manualshive.com logo in svg

Lincoln Electric Idealarc DC-600, Service Manual, Page: 110 / 114

Share
Download
Lincoln Electric Idealarc DC-600 Service Manual Download Page 110

G-5

ELECTRICAL DIAGRAMS

T O   G R O U N D   P E R

N A T I O N A L

H 3
H 1

X 1

2 1 1

2 1 2

T O

S U P P L Y

L I N E S

L 3

L 2

L 1

2 7 1

2 7 2

3

2

1

6

5

4

9

8

7

T O   P R I M A R Y   C O I L S

C O D E

E L E C T R I C A L

2 1 1

2 1 2

S W 1

S T A R T

S T O P

2 5 5

X 1

X 2

T 2

H 1

H 2

H 3

V M

A M

+

+

-

-

2 1 0

2 1 0

S W 2

2 2 2

2 2 2

2 1

2

3 1

3 2 A

3 2

2 1 4

2 3 1 3 2

T . S . 2

N . C .

2 2 6
2 3 8

2 3 6

R 1

2 3 7

7 5

8 0

O U T P U T
C O N T R O L

2 2 9

2 1 5

2 3 2

2 2 4

8 1

7 7

7 6

7 6

7 5

7 7

8 0

8 1

T . S . 3

8 0

2 8 0

8 1

2 2 9

2 1 5

2 1 0

8 1

2 1 5

2 2 0

2 8 0

1

1
2

2

3

3

4

4
5

5

6

6

7
8
9

1

2

8 0

2 2 6

2 2 4

2 3 2

7 5

2 2 2

2 3 5
2 5 6

2 5 5
2 3 1

2 3 8
2 3 3

J 1

J 2

J 3

C O N T R O L

P . C .   B O A R D

2 0 3

1

1

2

2

3

3

4

4

5

5

6

6
7

8
9

J 4

J 5

F I R I N G C I R C U I T

P . C .   B O A R D

TO T1 AUX. WINDING

2

4

2 1 0

2 1 5

2 2 0

2 1 5

2 1 5

2 1 5

+

-

W O R K

E L E C T R O D E

L E A D S   2 1 0   &   2 1 5   A R E

T W I S T E D   T O G E T H E R

T O   S T I C K   E L E C T R O D E   H O L D E R   O R

A I R - C A R B O N   A R C   T O R C H

T O   " W O R K "   U S E D   W I T H   S T I C K

O R   A I R - C A R B O N   A R C

S T I C K   W O R K   L E A D   N O T

U S E D   W H E N   J U M P E R   I S

U S E D .

O P T I O N A L   U S E R   S U P P L I E D   J U M P E R   F O R
T H O S E   S I T U A T I O N S   W H E R E   I T   I S   N O T

C A B L E S   F O R   S T I C K   A N D   S E M I - A U T O M A T I C

W E L D I N G .

N . D .

N . E .

N . D . ,   N . F .

O P T I O N A L

  M U L T I - P R O C E S S

  S W I T C H

2 1 0

2 1 0

2 1 0

2 1 5

O U T P U T   S H U N T

( 5 0 M V   @ 8 0 0   A M P S }

2 2 0

2 1 5

2 1 5

O U T P U T

C H O K E

C 7

2 2 2

OUTPUT

N . D .

( + )

( - )

2 1 5

2 1 0

2 2 2

R 2

2 1 4

A

B

7

4

8

5

9

6

3 1

2 1 5

2 1 6

3 2 A

3 1

F A N

M O T O R

2 1 5

2 7 2

2 7 3

S E C .   L E A D

T H E R M O S T A T

2 5 6

P R I M A R Y

T H E R M O S T A T

2 5 6

P I L O T
L I G H T

2 3 3

2 3 5

2 5 5

B

5

7

A

2 7 1

2 7 1

R

S

S

F

F

3 2 A

2 0 7

2 0 8

3

1 5

6

9

1 2

S

F

2 0 5

2 0 6

2

1 4

5

8

1 1

A U X .   1

S

F

2 0 3

2 0 4

F

3 1

S

A U X . 2

1
1

P R I .

4

7

P R I .

1 0

S E C .

S E C .

