut 3/8-16 x 1 Cap Scre[...]

  • Page 84

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES F-44 F-44 DC-600[...]

  • Page 85

    Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid electrical shock, please observe all saf ety notes and precaution[...]

  • Page 86

    A A A A A A A A A A A A A A A A OUTPUT SHUNT 210 215 SECONDARY LEAD (6 PLACES) CONNECTION STRAP OUTPUT CHOKE MOUNTING HARDWARE (4 PLACES) FIRING BOARD CONNECTORS (J-4 & J-5) AUXILIARY LEADS PRIMARY LEADS NEGA TIVE OUTPUT LEAD SECONDARY THERMOST AT INPUT ACCESS COVER CONTROL P ANEL BAFFLES 30 Ω RESISTOR FIGURE F .19 – TRANSFORMER REMO V AL MA[...]

  • Page 87

    FIGURE F .20 – TRANSFORMER REMO V AL MAIN TRANSFORMER AND CHOKE REMO V AL AND REPLA CEMENT (continued) REMO V AL PROCEDURE (cont.) 12. Disconnect the five (5) #215 and the two(2) #210 leads from the Shunt, noting their positions f or reassembly . . NO TE: It is important that the twisted pair (feed- back leads) and the meter leads be recon- necte[...]

  • Page 88

    WELD W W XXXXXXXXXXX XXXXXXXXXXX XXXXXXXXXXX FIGURE F .21 – CHOKE TIG WELD MAIN TRANSFORMER AND CHOKE REMO V AL AND REPLA CEMENT (continued) REPLA CEMENT PROCEDURE 1. Place the flat washers and the chok e on top of the transf or mer and the lift bale assembly o ver both. 2. Install the f our thread cutting bolts that mount the lift bale to the tr[...]

  • Page 89

    TROUBLESHOOTING AND REP AIR F-49 F-49 DC-600 Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC RETEST AFTER REP AIR Should a machine under test be rejected for any r eason requiring the removal of any mechanical part [...]

  • Page 90

    Return to Section T OC Retur n to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES F-50 F-50 DC-600[...]

  • Page 91

    T ABLE OF CONTENTS - DIA GRAM SECTION G-1 G-1 Return to Master T OC Return to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 E l e c t r i c a l D i a g r a m s ..................................................................... G - 1 W i r i n g D i a g r a m ( G 3 5 0 6 ) .......................................................[...]

  • Page 92

    ELECTRICAL DIA GRAMS G-2 WIRING DIA GRAM - G3506 EN-170 S O L ID E D G E G3506 DC -600 W IRI N G DIA GRAM NONE - DO NO T SC AL E T HIS DR A WING EQ UIP M ENT TYPE: SUBJECT: SCA L E: UF CRM38710 1 PAGE ___ OF ___ 1 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT URE R: No THIS DOCUMENT CONTAINS PROPRIETAR Y INFORMATION OWNED B Y LINCOLN GLOBA L, INC. AN[...]

  • Page 93

    ELECTRICAL DIA GRAMS G-3 WIRING DIA GRAM - 230/460/575 V OL T MA CHINES - G3506-1 EN-170 S O L ID E D G E G350 6- 1 DC -600 W IRI N G DIA GRAM (230/4 60/57 5) NONE G3506 DO NO T SC AL E T HIS DR A WING EQ UIP M ENT TYPE: SUBJECT: SCA L E: UF CRM36965 1 PAGE ___ OF ___ 1 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT URE R: No THIS DOCUMENT CONTAINS PR[...]

  • Page 94

    ELECTRICAL DIA GRAMS G-4 SCHEMA TIC - COMPLETE MA CHINE - G3575 Printed by John Howell Printed at 10:20 on 08/15/2008 (month/day/year) Drawing Number- G3575 Revision- 12-17-99 Status- STANDARD This print is Current G-4 NO TE: This diagram is f or ref erence only . It ma y not be accurate for all machines co vered by this man ual. Return to Section [...]

  • Page 95

    ELECTRICAL DIA GRAMS G-5 SCHEMA TIC - CONTROL PC BO ARD - G3408-1 Printed by John Howell Printed at 10:22 on 08/15/2008 (month/day/year) Drawing Number- G3408-1C1 Revision- 11-30-2001E Status- STANDARD This print is Current G-5 NO TE: This diagram is f or ref erence only . It ma y not be accurate for all machines co vered by this man ual. Return to[...]

  • Page 96

    NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board lev el troubleshooting. PC Board repairs will inv alidate your f actor y warranty . Individual Printed Cir cuit Board Components are not av ailable from Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electr ic discourages board l[...]

  • Page 97

    ELECTRICAL DIA GRAMS G-7 SCHEMA TIC - FIRING PC BO ARD - G3741-1 Printed by John Howell Printed at 10:23 on 08/15/2008 (month/day/year) Drawing Number- G3741-1B1 Revision- 11-30-2001E Status- STANDARD This print is Current G-7 NO TE: This diagram is f or ref erence only . It ma y not be accurate for all machines co vered by this man ual. Return to [...]