background image

INSTALLATION

A-7

A-7

DC-600

Retur

n

to

Section

T

OC

Retur

n

to

Section

T

OC

Retur

n

to

Section

T

OC

Retur

n

to

Section

T

OC

Retur

n

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 Panel Board 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. CONNECT TERMINAL MARKED       TO GROUND PER NATIONAL ELECTRIC CODES.

3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.

W

V

U

CONTACTOR

CRI

FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines

Summary of Contents for SVM188-A

Page 1: ...HOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machine code numbers Above Code 10580 DC 600 1 2 3 4 5 6 7 8 9 10 DC 600 Return to Master TOC Return to Master...

Page 2: ...JURY 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 strongl...

Page 3: ...rom sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resist...

Page 4: ...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 compres...

Page 5: ...aillant proximit au soudage 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 hui...

Page 6: ...he welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note I...

Page 7: ...o the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bond...

Page 8: ...DC 600 RETURN TO MAIN INDEX Page Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F E...

Page 9: ...nical Specifications A 2 Safety Precautions A 3 Select Proper Location A 3 Limit on Stacking A 3 Stacking A 3 Tilting A 3 Electrical Input Connections A 4 Fuses and Wire Sizes A 4 Ground Connection A...

Page 10: ...current increases RECOMMENDED INPUT WIRE AND FUSE SIZES Standard Volatge 230 460 60 230 460 575 60 460 60 575 60 220 380 440 50 60 380 500 50 60 440 50 60 200 400 50 60 415 50 60 100 Duty Cycle 108 54...

Page 11: ...IT ON STACKING STACKING Three DC 600 machines can be stacked DO NOT stack more than three machines in one grouping DO NOT stack the DC 600 on another type of machine Follow these guidelines when stack...

Page 12: ...the machine A ground terminal marked with the symbol is located inside the Case Back of the machine near the input contactor Access to the Input Box Assembly is at the upper rear of the machine See yo...

Page 13: ...0 575 see Figure A 8 M15666 6 For Voltages not listed see the Input Connection Diagram pasted on the inside of the Case Back Input Access Door L3 L2 L1 LINK LINES INPUT GND H2 H1 H3 L3 L2 L1 LINK LINE...

Page 14: ...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 TERM...

Page 15: ...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 CONNE...

Page 16: ...itch to OFF 2 Locate the retractable strain relief loops directly below the output terminals in the lower right and lower left corners of the Case Front Assembly See Figure A 9 3 Pull out the retracta...

Page 17: ...e case front see Auxiliary Power Table for details 115VAC DUPLEX RECEPTACLE 60 HERTZ MODELS ONLY The 115VAC duplex receptacle is protected by a circuit breaker located on the nameplate The receptacle...

Page 18: ...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 NOTES A 10 A 10 DC 600...

Page 19: ...B 4 Meaning of Graphical Symbols on Rating Plate B 5 Meaning of Graphical Symbol for Ground Connection B 5 Controls and Settings B 5 B 6 Auxiliary Power in MS Receptacle B 6 Overload Overcurrent and...

Page 20: ...er or inside work piece Use the following equipment Semiautomatic DC constant voltage wire welder DC manual stick welder AC welder with reduced voltage con trol Do not operate with panels removed Disc...

Page 21: ...Excellent arc characteristics for optimum constant voltage submerged arc and Innershield welding performance A control circuit designed to provide good starting for a large variety of processes and pr...

Page 22: ...OUTPUT VOLTAGE AND CURRENT Clockwise Increase of Output Voltage and Current TERMINALS ON REMOTE Switch OUTPUT TERMINALS ENERGIZED Remote Control of Output Terminals Energized or Non Energized LOCAL R...

Page 23: ...Hertz Models Gas Metal Arc Welding GMAW Flux Cored Arc Welding FCAW MEANING OF GRAPHICAL SYMBOLS ON RATING PLATE LOCATED ON CASE BACK NEMA EW 1 100 Shielded Metal Arc Welding SMAW Submerged Arc Weldin...