T 1

T H E R E   I S   N O

1 0 ,   1 1   &   1 2

C O N N E C T I O N
O N   3 8 0   O R

T R I P L E   V O L T A G E

M A C H I N E S .

4

L E A D S   4
T H R U   9

T O   I N P U T

P A N E L

S C R

S C R

S C R

S C R

S C R

S C R

1

2

3

4

5

6

O U T P U T

S N U B B E R

G 6

G 4

G 2

P . C .   B O A R D

O U T P U T   R E C T I F I E R

A S S E M B L Y

G A T E

L E A D S   T O

  C I R C U I T

  F I R I N G

  B O A R D

P . C .

S C R

L E G E N D

C 7   . 0 5   + . 0 5   M F D

F 1   8   A M P   S L O W   B L O W   F U S E

R 1   1 0 K       P O T

T 1   M A I N   P O W E R   T R A N S F O R M E R

R 2   3 0     ,   1 0 0 W

T 2   C O N T R O L   T R A N S F O R M E R

2 C R   F A U L T   P R O T E C T I O N   R E L A Y

1 C R   I N P U T   C O N T A C T O R

4 C R   O U T P U T   P I L O T   R E L A Y

3 C R   C U R R E N T   A C T I V A T E D   R E E D   S W I T C H

S W 1   I N P U T   P O W E R

S W 2   E L E C T R O D E   P O L A R I T Y

S W 3   O U T P U T   C O N T R O L

S W 4   W E L D I N G   M O D E   ( S H O W N   I N   S T I C K   P O S I T I O N )

N O T E S :

N . B .     F O R   S T I C K   W E L D I N G   O R   A I R   C A R B O N   A R C

W I T H O U T   A   M U L T I - P R O C E S S   S W I T C H   I N S T A L L E D ,
D I S C O N N E C T   A L L   E L E C T R O D E ,   W O R K ,   A N D

C O N T R O L   L E A D S   T O   A N Y   W I R E   F E E D E R S .
J U M P E R   2   T O   4 .   O U T P U T   T E R M I N A L S   W I L L
N O W   B E   E N E R G I Z E D .   P L A C E   M O D E   S W I T C H
I N   V V   F O R   S T I C K   A N D   C V   ( I )   F O R   A I R
C A R B O N   A R C .   S E E   O P E R A T I N G   M A N U A L

F O R   F U R T H E R   I N S T R U C T I O N S .

N . C .     C E N T E R   T E R M I N A L   O F   F U S E   H O L D E R .

N . D .     W E L D I N G   C A B L E   M U S T   B E   O F   T H E   P R O P E R

C A P A C I T Y   F O R   T H E   C U R R E N T   A N D   D U T Y   C Y C L E
O F   I M M E D I A T E   A N D   F U T U R E   A P P L I C A T I O N S .

" P O S I T I V E " .   T O   C H A N G E   T H E   P O L A R I T Y ,   T U R N

T H E   D C - 6 0 0   O F F ,   A N D   R E V E R S E   T H E   L E A D S   A T
T H E   M U L T I - P R O C E S S   S W I T C H .

C O N N E C T I O N   D I A G R A M ,   C O N N E C T   E L E C T R O D E

A N D   W O R K   L E A D S   T O   T H E S E   T E R M I N A L S

I N S T E A D   O F   T H E   P O W E R   S O U R C E
O U T P U T   T E R M I N A L S .

T H E S E   N O T E S   A P P L Y   O N L Y   T O   D C - 6 0 0   W I T H   A

M U L T I - P R O C E S S   S W I T C H   I N S T A L L E D .

S N U B B E R S

+

-

G 1

G 3

G 5

F 1

N . E .               T H I S   D I A G R A M   S H O W S   T H E   " S T I C K "   P O L A R I T Y

N . F .             U S I N G   A   W I R E   F E E D E R ,   K - 3 1 7   O R   K - 3 1 8

2 1 5

G A T E   L E A D S   T O

  F I R I N G   C I R C U I T

N E C E S S A R Y   T O   H A V E   S E P A R A T E   G R O U N D

A

A

A

A

A

A

C

C

C

C

C

C

N . A .     L E A D S   4   T H R U   9   A R E   N O T   P R E S E N T   O N

C R   1

S I N G L E   V O L T A G E   O V E R   3 0 0   V .

