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ELECTRICAL DIAGRAMS

G-5

SCHEMATIC - CONTROL PC BOARD - 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

NOTE:

This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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Содержание SVM188-A

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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