Page 24: ...in the Installation Section for information about the circuits made available at this receptacle 11 Terminal Strip Cover Panel Rotate this panel to gain access to the circuits made available at the tw...

Page 25: ...using the DC 600 with semi automatic or auto matic wire feeding equipment and for stick welding or air carbon arc cutting it is recommended that the optional MULTI PROCESS SWITCH be used This switch p...

Page 26: ...NA 3 AUTOMATIC WIRE FEEDER 1 Set the DC 600 LOCAL REMOTE Switch to REMOTE Set the OUTPUT TERMINALS switch to REMOTE NOTE Later model NA 3 automatic wire feeders are capable of cold starts when the NA...

Page 27: ...terminal strips behind the DC 600 nameplate See the Installation section of this manual and the appropriate Connection Diagram 3 Run a test weld Set proper current voltage and travel speed For the bes...

Page 28: ...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 NOTES B 10 B 10 DC 600...

Page 29: ...BLE OF CONTENTS ACCESSORIES SECTION C 1 C 1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC 600 Accessories C 1 Factory Installed Equipment C 2 Accessories C 3 C...

Page 30: ...pin connector on the case front Remote Control Adapter Cable K864 A V cable 12 30 m long to connect a K857 Remote Control 6 pin connector with an LN 7 wire feeder 14 pin connector and the machine 14 p...

Page 31: ...start the four screws then tighten them 5 Route the MULTI PROCESS SWITCH control leads through the strain relief box connectors and into the terminal strip Connect wire feeder control cable as specifi...

Page 32: ...structions above are for connecting the stick polarity positive To change the polarity turn the DC 600 OFF and reverse the cables NOTE When it is not necessary to have separate ground cables for stick...

Page 33: ...TENTS MAINTENANCE SECTION D 1 D 1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC 600 Maintenance D 1 Safety Precautions D 2 Routine Maintenance D 2 Periodic Mai...

Page 34: ...ock the air flow to the machine for cooling 3 Inspect the electrode cables for any slits or punctures in the cable jacket or any condition that would affect the proper operation of the machine Perform...

Page 35: ...GIC DIAGRAM CONTROL TRANSFORMER R E C O N N E C T CONTACTOR FAULT PROTECTION 115VAC MAIN TRANSFORMER CONTROL BOARD SHUNT OUTPUT CONTROL MODE SWITCH POSITIVE TERMINAL NEGATIVE TERMINAL LATCHING RESISTO...

Page 36: ...he high voltage low current input power to a lower voltage higher cur rent output The finishes or neutrals of the main sec ondary coils are connected together and the six starts of the secondary windi...

Page 37: ...orma tion from the shunt and voltage feedback information from the choke and welding output terminals This feedback information is processed on the control board The control board compares the command...

Page 38: ...horter the time The input contactor will remain open until the power source is manually started by resetting the POWER ON OFF toggle switch FIGURE E 2 GENERAL DISCRIPTION REMOTE CONTROL FAULT PROTECTI...

Page 39: ...applied to the SCR the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state The amount of time spent in the ON state is con trolled by th...

Page 40: ...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 NOTES E 6 E 6 DC 600...

Page 41: ...oubleshooting Guide F 4 Test Procedures PC Board Troubleshooting Guide F 9 Internal Trigger Test F 13 Firing Board Test F 17 Control Board Test F 19 Main Transformer Voltage Test F 21 Control Transfor...

Page 42: ...It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to e...

Page 43: ...pment 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 coul...

Page 44: ...er Test 3 The primary or secondary ther mostats may be open Check or replace Also check the associ ated wiring See the Wiring Diagram 4 The pilot relay CR2 may be faulty Check or replace 5 The input c...

Page 45: ...7 including the Output Terminals Switch S3 and the Output Control R1 for grounds or shorts See the Wiring Diagram 4 The Control Board may be faulty See the PC Board Troubleshooting Guide Machine shuts...

Page 46: ...ntrol Board may be defective See the PC Board Troubleshooting Guide TROUBLESHOOTING AND REPAIR F 6 F 6 DC 600 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Re...