( E X C E P T   3 8 0 V . )

R E C O N N E C T
P A N E L

T O   G R O U N D   P E R

N A T I O N A L

H 1

X 1

2 1 1

2 1 2

T O

S U P P L Y

L I N E S

L 3

L 2

L 1

2 7 1

2 7 2

3

2

1

9

8

7

T O   P R I M A R Y   C O I L S

C O D E

E L E C T R I C A L

C R   1

R E C O N N E C T

H 2

T O   G R O U N D   P E R

N A T I O N A L

H 1

X 1

2 1 1

2 1 2

T O

S U P P L Y

L I N E S

L 3

L 2

L 1

2 7 1

2 7 2

T O   P R I M A R Y   C O I L S

C O D E

E L E C T R I C A L

C R   1

R E C O N N E C T
P A N E L

H 2

3 8 0 / 5 0 0 V .   &   4 6 0 / 5 7 5 V .

F O R   L O W   V O L T A G E )

( S H O W N   C O N N E C T E D

1 5

1 4

1 3

3

2

1

T O   G R O U N D   P E R

N A T I O N A L

H 1

X 1

2 1 1

2 1 2

T O

S U P P L Y

L I N E S

L 3

L 2

L 1

2 7 1

2 7 2

3

2

1

6

5

4

9

8

7

T O   P R I M A R Y   C O I L S

C O D E

E L E C T R I C A L

C R   1

R E C O N N E C T
P A N E L

D U A L   &   S I N G L E   V O L T A G E
U N D E R   3 0 0 V .

H 2

3 8 0 V .   O R   T R I P L E   V O L T A G E

6

5

4

1 1

1 0

1 2

P A N E L   ( S H O W N

C O N N E C T E D

F O R   3 8 0 V . )

N . A .

1 3

4 6 0 V . ,   3 8 0 / 5 0 0 V .   &   4 6 0 / 5 7 5 V .   M A C H I N E S .

C R 3

C R 4

C R 2

S W 3

S W 4

  1-17-92B  

            

            

            

            

            

            

            

            

            

            

            

            

            

            

            

            

            

          IDEALARC DC-600         

          WIRING DIAGRAM          

8750      

L

J 4            

J 4            

1 0

7
8

9

1 0

1 1

1 2
1 3

1 4

J 7

1

2
3

4

5

6

7

8

1 0

1 1

1 2

1

2
3

4

J 6

A
B

B '
C
C '

A '

G 3

G 6

G 1
G 4

G 5
G 2

2 1 6

2 0 6
2 0 4

2 1 5
2 1 5
2 0 5

2 0 8

2 0 7

2 3 1

X
Y

Z

R E C T I F I E R        

A S S E M B L Y                    

T O   O U T P U T          

E L E C T R I C A L   S Y M B O L S   P E R   E 1 5 3 7

J 3

J 1

J 7

C O N N E C T O R   C A V I T Y   N U M B E R I N G   S E Q U E N C E

( V I E W E D   F R O M   C O M P O N E N T   S I D E   O F   B O A R D )

J 6

J 4

J 2

J 5

IDEALARC DC600 

FIGURE G1 - Wiring Diagram for Codes 9773, 9776, 9778, 9779, 9780, 9910

NOTE:  This diagram is for reference only.  It may not be accurate for all machines covered by this manual.  The  specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

Retur

n to Section TOC

Retur

n to Section TOC

Retur

n to Section TOC

Retur

n to Section TOC

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

Summary of Contents for Idealarc DC-600

Page 1: ...pends 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 pa...

Page 2: ...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 W...

Page 3: ...g sparks from start ing a fire Remember that welding or cutting sparks and hot materials from welding or cutting can easily go through small cracks and openings to adjacent areas Avoid welding or cut...

Page 4: ...r hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 7 g To prevent accidentally starting gasoline engines w...

Page 5: ...udage l aide d crans appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants...

Page 6: ...n Features and Advantages B 3 Welding Capability B 4 Controls and Settings B 5 Operating Steps B 6 Welding Procedure Recommendations B 6 Accessories Section C Accessories C 2 C 8 Maintenance Section D...

