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Lincoln Electric IDEALARC DC-600 VRD, Руководство оператора

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E-9

TROUbLESHOOTING

E-9

IDEALARC® DC-600 VRD

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 possible cause 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  IDEALARC®
DC-600 VRD.

RECOMMENDED
COURSE OF ACTION

OUTPUT PRObLEMS

Observe all Safety Guidelines detailed throughout this manual

Содержание IDEALARC DC-600 VRD

Страница 1: ...Y PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful 1 2 3 4 5 6 7 8 9 10 DC 600 VRD 1 2 3 4 5 6 7 8 9 10 DC 600 VRD For use with machines having Code Numbers 1...

Страница 2: ...S SHOULD CONSULT WITH THEIR DOCTOR bEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety...

Страница 3: ...n water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of...

Страница 4: ...d openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used...

Страница 5: ...i 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 en cuir chemise paisse pan t...

Страница 6: ...mportant when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the...

Страница 7: ...ical Symbol for Ground Connection B 4 Controls and Settings B 4 B 5 Auxiliary Power in MS Receptacle B 5 Overload Overcurrent and Fault Protection B 6 VRD Voltage Reduction Device Operation B 6 Operat...

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

Страница 9: ...a delay in tripping action that decreases as the magnitude of the current increases RECOMMENDED INPUT WIRE AND FUSE SIzES Standard Voltage 230 460 575 60 415 50 60 CODES 11613 11707 11598 11725 100 D...

Страница 10: ...three machines in one grouping DO NOT stack the IDEALARC DC 600 VRD on another type of machine Follow these guidelines when stacking 1 Select a firm level surface capable of supporting the total weigh...

Страница 11: ...et local 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...

Страница 12: ...es A 4 INSTALLATION IDEALARC DC 600 VRD A 4 RECONNECT PROCEDURE Multiple voltage machines are shipped connected to the highest input voltage listed on the machine s rating plate Before installing the...

Страница 13: ...below the output terminals in the lower right and lower left corners of the Case Front Assembly See Figure A 6 3 Pull out the retractable strain relief loops 4 Insert the electrode lead through the lo...

Страница 14: ...tions At Duplex 15A No Duplex Receptacle 115V Terminal strip 115V 15A 115V 15A terminals 31 32 MS Receptacle 115V 15A 115V 15A pins A J MS Receptacle 42V 10A 42V 10A pins I K PIN LEAD NO FUNCTION A 32...

Страница 15: ...volt age wire welder DC manual stick welder AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before servicing READ THIS WARNING PROTECT YOURSELF OTHERS...

Страница 16: ...ors or Solid State switches such as SCR s etc are added to the Electrode to Work output circuit Tamper Resistant design Circuitry is built into power source not an exterior package which could easily...

Страница 17: ...D Remote Control of Output Terminals Energized or Non Energized LOCAL REMOTE Switch SYMbOL MEANING Control Of Output Voltage and Current is Via IDEALARC DC 600 VRD s Control Dial Remote Control of Out...

Страница 18: ...ding 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 Welding SAW MEANING OF GRAPHICAL SYM...

Страница 19: ...connections for auxiliary power output switching remote out put control wire feeder voltmeter sense lead and ground Refer to 14 Pin MS Type Receptacle in the Installation Section for information abou...

Страница 20: ...emain open until the machine cools the white POWER light stays illuminated No welding is possible during this cool down period The machine will reset automatically when the thermostat cools The power...

Страница 21: ...T TERMINALS switch to either ON output terminals energized or REMOTE output terminals energized when 2 and 4 closed by remote device such as wire feeder 7 Make the weld CC MODE 1 Connect the 21 work l...

Страница 22: ...piece Hot On the Fly starts For hot starts travel should begin before the wire contacts the work piece b 8 OPERATION b 8 IDEALARC DC 600 VRD 3 Air Carbon Arc Cutting AAC Stick Welding SMAW High Curre...

Страница 23: ...shooting the desired arc voltage the Open Circuit Voltage Control is set properly If the voltmeter pointer overshoots the desired voltage and then returns back to the desired volt age the Open Circuit...

Страница 24: ...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 used Undercarriages K817P K842 For easy moving of t...