Page 47: ...ead for continu ity zero ohms from the Output Control Potentiometer R1 to the control board connector J1 Pin2 See Wiring Diagram 4 Possible defective Control Board or Firing Board See the PC Board Tro...

Page 48: ...amps 2 Perform the Firing Board Test 3 Perform the SCR Output Bridge Test 4 The Control Board may be faulty Poor arc characteristics in all processes 1 Check for the correct input volt ages on the thr...

Page 49: ...lectrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This is a quick reference guide to explain the function of the LEDs Light Emitting Diodes on the PC Boards...

Page 50: ...een pins C D of 14 pin connector If LED 10 does not come ON check wiring Perform the Internal Trigger Circuit Test 4 LEDs 1 thru 6 indicate that gate signals are being sent to the SCRs in the Main Rec...

Page 51: ...nder a fault condition LED 3 will go OFF and LED 4 will turn ON See Protective Devices and Shutdown Circuits 5 LED 4 indicates an overload or fault condition and is normally OFF If it comes ON the inp...

Page 52: ...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 NOTES F 12 F 12 DC 600...

Page 53: ...ncoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help to determine if the wiring and connections are...

Page 54: ...rmer Test 5 Remove the main input supply power to the DC 600 6 Check for continuity zero ohms from lead 42A to lead 2 at the 14 pin receptacle pin C Also check continuity to the Output Terminal Switch...

Page 55: ...F 15 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 TOC Return to Master TOC Return to Master TOC 2 4 C D 2 4 41...

Page 56: ...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 NOTES F 16 F 16 DC 600...

Page 57: ...fely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will help to determine if the Fir...

Page 58: ...s 1 thru 6 and LED 10 come on NOTE LEDs 1 thru 6 should alwaysl be the same bril liance as each other The brilliance will vary as the Output Control is changed 8 If LED 10 does not come ON perform the...

Page 59: ...n Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will help to determine if the Control Board is functioni...

Page 60: ...D4 still comes ON Check the Output Studs and associated wiring for a shorted or grounded condition Check for grounds in the control circuit Output Control Local Remote Switch TS1 Control Board may be...

Page 61: ...oln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltages are being applied to...

Page 62: ...5 Turn the power switch SW1 to the ON position 6 Make sure the input contactor CR1 energizes 7 Test with an AC voltmeter for the proper main AC input voltages applied to the line side of the input co...

Page 63: ...Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 2 3 4 5 6 7 8 9 10 DC 600 21 21 41 4 2 31 32 TS 2 RECEPTACLE PROCEDURE 10 Test for 120 VAC b...

Page 64: ...t the following pins of plug J5 These are the phase angle winding voltages See Figure F 11 Plug J5 pin 15 lead 203 to pin 16 lead 204 Plug J5 pin 8 lead 205 to pin 7 lead 206 Plug J5 pin 6 lead 207 to...

Page 65: ...afely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the correct vo...

Page 66: ...SHOCK can kill Do not touch electrically hot parts 3 Measure the voltage from X1 to X2 It should be approximately 120VAC 4 If this reading is incorrect check the connections on the Primary and Seconda...

Page 67: ...re unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This pro...

Page 68: ...TACT TEST 1 Disconnect the input power and remove leads 271 and 272 from the CR1 coil terminals See Figure F 13 2 Remove the contactor cover plate blow out any dust or dirt with low pressure air 3 Exa...

Page 69: ...test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the techn...

Page 70: ...ode plate with the Positive meter lead on the Anodes The resistance should be very high or open Reverse the meter leads and measure all the same points The readings should be very high or open and typ...

Page 71: ...s and release and read the meter a If the voltage is 3 6 volts while the switch is closed and after the switch is open the SCR is functioning b If the voltage is 3 6 volts only when the switch is clos...

Page 72: ...erminals probe to positive terminal probe to nega tive high inductance terminal SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVE...

Page 73: ...to positive terminal probe to nega tive high inductance terminal SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT V...

Page 74: ...to positive terminal probe to nega tive high inductance terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT V...