Page 7: ...3 Tilting A 3 Electrical Input Connections A 4 Fuses and Wire Sizes A 4 Ground Connection A 4 Input Power Supply Connections A 4 Reconnect Procedure A 5 Output Connections A 8 Electrode and Work Leads...

Page 8: ...s 70 to 850 Amps Input Voltage Frequency Fuse Super Lag or Breaker Size Input Ampere Rating on Nameplate 2 35mm2 2 35mm2 6 16mm2 6 16mm2 6 16mm2 6 16 mm2 6 16 mm2 8 10 mm2 8 10 mm2 8 10 mm2 208 60 230...

Page 9: ...foreign material that can be drawn into the machine should be kept at a minimum Not following these precautions can result in the nuisance shutdown of the machine because of excessive operating tempe...

Page 10: ...ecommended This can result in nui sance tripping caused by inrush current even when machine is not being used for welding at high output currents Use input and grounding wire sizes that meet local ele...

Page 11: ...ted on the inside of the Case Back Input Access Door L3 L2 L1 LINK LINES INPUT GND H2 H1 H3 L3 L2 L1 LINK LINES INPUT H3 H1 H2 GND W V U W V U CONTACTOR CRI CRI CONNECTION FOR HIGHEST RATING PLATE VOL...

Page 12: ...W V U CONTACTOR CRI H4 L3 L2 L1 LINKS LINES INPUT H2 H1 H3 GND W V U CONTACTOR CRI H4 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 DISCONNECTAND INSULATE THE H3 H4 LEAD TE...

Page 13: ...d Positions for Single Voltage Machines L3 L2 L1 LINES INPUT GND SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 CON...

Page 14: ...150 ft 46m to 200 ft 61m 3 0 85mm2 200 ft 61m to 250 ft 76m Connect Electrode and Work Leads to Output Terminals 1 Set the ON OFF PUSH BUTTON to OFF 2 Locate the retractable strain relief loops direct...

Page 15: ...omatic automatic welding the optional Multi Process Switch K804 must be used See the ACCESSORIES Section of this manual for instructions on installing and using the Multi Process Switch When the Multi...

Page 16: ...Remote Control of Machine Operation B 6 Welding Procedure Recommendations B 6 B 9 Semi Automatic and Automatic Wire Feeding with a DC 600 and Wire Feeders B 7 NA 3 Automatic Wire Feeder B 7 NA 5 Autom...

Page 17: ...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 CUTTING and GOUGING SPARKS can cause fire...

Page 18: ...DED PROCESSES AND EQUIPMENT The IDEALARC DC 600 is recommended for the fol lowing welding or cutting processes within its output capacity of 70 amps to 850 amps in the Constant Voltage mode and 90 amp...

Page 19: ...ircuit to protect power source against overloads Input line voltage compensation to provide an essentially constant output SCR electronically controlled welder output pro vides extra long life especia...

Page 20: ...shield CV Constant Voltage Submerged Arc and VV Variable Voltage CC Constant Current Submerged Arc 4 OUTPUT CONTROL SWITCH This toggle switch is used to switch between Output Control at DC 600 for loc...

Page 21: ...ld NOTE Terminal 2 and 4 must be connected together to energize the machine output REMOTE CONTROL OF MACHINE OPERATION The toggle switch on the control panel labeled Output Control at DC 600 Output Co...

Page 22: ...arc striking techniques that apply to all wire feed processes Using these proce dures should provide trouble free starting These pro cedures apply to single solid wires and Innershield wires 1 Cut th...

Page 23: ...correct arc striking procedure with the NA 3 Start Board timer set at maximum a For the best starting performance the NA 3 Open Circuit Voltage Control and Voltage Control setting should be the same S...

Page 24: ...ATIC WIRE FEEDER To use the LN 8 Semi Automatic Wire Feeder with IDEALARC DC 600 1 Set the IDEALARC DC 600 WELDING MODE SWITCH to either CV Innershield mode or CV Submerged Arc mode depending on the w...

Page 25: ...Undercarriage C 4 Meters C 4 Connections for Wire Feeder Control C 5 NA 3 C 5 NA 5 C 6 LN 8 or LN 9 C 7 LN 7 C 8 IDEALARC DC 600 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION Return to Master TOC...

Page 26: ...t cables to the set of terminals on the left side of the box and the stick or air carbon arc cables to the set of terminals on the right side facing the front of the machine as shown in Figure C 1 Whe...

