Lincoln Electric DC-600 series Скачать руководство пользователя страница 37 | Manualshive

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E-9

TROUBLESHOOTING

E-9

DC-600

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

PROBLEMS
(SYMPTOMS)

The weld output terminals are
always electrically "hot".

POSSIBLE
CAUSE

1.

Remove any external leads
hooked to #2 and #4 on the ter-
minal strip or any connections
to the 14 pin MS connector.
Set OUTPUT TERMINALS
switch to the OFF position. If
the problem disappears the
fault is in the control cable 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 DC-600.

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS

Observe all Safety Guidelines detailed throughout this manual

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Содержание DC-600 series

Страница 1: ...S MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful 1 2 3 4 5 6 7 8 9 10 DC 600 For use with machines having Code Numbers 10588 to 10701 1...

Страница 2: ...RERS 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 Safe...

Страница 3: ...or 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 the open circuit voltage of both weld...

Страница 4: ...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 line...

Страница 5: ...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 en cuir chemise paisse pan talon...

Страница 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Страница 7: ...r Ground Connection B 4 Controls and Settings B 4 B 5 Auxiliary Power in MS Receptacle B 6 Overload Overcurrent and Fault Protection B 6 Operating Steps B 7 Remote Control of Machine Operation B 7 Wel...

Страница 8: ...Precautions D 1 Routine and Periodic Maintenance D 2 Troubleshooting Section E Safety Precautions E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 Wiring Diagrams Connection Diagram...

Страница 9: ...0 460 575 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 54 108 54 43 54 43 116 67 58 67 51 58 128 64 61 50 Duty Cycle 134 67 134 67 54 67 54 138...

Страница 10: ...ree machines in one grouping DO NOT stack the DC 600 on another type of machine Follow these guidelines when stacking 1 Select a firm level surface capable of sup porting the total weight of up to thr...

Страница 11: ...al electrical codes or see the Technical Specifications page in this manual GROUND CONNECTION Ground the frame of the machine A ground terminal marked with the symbol is located inside the Case Back o...

Страница 12: ...m 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 LINES INPUT H3 H1 H2 GND W V U W V U CONTACTOR CRI CRI CONNECTION FOR HIGHEST RATING PLAT...

Страница 13: ...TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 DISCONNECTAND INSULATE THE H3 H4 LEAD TERMINALS SEPARATELYWITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION 3 CONNECT L1 L2 L3 I...

Страница 14: ...E FOR REQUIRED INPUT SUPPLY VOLTAGE 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 CONNECT TERMINALMARKED TO GROUND PER NATIONAL ELECTRIC CODES 3 CONNECT THE L1 L2 L3 INPUT S...

Страница 15: ...minals in the lower right and lower left corners of the Case Front Assembly See Figure A 9 3 Pull out the retractable strain relief loops 4 Insert the electrode lead through the loop directly below th...

Страница 16: ...DELS ONLY The 115VAC duplex receptacle is protected by a circuit breaker located on the nameplate The receptacle is a NEMA 5 15R AUXILIARY POWER TABLE Voltage and Circuit Breaker Ratings at Auxiliary...

Страница 17: ...wire welder DC manual stick welder AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before ser vicing READ THIS WARNING PROTECT YOURSELF OTHERS FUMES A...

Страница 18: ...ld welding performance A control circuit designed to provide good starting for a large variety of processes and procedures Output Control Potentiometer that provides easy single range continuous contr...

Страница 19: ...ON REMOTE Switch OUTPUT TERMINALS ENERGIZED Remote Control of Output Terminals Energized or Non Energized LOCAL REMOTE Switch SYMBOL MEANING Control Of Output Voltage and Current is Via DC 600 s Cont...

Страница 20: ...L SYMBOLS ON RATING PLATE LOCATED ON CASE BACK NEMA EW 1 100 Shielded Metal Arc Welding SMAW Submerged Arc Welding SAW MEANING OF GRAPHICAL SYMBOL FOR GROUND CON NECTION Signifies the equipment connec...

Страница 21: ...this receptacle 11 Terminal Strip Cover Panel Rotate this panel to gain access to the circuits made available at the two terminal strips T S 1 and T S 2 These terminal strips contains the same circuit...

Страница 22: ...c cutting it is recommended that the optional MULTI PROCESS SWITCH be used This switch permits you to easily change the polarity of the connected wire feeding equipment or switch to stick welding or a...

Страница 23: ...E 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 3 Mode switch is i...

Страница 24: ...t maximum For the best starting performance the NA 3 Open Circuit Voltage Control and Voltage Control set ting should be the same Set the Inch Speed Control for the slowest inch speed possible To adju...

Страница 25: ...ong to connect a K857 Remote Control 6 pin connector with an LN 7 wire feeder 14 pin connector and the machine 14 pin connector If a remote control is used alone the wire feeder connection is then not...

Страница 26: ...s through the strain relief box connectors and into the terminal strip Connect wire feeder control cable as specified in specific connection diagram and make other terminal strip connections as specif...

