Lincoln Electric IDEALARC DC-600 Service Manual
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Lincoln Electric IDEALARC DC-600 Service Manual

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IDEALARC
DC-600
®
For use with machines having Code Numbers:
8213; 8222; 8223; 8224; 8225; 8249; 8250; 8251; 8252; 8253; 8262; 8268; 8273; 8274; 8288; 8289; 8295; 8298; 8301;
8304; 8315; 8318; 8324; 8353; 8380; 8549; 8555; 8584; 8692; 8693; 8694; 8695; 8702; 8722; 8728; 8738; 8764; 8782;
8789; 8825; 8902; 8904; 8906; 8907; 8911; 8934; 8954; 8988; 9080; 9093; 9130; 9158; 9170; 9171; 9353; 9354; 9355;
9356; 9357; 9358; 9359; 9360; 9361; 9362; 9363; 9364; 9384; 9385; 9463; 9464; 9465; 9470; 9483; 9607; 9620; 9621;
9716; 9717; 9773; 9774; 9775; 9776; 9777; 9778; 9779; 9780; 9781; 9782; 9793; 9832; 9910; 10159; 10282; 10283;
10334; 10335; 10407; 10408
SERVICE MANUAL
SVM108-B
| Issue D ate11, Jul
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. IDEALARC DC-600 ® For use with machines having Code Numbers: 8213; 8222; 8223; 8224; 8225; 8249; 8250; 8251; 8252; 8253; 8262; 8268; 8273; 8274; 8288; 8289; 8295; 8298; 8301; 8304;...
  • 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 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-iv Installation .

  • Page 7: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 8 INSTALLATION TECHNICAL SPECIFICATIONS - IDEALARC DC-600 INPUT - THREE PHASE ONLY Input Current at Rated Output Standard Voltage 208/230/416/460/575/3/60 125/113/63/57/45 RATED OUTPUT Duty Cycle AMPS Volts at Rated Amps 100% OUTPUT Auxiliary Power Mode Maximum Open Current Circuit Voltage Range...

  • Page 9: Installation

    INSTALLATION Read entire Installation Section before installing DO NOT stack the IDEALARC DC-600 on another type the IDEALARC DC-600. of machine. Follow these guidelines when stacking: SAFETY PRECAUTIONS 1. Select a firm, level surface capable of sup- WARNING porting total...

  • Page 10: Electrical Input Connections

    INSTALLATION ELECTRICAL INPUT CONNECTIONS INPUT POWER SUPPLY CONNECTIONS A qualified electrician should connect the input power Before installing the machine check that the input sup- supply leads. ply voltage, phase, and frequency are the same as the voltage, phase, and frequency as specified on the 1.

  • Page 11: Reconnect Procedure

    INSTALLATION RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different voltage, remove input power and change the position of the reconnect board on the Reconnect Panel. Multiple voltage machines are shipped connected to Follow The Input Connection Diagram located on the the highest input voltage listed on the machine’s rating inside of Case Back Input Access Door.
  • Page 12 INSTALLATION FIGURE A.5 - Reconnect Panel Board Positions for 220/380/440 VAC Machines CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ) 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT LINES LEAST 600 VOLT INSULATION.
  • Page 13 INSTALLATION FIGURE A.7 - Reconnect Panel Board Positions for Single Voltage Machines 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. LINES 3.

  • Page 14: Output Connections

    INSTALLATION OUTPUT CONNECTIONS See Table A.1 for recommended IDEALARC DC-600 cable sizes for combined lengths of electrode and work cables. TABLE A.1 IDEALARC DC-600 Cable Sizes for Combined Lengths of Electrode and Work Cable (Copper) at 100% Duty Cycle Cable Length...

  • Page 15: Connection For Semi-Automatic/Automatic Wire Feeder Control

    Tractors • LT-56 NOTE: To use the IDEALARC DC-600 for both stick welding / air/carbon arc cutting, AND semi-automatic / Connection for Stick Welding and Air/Carbon automatic welding, the optional Multi-Process Switch Arc Cutting Operation (K804) must be used.
  • Page 16 NOTES A-10 A-10 IDEALARC ® DC-600...
  • Page 17 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Operating Instructions .

  • Page 18: Operation

    OPERATION OPERATING INSTRUCTIONS Read and understand entire section before operating machine. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves.

  • Page 19: General Description

    OPERATION GENERAL DESCRIPTION OPERATIONAL FEATURES AND CONTROLS The IDEALARC DC-600 is an SCR controlled three phase welding and cutting power source. It uses a sin- The IDEALARC DC-600 comes with the following gle range potentiometer to control: standard controls: •...

  • Page 20: Welding Capability

    WELDING CAPABILITY The IDEALARC DC-600 has the following duty cycle ratings: If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal operating temperature.