Page 27: ...ure C 3 8 Connect the control leads from the MULTI PROCESS SWITCH to terminals 2 and 4 on the IDEALARC DC 600 s terminal strip 9 Position the MULTI PROCESS SWITCH flush with the front of the machine a...

Page 28: ...ief loop on the right side facing the front of the machine of the IDEALARC DC 600 b Connect the electrode cable to the Positive terminal on the right side of the MULTI PROCESS SWITCH c Connect the wor...

Page 29: ...BUTTON to OFF 3 Connect the wire feeder control cable leads to the IDEALARC DC 600 terminal strip as shown in Figure C 5 4 Connect the wire feeder control cable ground lead to the frame terminal mark...

Page 30: ...ork piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpos...

Page 31: ...y separate from the work cable circuit and connection d Tape the 21 lead to work cable for ease of use NOTE Using the extended 21 lead eliminates the need to use the LN 9 s remote work lead accessory...

Page 32: ...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 fee...

Page 33: ...CE SECTION Section D 1 IDEALARC DC 600 MAINTENANCE Section D Safety Precautions D 2 Routine and Periodic Maintenance D 3 3 D Exploded View D 4 Return to Master TOC Return to Master TOC Return to Maste...

Page 34: ...to Master TOC Return to Master TOC IDEALARC DC 600 D 2 MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL Only qualified personnel should perform this maintenance Turn the input power...

Page 35: ...ls are in the welding or cutting area or around the machine 2 Remove any debris dust dirt or materials that could block the air flow to the machine for cooling 3 Inspect the electrode cables for any s...

Page 36: ...eturn 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 IDEALARC DC 600 D 4 MAINTENANCE FIGURE D 1 General...

Page 37: ...TERMINAL STRIP CONTACTOR TO CONTROL BOARD REMOTE CONTROL MAIN TRANSFORMER CONTROL TRANSFORMER 115 VAC 115 VAC FAULT PROTECTION PROTECTION DEVICES CIRCUTS CONTACTOR HOLD IN FIRING BOARD CONTROL BOARD...

Page 38: ...low voltage high cur rent output The finishes or neutrals of the main sec ondary coils are connected together and the six starts of the secondary windings are connected to the rectifi er assembly In a...

Page 39: ...ctifiers SCR controlled by that phase The firing circuit supplies the proper amount of energy to the gates of the power SCRs When this energy is applied at the correct time the SCR will turn ON The am...

Page 40: ...he fan problem or air obstruction be corrected The DC 600 is also protected against high current overloads This electronic protection circuit senses an overload on the power source and opens the input...

Page 41: ...evice 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 con trolled by the Gate An SCR is fired b...

Page 42: ...ant Voltage Innershield Mode F 42 Normal Minimum Open Circuit Voltage Waveform Constant Voltage Innershield Mode F 43 Typical Output Voltage Waveform Machine Loaded Constant Voltage Innershield Mode F...

Page 43: ...hapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced e...

Page 44: ...ot touch electrically hot parts Remove the P C Board from the static shield ing bag and place it directly into the equipment Don t set the P C Board on or near paper plas tic or cloth which could have...

Page 45: ...achine The input voltage must match the rating plate and reconnect panel RECOMMENDED COURSE OF ACTION 1 The ON OFF PUSHBUTTON S1 may be faulty Check for proper operation See wiring diagram 2 The Contr...

Page 46: ...2 4 31 32 75 76 77 If contactor CR1 functions correctly there may be a ground or negative intrusion on the remote control leads 75 76 or 77 There may also be a short at the welder output terminals 3...

Page 47: ...blown 4 Check for loose or faulty weld cable connections RECOMMENDED COURSE OF ACTION 1 Check operation of output pilot relay CR4 There should be 115VAC present at leads 31 and 4 at CR4 when 2 and 4 a...

Page 48: ...lved check the remote control unit or wire feeder and associated control cable RECOMMENDED COURSE OF ACTION 1 Check OUTPUT CONTROL SWITCH SW3 and associat ed wiring 2 Check feedback leads 222 negative...