Страница 25: ...and make other terminal strip connections as specified on the connection diagram for the Lincoln wire feeder being used 6 Connect the control leads from the MULTI PROCESS SWITCH to terminals 2 and 4 o...

Страница 26: ...verse 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 terminal to the MULT...

Страница 27: ...r 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 and c...

Страница 28: ...SIBLE CAUSE 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 gener...

Страница 29: ...and place 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...

Страница 30: ...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 Power ON OFF switch may be defe...

Страница 31: ...line voltage 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...

Страница 32: ...e OUTPUT TERMINAL Switch to ON or install a jumper from 2 to 4 on machine terminal strip If machine weld output is restored the problem is in the wire feeder or control cable 2 If remote control is no...

Страница 33: ...ntrol VRD passes self test and green light is on but machine will not Weld POSSIbLE CAUSE 1 LOCAL REMOTE Switch S3 in wrong position 2 LOCAL REMOTE Switch S3 is faulty or an open lead going to the LOC...

Страница 34: ...to the 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 terminal...

Страница 35: ...ch is in 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 stri...

Страница 36: ...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 37: ...ObLEMS SYMPTOMS Poor arc starting when the IDE ALARC DC 600 VRD is in the CV Sub Arc or CV Innershield Modes Machine has output but trips off immediately when wire feed unit trigger is activated POSSI...

Страница 38: ...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 39: ...ss sec ondary 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 o...

Страница 40: ...ECTING REMOTE OUTPUT CONTROL RHEOSTAT TO THE MACHINE Extreme caution must be observed when installing or extending the wiring of a remote control Improper connection of this unit can lead to loss of c...

Страница 41: ...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 write...

Страница 42: ...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 write...

Страница 43: ...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 write...

Страница 44: ...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 write...

Страница 45: ...N B D I A G R A M S H O W S E L E C T R O D E P O S I T I V E T O C H A N G E P O L A R I T Y T U R N P O W E R O F F R E V E R S E E L E C T R O D E A N D W O R K C A B L E S A T P O W E R S O U R C...

Страница 46: ...6 s o u r c e a n d p o s i t i o n t h e s w i t c h o n w i r e f e e d e r i f e q u i p p e d t o p r o p e r p o l a r i t y A l s o r e f e r t o n o t e N F N B N C 1 4 P I N R E C E P T A C L...

Страница 47: ...r i p N o t e t h a t t h i s i s n o t t h e p r e f e r r e d c o n n e c t i o n b e c a u s e i t a d d s e r r o r s e p a r a t e f r o m t h e w e l d i n g w o r k l e a d c i r c u i t a n d...

Страница 48: ...o p e r m i t t h e i n c h d o w n b u t t o n t o o p e r a t e T h i s j u m p e r h o w e v e r w i l l d i s a b l e t h e c o l d s t a r t i n g a u t o s t o p f e a t u r e o f t h e a u t o...

Страница 49: ...l t a g e P C b o a r d T h i s j u m p e r h o w e v e r w i l l d i s a b l e t h e p e r m i t t i n g o n l y H o t S t a r t i n g t e c h n i q u e s t o b e u s e d C o l d S t a r t i n g A u...

Страница 50: ...N O F D H 1 0 O R L N 1 0 T O T H E D C 6 0 0 V R D P O W E R S O U R C E W I T H 1 4 P I N A M P H E N O L R E F E R T O P O W E R S O U R C E O P E R A T I N G M A N U A L F O R L I N C O L N W I R...

Страница 51: ...I M E N S I O N W I L L V A R Y W I T H P O S I T I O N O F H A N D L E D I M E N S I O N P R I N T W I T H K 8 1 7 P U N D E R C A R R I A G E 1 1 1 2 1 7 7 5 3 8 0 0 5 9 0 4 7 5 LOCATION OF BASE MO...

Страница 52: ...O U N T I N G H O L E S 2 9 9 3 9 4 3 2 5 2 3 2 8 2 2 2 5 1 1 1 2 2 7 5 0 7 1 1 5 4 9 1 4 9 8 9 D I M E N S I O N P R I N T W I T H K 8 4 2 U N D E R C A R R I A G E D C 6 0 0 V R D 6 18 93C 36 12 M15...

Страница 53: ...h 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 54: ...te 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 mentac...

Страница 55: ...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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