Page 75: ...cope probes connected at machine output terminals probe to positive terminal probe to nega tive high inductance terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger...

Page 76: ...cted 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 WAVEFORM CONSTANT VOLTAGE IN...

Page 77: ...onnected at machine output terminals probe to positive terminal probe to nega tive high inductance terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal ABNO...

Page 78: ...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 NOTES F 38 F 38 DC 600...

Page 79: ...unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The follow...

Page 80: ...ny of these conditions are present replace the input contactor assembly NOTE Lincoln does not supply contactor parts They may be available through the manufacturer 6 Replace the input contactor cover...

Page 81: ...epartment for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the SCR Rectifier...

Page 82: ...nnect the Output Snubber lead from the left side of the Choke and remove the Output Snubber from the left side rectifier mounting bracket See Figure F 17 5 Disconnect the 210 2 and 215 5 leads from th...

Page 83: ...leads will be connected 3 Carefully mount the SCR assembly into the DC 600 using the original hardware or the hardware provided with the new assembly See Figure F 18 A NOTE A new rectifier assembly w...

Page 84: ...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 NOTES F 44 F 44 DC 600...

Page 85: ...able to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedur...

Page 86: ...dent to facilitate reassembly 5 Cut off the crimp connectors from the fan leads 31 32A and lead 41 and 42A Tag any leads where the Lincoln lead number is not evident NOTE Cut ties and remove sleeving...

Page 87: ...ors for reassembly 19 Carefully grind the welds from the right hand choke connection to separate the common sec ondary strap from the choke Do not cut the choke lead or reduce it s size any more than...

Page 88: ...ing the hard ware and insulators removed in Step 18 of the removal procedure See Figure F 18 5 Connect the transformer secondary and snubber leads to the SCR assembly See Figure F 19 for proper assemb...

Page 89: ...1 0 1 0 230 3 60 10 0 1 0 380 3 60 6 0 1 0 416 3 60 5 5 1 0 460 3 60 5 0 1 0 550 3 60 4 2 1 0 575 3 60 4 0 1 0 200 3 50 21 0 1 3 220 3 50 19 1 1 3 230 3 50 18 3 1 3 380 3 50 11 0 1 3 400 3 50 10 5 1 3...

Page 90: ...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 NOTES F 50 F 50 DC 600...

Page 91: ...agram 230 460 575 Volt Machines G3506 1 G 3 Schematic Complete Machine G3575 G 4 Schematic Control PC Board G3408 G 5 Control PC Board Assembly G3409 G 6 Schematic Firing PC Board G3741 G 7 NOTE Many...

Page 92: ...75 222 233 256 235 231 255 J1 J2 J3 CONTROL P C BOARD 1 1 2 2 3 3 4 4 5 5 6 6 7 8 9 J4 J5 P C BOARD 2 4 215 WORK ELECTRODE TO STICK ELECTRODE HOLDER OR AIR CARBON ARC TORCH TO WORK USED WITH STICK OR...

Page 93: ...ONAL MULTI PROCESS SWITCH 210 210 210 215 OUTPUT SHUNT 50MV 800 AMPS OUTPUT CHOKE C7 222 R2 32A 31 FAN MOTOR 272 273 SEC LEAD THERMOSTAT 256 PRIMARY THERMOSTAT 256 PILOT LIGHT 233 235 255 271 W S S F...

Page 94: ...G3575 Revision 12 17 99 Status STANDARD This print is Current G 4 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to...

Page 95: ...408 1C1 Revision 11 30 2001E Status STANDARD This print is Current G 5 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Retu...

Page 96: ...110 R117 3 S19400 1301 1 3K 1 4W R66 1 S19400 5622 56 2K 1 4W R69 R100 R109 3 S19400 6810 681 1 4W R74 1 S19400 3923 392K 1 4W R111 1 S19400 47R5 47 5 1 4W R112 1 S19400 1000 100 1 4W R148 R149 2 S194...

Page 97: ...41 1B1 Revision 11 30 2001E Status STANDARD This print is Current G 7 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Retur...

Reviews: