Lincoln Electric SVM188-A Service Manual
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Lincoln Electric SVM188-A Service Manual

Lincoln Electric SVM188-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
SVM188-A
October, 2008
DC-600
Above Code 10580
For use with machine code numbers:
Safety Depends 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 part.
DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT.
And,
most importantly, think before you
act and be careful.

SERVICE MANUAL

Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales 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

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Summary of Contents for Lincoln Electric SVM188-A

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM188-A October, 2008 DC-600 Above Code 10580 For use with machine code numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety increased by proper installation .
  • Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX RETURN TO MAIN MENU Page Safety ................i-iv Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .

  • Page 10: Technical Specifications

    TECHNICAL SPECIFICATIONS – DC-600 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 Duty Cycle 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle Output Range 70A/13V-780A/44V (CV) 90A/24V-780A/44V (CC) RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT HERTZ VOLTAGE / FREQUENCY 50/60...

  • Page 11: Safety Precautions

    Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shut- downs.

  • Page 12: Electrical Input Connections

    Rating Plate located on the Case Back Assembly. Input power supply entry is through the hole in the Case Back Assembly. See Figure A.2 for the location of the machine’s input cable entry opening,...

  • Page 13: Reconnect Procedure

    Failure to follow these instructions can cause immediate failure of components within the machine. When powering welder from a generator be sure to turn off welder first, before generator is shut down, in order to prevent damage to the welder ------------------------------ CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
  • Page 14 CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ) LINES CONTACTOR INPUT PILOT LINKS TRANSF. CONNECTION FOR 380 VOLTS, 50 OR 60 HZ. LINES CONTACTOR INPUT PILOT LINKS TRANSF. CONNECTION FOR 220 VOLTS, 50 OR 60 HZ. LINES CONTACTOR INPUT PILOT LINKS...
  • Page 15 SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE LINES INPUT CONTACTOR FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines INSTALLATION 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2.

  • Page 16: Output Connections

    OUTPUT CONNECTIONS See Table A.1 for recommended DC-600 cable sizes for combined lengths of electrode and work cables. DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable ELECTRODE, WORK AND #21 LEAD Cable Length Lengths up to 150 ft. (46m) 150 ft.(46m) to 200 ft (61m) 200 ft.(61m) to 250 ft.(76m) CONNECTIONS...

  • Page 17: Auxiliary Power And Control Connections

    AUXILIARY POWER AND CONTROL CONNECTIONS Located at the left side of the front of the welder behind a hinged cover is a 115VAC duplex receptacle for aux- iliary power (60 Hertz Models only). On the right side of the case front is a 14 Pin MS type receptacle for con- nection of auxiliary equipment such as wire feeders.
  • Page 18 A-10 NOTES A-10 DC-600...
  • Page 19 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 20: Operation

    • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not use AC welder if your cloth- ing, gloves or work area is damp or if working on, under or inside work- piece.

  • Page 21: General Description

    • Input line voltage compensation to provide an essentially constant output. • SCR electronically controlled welder output pro- vides extra long life, especially for highly repetitive welding applications. • Solid state 2 and 4 circuit for extra long life.

  • Page 22: Welding Capability

    WELDING CAPABILITY The DC-600 has the following Output and Duty Cycle based on operation for a 10 minute period: 600 Amps, 44 Volts at 100% 680 Amps, 44 Volts at 60% 750 Amps, 44 Volts at 50% MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT Input POWER ON/OFF Switch SYMBOL MEANING...

  • Page 23: Meaning Of Graphical Symbols On Rating Plate

    MEANING GRAPHICAL SYMBOLS ON RATING PLATE (LOCATED ON CASE BACK) Designates welder complies with National Electrical Manufacturers NEMA EW 1 (100%) Association requirements EW 1 Class I with 100% duty cycle at 600Amps output. Three Phase Input Power 3 Phase transformer with recti-...

  • Page 24: Auxiliary Power In Ms - Receptacle

    This welder has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambi- ent temperatures. When the welder is subjected to an overload or loss of cooling, a thermostat will open. The input contactor will open and remain open until the machine cools;...

  • Page 25: Operating Steps

    You can use carbon rods up to 3/8" in diameter at currents as high as 750 amps with excellent arc control. The welder protection circuit protects the machine from extremely high short cir- cuiting pulses.

  • Page 26: Na-3 Automatic Wire Feeder

    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-3 Mode switch is in the CV or CC mode position. Some earlier models are capable of cold starting only in the CC mode position.
  • Page 27 3. Run a test weld. Set proper current, voltage, and travel speed. • For the best starting performance, the NA-3 Open Circuit Voltage Control and Voltage Control setting should be the same. Set the Inch Speed Control for the slowest inch speed possible. •...
  • Page 28 B-10 NOTES B-10 DC-600...
  • Page 29 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Factory Installed Equipment .

  • Page 30: Automatic Wire Feeder

    For easy moving of the machine, optional undercar- riages are available with polyolefin wheels (K817P) or a platform undercarriage (K842) with mountings for two gas cylinders at rear of welder. Paralleling Kit (K1611-1) Permits paralleling of two DC-600's for welding cur- rents of up to 1200 amps, 100% duty cycle.
  • Page 31 The MULTI-PROCESS SWITCH has two sets of output terminals. You connect the wire feeder unit 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.
  • Page 32 12. Connect stick or air/carbon arc electrode and work cable. See Figure C.2. • Insert the electrode and work cables through the strain relief loop on the right side (facing the front of the machine) of the DC-600. • Connect the electrode cable to the "Positive" ter- minal on the right side of the MULTI-PROCESS SWITCH.
  • Page 33 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 34: Routine And Periodic Maintenance

    SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE 1. Disconnect input AC power supply lines to the machine before performing periodic maintenance, tightening, cleaning, or replacing parts. Perform the following daily: 1. Check that no combustible materials are in the welding or cutting area or around the machine.
  • Page 35 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 36: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 - INPUT AND TRANSFORMER CONTROL POWER TRANSFORMER SWITCH 115VAC • Pilot Light • Secondary Thermostat Primary Theromstat 1CR Coil CONTACTOR GENERAL DESCRIPTION The DC-600 is a three-phase, SCR controlled DC power source. It is capable of either constant current or constant voltage output.

  • Page 37: Control Board

    THEORY OF OPERATION FIGURE E.2 - FIRING BOARD,CONTROL BOARD AND RECTIFICATION CONTROL POWER TRANSFORMER SWITCH 115VAC • Pilot Light • Secondary Thermostat Primary Theromstat 1CR Coil CONTACTOR FIRING CIRCUIT, CONTROL CIR- CUIT AND RECTIFICATION RECTIFICATION The “neutrals” of the welding secondary windings in the main transformer are connected together, and the six starts are connected to the six Silicon Controlled Rectifier (SCR) assemblies to form a six-phase output.
  • Page 38 This welder has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambi- ent temperatures. When the welder is subjected to an overload or loss of cooling, a thermostat will open. The input contactor will open and remain open until the machine cools;...

  • Page 39: Scr Operation

    THEORY OF OPERATION SCR OPERATION A silicon controlled rectifier (SCR) is a three-terminal device used to control rather large currents to a load. acts very much When a gate signal is applied to the SCR, it is turned ON and there is current flow from anode to cathode. In the ON state the SCR acts like a closed switch.
  • Page 40 NOTES DC-600...
  • Page 41 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 42: How To Use Troubleshooting Guide

    TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and 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 this manual.

  • Page 43: Troubleshooting And Repair

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.
  • Page 44 Input contactor (CR1) chatters. 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...

  • Page 45: Troubleshooting Guide

    (Output Terminals Switch ON). 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...

  • Page 46: Pc Board Troubleshooting Guide

    "hot". 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 47 Machine has minimum output and no control. 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 48 Poor arc characteristics in all processes. 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 49 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.
  • Page 50 F-10 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING GUIDE (continued) LED5 LED3 LED4 LED6 FIRING BOARD 1. With DC-600 set for the Test Conditions all ten LEDs on the Firing Board should be lit. 2. LEDs 7, 8 & 9 indicate that the three 34vac sup- plies from the Main Transformer are present on the Firing Board.
  • Page 51 (CR-1) will open and the machine will shut down. The Power Switch must be turned OFF and back ON to reset the welder. See Protective Devices and Shutdown Circuits. 6. LED 5 indicates a DC control signal to the Firing Board is present at lead 231 (J2-pin5).
  • Page 52 F-12 NOTES F-12 DC-600...
  • Page 53 TROUBLESHOOTING AND REPAIR INTERNAL TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.
  • Page 54 F-14 TROUBLESHOOTING AND REPAIR INTERNAL TRIGGER CIRCUIT TEST (continued) LED5 LED6 PROCEDURE WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
  • Page 55 F-15 TROUBLESHOOTING AND REPAIR INTERNAL TRIGGER CIRCUIT TEST (continued) FIGURE F.4 - TERMINAL STRIPS AND AMPHENOL TS 2 TS 1 41 4 2 31 32 75 76 77 FIGURE F.5 - SIMPLIFIED TRIGGER DIAGRAM 10AMP CIRCUIT BREAKER To 42A at Main Transformer TERMINAL STRIP TS 2...
  • Page 56 F-16 NOTES F-16 DC-600...

  • Page 57: Firing Board Test

    F-17 TROUBLESHOOTING AND REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.
  • Page 58 F-18 TROUBLESHOOTING AND REPAIR FIRING BOARD TEST (continued) LED5 LED3 LED4 LED6 PROCEDURE WARNING ELECTRIC SHOCK • Do not touch electrically hot parts. 1. Disconnect the AC input power to the DC-600 machine. 2. Locate the firing board on the left side of the con- trol box.

  • Page 59: Control Board Test

    F-19 TROUBLESHOOTING AND REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.
  • Page 60 F-20 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) 2 (256) (291) 8 (290) 7 5 (231) (255) 6 LED3 LED1 1 (210) (222)12 LED2 LED6 PROCEDURE WARNING ELECTRIC SHOCK • Do not touch electrically hot parts. 1. Turn the POWER Switch ON. LEDs 1 and 3 should turn ON.

  • Page 61: Main Transformer Voltage Test

    TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER VOLTAGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.
  • Page 62 F-22 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER VOLTAGE TEST (continued) FIGURE F.8 - INPUT CONTACTOR AND RECONNECT PANEL PROCEDURE 1. Disconnect the main input power from the DC-600. 2. Inspect the input contactor, reconnect panel and primary leads to the main transformer for loose or faulty connections.
  • Page 63 F-23 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER VOLTAGE TEST (continued) FIGURE F.9 – TRANSFORMER SECONDARIES SECONDARY LEADS (6 PLACES) PROCEDURE 9. Test with an AC voltmeter for approximately 55 VAC from each of the six main transformer secondary leads to the common bus connected to the output choke.
  • Page 64 F-24 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER VOLTAGE TEST (continued) LED5 LED3 LED6 PROCEDURE WARNING ELECTRIC SHOCK • Do not touch electrically hot parts. 13. Remove the input power to the DC-600. Remove the screws from the control box cover and careful- ly lower the cover and locate plug J5 on the Firing Board.

  • Page 65: Control Transformer Test

    TROUBLESHOOTING AND REPAIR CONTROL TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.

  • Page 66: Input Contactor Test

    Input Access Door when installing the new transformer. If you do not have those instructions, call The Lincoln Electric Co. (1-888-935-3877) with the Code Number of the DC-600 and the instructions can be faxed or e- mailed to you.
  • Page 67 F-27 TROUBLESHOOTING AND REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.
  • Page 68 F-28 TROUBLESHOOTING AND REPAIR INPUT CONTACTOR TEST (continued) CR 1 Contactor Coil Terminals Apply External 120vac Here Cover Plate Screws PROCEDURE VOLTAGE TEST 1. Disconnect the input power and remove the Input Access Panel from the rear of the machine 2.

  • Page 69: Scr Bridge Test

    F-29 TROUBLESHOOTING AND REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 this manual.
  • Page 70 F-30 TROUBLESHOOTING AND REPAIR SCR BRIDGE TEST(continued) FIGURE F.14 – SCR BRIDGE ASSEMBLY ANODE CATHODE REMOVE INSULATING PAINT PROCEDURE STATIC TEST 1. Disconnect the input power from the DC-600. 2. Remove the top and side panels and drop the nameplate to access the PC Boards. 3.
  • Page 71 F-31 TROUBLESHOOTING AND REPAIR SCR BRIDGE TEST(continued) PROCEDURE ACTIVE TEST 1. With the circuit shown in Figure F.17. One 6-volt lantern battery can be used. Set the voltmeter scale low, at approximately 0-5 volts or 0-10 volts. a. Test the voltage level of the battery. Short leads (A) and (C).
  • Page 72 F-32 TROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE – NO LOAD This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal divi- sion represents 2 milliseconds in time.
  • Page 73 F-33 TROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MAXIMUM OUTPUT SETTING – NO LOAD This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal divi- sion represents 2 milliseconds in time.
  • Page 74 F-34 TROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MINIMUM OUTPUT SETTING – NO LOAD This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal divi- sion represents 2 milliseconds in time.
  • Page 75 F-35 TROUBLESHOOTING AND REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED CONSTANT VOLTAGE INNERSHIELD MODE This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal divi- sion represents 2 milliseconds in time.
  • Page 76 F-36 TROUBLESHOOTING AND REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MAXIMUM OUTPUT SETTING – NO LOAD This is the typical DC open circuit voltage waveform. The machine was in an open circuit condition (no load) and operating properly. Note that each vertical division represents 2 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 77 F-37 TROUBLESHOOTING AND REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD ONE OUTPUT SCR NOT FUNCTIONING This is NOT the typical DC open cir- cuit voltage waveform. One output SCR is not functioning. Note the “gap” in the waveform. One SCR gate is disconnected to simulate an open or non-functioning output SCR.
  • Page 78 F-38 NOTES F-38 DC-600...
  • Page 79 F-39 TROUBLESHOOTING AND REPAIR F-39 INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT WARNING TEST DESCRIPTION MATERIALS NEEDED DC-600...
  • Page 80 F-40 TROUBLESHOOTING AND REPAIR INPUT CONTACTOR CLEANING/REPLACEMENT PROCEDURE (continued) CR 1 Contactor Coil Terminals Apply External 120vac Here Cover Plate Screws CLEANING PROCEDURE Figure F.18. WARNING NOTE: FIGURE F.16 – CONTACTOR L3 T3 L2 T2 L1 T1 CONTACTOR REPLACEMENT PROCEDURE Diagram.
  • Page 81 F-41 TROUBLESHOOTING AND REPAIR REMOVAL AND REPLACEMENT PROCEDURE TEST DESCRIPTION MATERIALS NEEDED NOTE: If the Transformer and Rectifer both need to be replaced, perform the Transformer Removal and Replacement Procedure first to provide easier access to the rectifier assembly SCR RECTIFIER BRIDGE WARNING DC-600 F-41...
  • Page 82 SCR RECTIFIER BRIDGE SECONDARY LEAD (6 PLACES) MOUNTING BOLTS (4) OUTPUT SHUNT CONNECTION STRAP NOTE: Lincoln Electric does not recommend replacement of individual SCRs. In the event of a failure, the entire assembly should be replaced. DC-600 F-42 LEFT SIDE OF CHOKE...