Page 49: ...put lines at the DC600 Make sure input voltages match machine rating and recon nect panel 2 Put OUTPUT CONTROL SWITCH SW3 in OUT PUT CONTROL AT DC600 position If problem is solved then check remote co...

Page 50: ...e output cable or there is a short on the welding output ter minals 2 If the machine still shuts off when all control and welding cables are removed then the problem is internal to the DC600 1 Contact...

Page 51: ...ble or wire feeder 2 If some open circuit voltage is present over 3VDC after per forming Step 1 then the prob lem is within the DC600 RECOMMENDED COURSE OF ACTION 1 Check for an internal short between...

Page 52: ...eck weld cables for loose or faulty connections RECOMMENDED COURSE OF ACTION 1 Check the CR3 reed switch The voltage from lead 215 to lead 220 should be 8VDC when the DC600 is in an idle condition on...

Page 53: ...loose or faulty connections RECOMMENDED COURSE OF ACTION 1 Check the WELDING MODE SWITCH SW4 and the asso ciated wiring for loose or faulty connections See wiring dia gram 2 Check the CR3 reed switch...

Page 54: ...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...

Page 55: ...Sides 3 Locate the Control Transformer T2 on the left side of the Input Box facing the back the of the machine See Figure F 1 4 Locate the Control Transformer pri mary leads H1 H2 H3 etc See wiring di...

Page 56: ...BACK b Connect the other end of the alligator clip to one of the meter probes Be sure that neither the alligator clip nor the meter probe touches any metal sur faces c Connect the other meter probe t...

Page 57: ...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 tests repairs safely contact the Linc...

Page 58: ...irm that the Reconnect Panel is connected properly for the three phase main AC input power supplied to the machine See the Reconnect Panel Connection Diagram located on the inside of the Input Box Ass...

Page 59: ...output side of the Input Contactor CR1 See wiring diagram a T1 to T2 b T2 to T3 c T1 to T3 9 Read meter a If proper voltage is present for all three phases the Contactor is working properly b If the p...

Page 60: ...om the Control Box Cover with a 5 16 nut driver and flip the cover down It does not have to be completely removed to perform the tests 13 Test with an AC voltmeter for 75 VAC for each phase angle wind...

Page 61: ...s See Figure F 6 c If one or more of the above voltage tests are incorrect check for loose or faulty wiring d If the wiring is good then the Main Transformer may be faulty Replace MAIN TRANSFORMER T1...

Page 62: ...out this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical trou bleshoo...

Page 63: ...ocate the Firing Board on the left side of Control Box facing the machine 3 Perform a visual inspection of the Firing Board to see if there are any loose or faulty connections 4 Connect the correct ma...

Page 64: ...ED and Molex Plug Locations F 23 TROUBLESHOOTING REPAIR IDEALARC DC 600 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TO...

Page 65: ...cted to the phase angle winding in the Main Transformer LED 8 is OFF or is DIMMER than other LEDs The proper AC voltage may not be reaching Firing Board Check for loose or faulty connections Perform M...

Page 66: ...Master TOC Return to Master TOC 7 Locate the terminal strip directly below the Control Box 8 Connect a jumper wire from termi nal 2 to terminal 4 on the termi nal strip See Figure F 8 FIGURE F 8 Jumpe...

Page 67: ...hen the SCR Bridge may be faulty Perform SCR Bridge test b If any or all of LEDs 1 6 do not glow or do not change in brightness equally as the pot is turned go to Step 13 13 Test for 10 VDC to 13 VDC...

Page 68: ...e DC voltage between leads 231 and 215 should be constant at approximately 5 8 VDC This voltage should not vary when the pot is turned e Remove probes inserted into the Molex Plug lead cavities of lea...

Page 69: ...ranty 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 u...

Page 70: ...lay that power is applied to fault protection relay CR2 3 DOES NOT GLOW Glows only if there is a fault condition 4 Glows to display a control signal lead 231 is being supplied to the Firing Circuit Wh...

Page 71: ...e Replace the Molex Plug J2 f Connect main AC input power to the machine g Set the ON OFF PUSH BUT TON to ON h Read meter for 115 VAC If 115 VAC is present AND LED 1 does not glow the Control Board ma...

Page 72: ...meter probe to the negative Weld Output Terminal and positive meter probe to the positive Weld Output Terminal 3 Read meter a If the open circuit voltage is present at the Weld Output Terminals then t...