Страница 27: ...he DC 600 OFF and reverse the cables NOTE When it is not necessary to have separate ground cables for stick and semi automatic or automatic welding connect a jumper from the MULTI PROCESS SWITCH Work...

Страница 28: ...cket or any condition that would affect the proper operation of the machine Perform Periodically Clean the inside of the machine with low pressure air stream Clean the following parts Main transformer...

Страница 29: ...AUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it...

Страница 30: ...ace it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a static charge If the P C Board can t be installed immediately put it back in the static...

Страница 31: ...1 800 833 9353 WELD 1 Check for blown or missing fuses in input lines 2 Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel 3 Pow...

Страница 32: ...oltage may be low Check all three phases 2 Make sure input line voltage matches machine rating and the reconnect panel is connect ed correctly for the line voltage 1 Poor electrode or work lead con ne...

Страница 33: ...hine input contactor operates but machine has no weld output Fan runs and pilot light glows POSSIBLE CAUSE 1 Place OUTPUT TERMINAL Switch to ON or install a jumper from 2 to 4 on machine terminal stri...

Страница 34: ...f all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility PROBLEMS SYMPTOMS Machine has maximum weld out...

Страница 35: ...terminal strip 75 76 and 77 terminals or is not connected to the 14 pin MS receptacle the LOCAL REMOTE SWITCH must be in the Local position 2 If a remote control cable is con nected to terminals 75 76...

Страница 36: ...n ON position The DC600 will NOT shut off when the Power Switch is turned to OFF POSSIBLE CAUSE 1 Remove all welding cables and control cables from the DC 600 Jumper 2 to 4 at the terminal strip or se...

Страница 37: ...coln Authorized Field Service Facility PROBLEMS SYMPTOMS The weld output terminals are always electrically hot POSSIBLE CAUSE 1 Remove any external leads hooked to 2 and 4 on the ter minal strip or an...

Страница 38: ...ity PROBLEMS SYMPTOMS Poor arc starting when the DC600 is in the CV Sub Arc or CV Innershield Modes Machine has output but trips off immediately when wire feed unit trigger is activated POSSIBLE CAUSE...

Страница 39: ...e been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility PROBLEMS SYMPTOMS Poor arc characteristics in all processes POSSIBLE CAUSE 1 Check for the correct...

Страница 40: ...dary winding of the control transformer T2 which supplies leads 255 and 256 Measure 16VDC from TEST POINTS A to C and 10VDC from TEST POINTS A to J on Control board 2 LED 2 indicates welder output vol...

Страница 41: ...damaging rheostat tabs 6 Rotate the OUTPUT voltage control rheostat The resistance reading should be from around zero to 10K ohms Check the resistance reading between the two outer tabs on the rheosta...

Страница 42: ...e 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 If the diagram is illegible...

Страница 43: ...E LEAD 32 TO BE CONNECTED TO THE HOT LINE 11338 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 pas...

Страница 44: ...2V AC WORK OUTPUT CONTROL OUTPUT CONTROL OUTPUT CONTROL TRIGGER CIRCUIT TRIGGER CIRCUIT SEE APPROPRIATE WIRING DIAGRAM FUNCTION FUNCTIONS ARE LISTED FOR REFERENCE ONLY AND EACH MAY OR MAY NOT BE PRESE...

Страница 45: ...adds error to the LN 7 voltmeter Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power 41 4 2 31 32 75 76 77 NEGATIVE PO...

Страница 46: ...r the electrode polarity is changed N G If lead 21 is to be connected to the terminal strip connect to N F The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual...

Страница 47: ...al 21 on the terminal strip Note that this is not the preferred connection because it adds error N D Connect the control cable ground lead to the frame terminal marked near the power source terminal s...

Страница 48: ...t the power source physically suitable for the installation An S16586 LENGTH N D N F INPUT CABLE PLUG CONTROL CABLE 41 4 2 31 32 75 76 77 N F 21 21 REMOTE VOLTAGE SENSING LEAD TO NA 5 5R BOLT TO CABLE...

Страница 49: ...UT CONTROL OUTPUT CONTROL OUTPUT CONTROL TRIGGER CIRCUIT Only qualified persons should install use or service this machine Do not operate with covers removed Disconnect power source before servicing D...

Страница 50: ...LOCATION OF BASE MOUNTING HOLES 94 20 00 M12244 6 DC 600 1 20 89A 27 87 9 20 27 50 3 25 39 95 22 25 29 93 THIS DIMENSION WILL VARY WITH POSITION OF HANDLE DIMENSION PRINT WITH K817P UNDERCARRIAGE 11 1...

Страница 51: ...8 93C 36 12 M15200 3 17 76 38 00 5 19 DIMENSION PRINT WITH K842 UNDERCARRIAGE 20 00 27 65 37 86 LOCATION OF BASE MOUNTING HOLES 29 93 94 3 25 23 28 22 25 11 12 27 50 7 11 54 91 49 89 DIMENSION PRINT W...

Страница 52: ...NOTES DC 600...

Страница 53: ...NOTES DC 600...

Страница 54: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Страница 55: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Страница 56: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

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