  • Page 83: Replacement Procedure

    F-43 TROUBLESHOOTING AND REPAIR REMOVAL AND REPLACEMENT PROCEDURE (cont.) FIGURE F.18 – RECTIFIER REPLACEMENT Thread Forming Screw Plain Washer Insulator Bridge Mounting Bracket Insulator Rectifer Mounting Insulator Bracket Fig. 18 ‘A’ MOUNTING BOLTS (4) OUTPUT SHUNT CONNECTION STRAP REPLACEMENT PROCEDURE NOTE: Any instructions packaged with the replace- ment SCR Bridge assembly will supercede these instructions.
  • Page 84 F-44 NOTES F-44 DC-600...
  • Page 85 F-45 TROUBLESHOOTING AND REPAIR F-45 MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT WARNING TEST DESCRIPTION MATERIALS NEEDED DC-600...
  • Page 86 F-46 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.19 – TRANSFORMER REMOVAL CONTROL PANEL FIRING BOARD CONNECTORS (J-4 & J-5) OUTPUT SHUNT CONNECTION STRAP SECONDARY THERMOSTAT RESISTOR REMOVAL PROCEDURE NOTE: Pay close attention to the positioning of the brass and steel hex nuts for reassembly.
  • Page 87 F-47 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.20 – TRANSFORMER REMOVAL Thread Forming Screw Plain Washer Insulator Bridge Mounting Bracket Insulator Rectifer Mounting Insulator Bracket RECTIFIER MOUNTING (4 Places) REMOVAL PROCEDURE (cont.) NOTE: It is important that the twisted pair (feed- back leads) and the meter leads be recon- nected correctly to the Shunt.
  • Page 88 F-48 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT (continued) WELD REPLACEMENT PROCEDURE NOTE: Cover the transformer assembly with ‘damp’ shop cloths before performing Step 3 to prevent weld spatter from damaging the transformer. Figure F.18. FIGURE F.21 – CHOKE TIG WELD XXXXXXXXXXX Figure F.20.

  • Page 89: Retest After Repair

    F-49 TROUBLESHOOTING AND REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. Input volts/Phase/Hertz 208/3/60 230/3/60...
  • Page 90 F-50 NOTES F-50 DC-600...
  • Page 91 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 * NOTE: DC-600...
  • Page 92 G3506 ENGINEERING CONTROLLED REVISED GRAPHICS FOR RECONNECT PANEL. CHANGE DETAIL: MANUFACTURER: SINGLE VOLTAGE OVER 345 V. (EXCEPT 440 & 460V.) SUPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE RECONNECT PANEL INPUT TO PRIMARY COILS CONTACTOR DUAL EXCEPT 380/500V AND SINGLE VOLTAGE UNDER 346V. SUPPLY (SHOWN CONNECTED FOR LOW VOLTAGE) LINES...
  • Page 93 G3506-1 ENGINEERING CONTROLLED REVISED GRAPHICS FOR CR2. CHANGE DETAIL: MANUFACTURER: 230/460/575V N.G. (SHOWN CONNECTED FOR LOW VOLTAGE) SUPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE RECONNECT PANEL TO PRIMARY COILS INPUT CONTACTOR 18,17,16 15,14,13 N.G. N.G. T1 MAIN TRANSFORMER N.G. ALL PRIMARY LEADS TO RECONNECT...
  • Page 94 Printed by John Howell Printed at 10:20 on 08/15/2008 (month/day/year) Drawing Number- G3575 Revision- 12-17-99 Status- STANDARD This print is Current This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 95 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 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 96 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 97 Printed by John Howell Printed at 10:23 on 08/15/2008 (month/day/year) Drawing Number- G3741-1B1 Revision- 11-30-2001E Status- STANDARD This print is Current This diagram is for reference only. It may not be accurate for all machines covered by this manual.

This manual is also suitable for:

Dc-600

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