Page 73: ...ightness Under the Following Conditions Machine is operating under load or ter minals 2 and 4 are jumpered togeth er on the terminal strip The OUTPUT CONTROL POTEN TIOMETER is rotated The WELD MODE SW...

Page 74: ...o 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 tests...

Page 75: ...ter TOC Return to Master TOC Return to Master TOC IDEALARC DC 600 F 34 TROUBLESHOOTING REPAIR 1 Disconnect main AC input power to the machine 2 Disconnect all Molex Plugs from the Firing Board and Con...

Page 76: ...to Master TOC 3 Remove the red insulating paint from the heat sink test points See FIGURE F 13 NOTE DO NOT DISASSEMBLE THE HEAT SINKS 4 Test for high or infinite resistance from the anode to the cath...

Page 77: ...ps 4 or 5 go to Step 6 6 Disconnect the snubber circuit See wiring diagram 7 Retest SCR 1 with the snubber cir cuit disconnected a If a low resistance is still indi cated SCR 1 is faulty Replace If on...

Page 78: ...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 perfo...

Page 79: ...ter TOC Return to Master TOC Return to Master TOC IDEALARC DC 600 F 38 TROUBLESHOOTING REPAIR TEST PROCEDURE 1 Disconnect main AC input power to the machine 2 Disconnect all Molex Plugs from the Firin...

Page 80: ...See FIGURE F 16 4 Construct the circuit shown in Figure F 17 One 6 volt lantern bat tery can be used Set voltmeter scale low at approximately 0 5 volts or 0 10 volts IDEALARC DC 600 F 39 TROUBLESHOOT...

Page 81: ...and after the switch is open the SCR is functioning b If the voltages is 3 6 volts only when the switch is closed or there is no voltage when the switch is closed the SCR is defective NOTE Be sure bat...

Page 82: ...FORM CONSTANT CURRENT MODE NO LOAD This is the typical DC open circuit voltage waveform generated from a properly operat ing machine Note that each vertical division represents 50 volts and that each...

Page 83: ...OLTAGE INNERSHIELD MAXIMUM OUTPUT SETTING NO LOAD This is the typical DC open circuit voltage waveform generated from a properly operat ing machine Note that each vertical division represents 50 volts...

Page 84: ...OLTAGE INNERSHIELD MINIMUM OUTPUT SETTING NO LOAD This is the typical DC open circuit voltage waveform generated from a properly operat ing machine Note that each vertical division represents 20 volts...

Page 85: ...s the typical DC open circuit voltage waveform generated from a properly operat ing machine Note that each vertical division represents 20 volts and that each horizontal division represents 2 millisec...

Page 86: ...AGE INNERSHIELD MAXIMUM OUTPUT SETTING NO LOAD This is the typical SCR gate pulse voltage waveform The machine was in an open cir cuit condition no load and operating proper ly Note that each vertical...

Page 87: ...NCTIONING This is NOT the typical DC output voltage waveform One output SCR is not function ing Note the gap in the waveform One SCR gate is disconnected to simulate an open or non functioning output...

Page 88: ...r to the technician or the 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...

Page 89: ...or cover plate CONTACTOR REPLACE MENT PROCEDURE 1 Disconnect main AC input power supply to the machine 2 Locate and get access to the Input Contactor CR1 in the Input Box See Figure F 18 3 Disconnect...

Page 90: ...ult in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed...

Page 91: ...ransformer secondary lead heavy aluminum conduc tor connected to the anode of the SCR heat sink for each assembly to be removed See Figure F 19 b The snubber leads for each SCR heat sink to be removed...

Page 92: ...assem bly to the frame rail may have to be loosened to slide the SCR Heat Sink out from under the buss jumper strap b When all four thru bolts are removed the SCR Heat Sink directly above or below wi...

Page 93: ...and there is no Gate Lead Molex Board identify and label the six Gate leads and cut or unsolder the leads from their respective snubber boards 2 Remove the four self tapping bolts that mount the SCR B...

Page 94: ...SCR Heat Sinks following the procedure described in A above 10 Replace all insulating materials including the insulators on the frame rail and all insulating tubes when installing the SCR Output Bridg...

Page 95: ...el Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical s...

Page 96: ...and cut or unsolder the leads from their respective Snubber Board 2 Disconnect the Shunt lead from the SCR Bridge Assembly See Figure F 21 3 Disconnect the leads from the sec ondary thermostat See wi...

Page 97: ...See Figure F 21 10 Cut and remove all cable ties and unbundle all wires 11 Label and cut fan motor leads 12 Separate leads 271 211 and X2 from the harness 13 Disconnect lead 272 from Input Contactor...

Page 98: ...to the technician or the 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 t...

Page 99: ...socket wrench and a 9 16 open end wrench a Identify and label the small snubber leads 3 Remove the four nuts mounting the Output Choke to the transformer through bolts using a 9 16 socket wrench TRAN...

Page 100: ...must be removed by inserting the wrench through the hole in Lift Bail 7 Remove the Lift Bail and Output Bridge Assembly from the trans former by lifting the Lift Bail up slightly and sliding the Lift...

Page 101: ...lated wedges b Using a high temperature industrial epoxy such as Lincoln E 1603 glue the pri mary coils in place by applying the epoxy to the coil side and cell insulation opposite the wedges Using a...

Page 102: ...60 3 50 346 3 60 380 3 50 400 3 50 415 3 50 440 3 50 500 3 50 550 3 50 14 4 13 0 7 9 7 2 6 5 5 4 5 2 30 8 28 0 23 7 17 8 16 2 15 4 14 8 14 0 12 3 11 2 1 488 1 488 1 488 1 488 1 488 1 488 1 488 3 5 3 5...

Page 103: ...TINGS Mode Variable Voltage Variable Voltage Constant Voltage Innershield Constant Voltage Innershield Input Hertz 60 50 60 50 Load 75 Amps 24 26VDC 75 Amps 24 26VDC 100 Amps 11 5 12 5VDC 100 Amps 11...

Page 104: ...EALARC DC600 ELECTRICAL DIAGRAMS SECTION Section G Control Board Layout G 1 G1504 4 and above Firing Board Layout G 3 G1486 5 and above Wiring Diagram G 5 Codes 9773 9776 9778 9779 9780 9910 Wiring Di...

Page 105: ...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 IDEALARC 600 G 1 ELECTRICAL DIAGRAMS CONTROL PC BO...

Page 106: ...ALEL 47 160V 50 20 C17 CAPACITOR ALEL 6 150V 50 10 C13 CAPACITOR TAEL 0 47 50V 10 C25 CAPACITOR ALEL 2 50V 75 10 SCR1 SCR T202 4A 400V C106D C9 C21 C22 C23 C24 C26 CAPACITOR CEMO 022 50V 20 C27 C28 C...

Page 107: ...on 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 IDEALARC 600 ELECTRICAL DIAGRAMS FIRING PC BOARD G1486 5 AND ABOV...

Page 108: ...EAR D7 D8 D9 D22 D23 D24 D25 DIODE AXLDS 1A 400V D26 D27 D28 D29 D30 D31 D32 D33 D34 D35 D36 D37 D38 D39 D1 D2 D3 D4 D5 D6 D10 D11 DIODE AXLDS 1A 1000V D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 R1 R2 R3...

Page 109: ...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 IDEALARC 600 NOTES...

Page 110: ...L L N O W B E E N E R G I Z E D P L A C E M O D E S W I T C H I N V V F O R S T I C K A N D C V I F O R A I R C A R B O N A R C S E E O P E R A T I N G M A N U A L F O R F U R T H E R I N S T R U C T...

Page 111: ...C T R O D E P O L A R I T Y S W 3 O U T P U T C O N T R O L S W 4 W E L D I N G M O D E S H O W N I N S T I C K P O S I T I O N N O T E S N B F O R S T I C K W E L D I N G O R A I R C A R B O N A R C...

Page 112: ...m p s F I R I N G P C B O U T P U T S T U D O U T P U T S T U D 1 2 0 V A C 1 2 0 V A C F I R I N G C I R C U I T F I R I N G C I R C U I T F I R I N G C I R C U I T 2 3 1 2 3 1 2 3 1 F I R I N G B D...

Page 113: ...level troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s spe...

Page 114: ...level troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s spec...

Reviews:

No comments