  • Page 21: Controls And Settings

    OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the Case Front Assembly of the IDEALARC DC-600. See Figure B.1 for the location of each control. FIGURE B.1 - CONTROL PANEL KEYS AMMETER 8. VOLTMETER WELDING MODE...

  • Page 22: Operating Steps

    OPERATION REMOTE CONTROL OF MACHINE OPERATING STEPS OPERATION The following procedures are for using the IDEAL- ARC DC-600 in the local control mode of operation. The toggle switch on the control panel labeled “Output For remote control of the machine, see the Remote Control at DC-600”...
  • Page 23 FEEDERS is to set the Open Circuit Voltage Control to # 6. When using the IDEALARC DC-600 with semi-auto- NOTE: The open circuit voltage of the matic or automatic wire feeding equipment and for...
  • Page 24 OPERATION ARC STRIKING WITH IDEALARC DC-600 AND THE 6. Establish the correct arc striking procedure with NA-3 START BOARD the NA-3 Start Board timer set at maximum. When electrical strikeouts exceed 1 3/4” (44.4mm) an a. For the best starting performance, the NA-3...
  • Page 25 To use the LN-8 Semi-Automatic Wire Feeder with WIRE FEEDER IDEALARC DC-600 When using the IDEALARC DC-600 with the NA-5 wire 1. Set the IDEALARC DC-600 WELDING MODE feeder, set the controls on the IDEALARC DC-600 as SWITCH to either CV Innershield mode or CV...
  • Page 26 NOTES B-10 B-10 IDEALARC ® DC-600...
  • Page 27 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Options/Accessories .

  • Page 28: Accessories

    Follow these steps to install the MULTI-PROCESS SWITCH: MULTI-PROCESS SWITCH 1. Confirm that the IDEALARC DC-600 ON/OFF PUSH BUTTON is in the OFF position. The MULTI-PROCESS SWITCH gives you the ability 2. Disconnect main AC input power to the IDE- •...
  • Page 29 See Figure C.3. 11. Connect the right cable from the MULTI- PROCESS SWITCH (facing the front of the machine) to the IDEALARC DC-600 positive (+) 7. Route the MULTI-PROCESS SWITCH control leads through the strain-relief box connectors and output terminal.

  • Page 30: Undercarriage (K817P, K842

    See connection diagrams for details. UNDERCARRIAGE (K817P, K842) 14. Connect wire feeder control cable to the terminal The IDEALARC DC-600 is designed for use with the strip of the IDEALARC DC-600. Lincoln K817, K817R, or K842 Undercarriage. Complete installation instructions are included with the NOTE: Connect the control cable ground lead to undercarriage.
  • Page 31 1. Disconnect main AC input power to the IDEALARC DC-600. NOTE: The connection diagram shown in Figure C.5 shows the electrode connected for positive 2. Set IDEALARC DC-600 ON/OFF PUSH BUTTON polarity. To change polarity: to OFF. a. Set the IDEALARC DC-600 ON/OFF PUSH BUTTON to OFF 3.
  • Page 32 An S-16586- X remote voltage sensing work DC-600. lead is available for this purpose. 2. Set the IDEALARC DC-600 ON/OFF PUSH  c. Keep the # 21 lead electrically separate from BUTTON to OFF. the work cable circuit and connection.
  • Page 33 CABLE 1. Disconnect AC input power to the IDEALARC DC- TO INPUT CABLE 600. 2. Set the IDEALARC DC-600 ON/OFF PUSH  BUTTON to OFF. 21 4 2 31 32 75 76 77 80 81 3. Connect the wire feeder control cable leads to the IDEALARC DC-600 terminal strip as shown in Figure C.7.
  • Page 34 IDEALARC DC-600. c. Keep the #21 lead electrically separate from the work cable circuit and connection. 2. Set the IDEALARC DC-600 ON/OFF PUSH  BUTTON to OFF. d. Tape the #21 lead to work cable for ease of 3. Connect the wire feeder control cable leads to the use.
  • Page 35 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
  • Page 36 MAINTENANCE SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE WARNING 1. Disconnect input AC power supply lines to the machine before performing periodic maintenance, ELECTRIC SHOCK CAN KILL. tightening, cleaning, or replacing parts. Figure D.1 Only qualified personnel should perform this maintenance. Perform the following daily: Turn the input power OFF at the 1.
  • Page 37 MAINTENANCE FIGURE D.1 - MAJOR COMPONENT LOCATION IDEALARC ® DC-600...
  • Page 38 NOTES IDEALARC ® DC-600...
  • Page 39 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Input Line Voltage, Contactor and Main Transformer .
  • Page 40 THEORY OF OPERATION FIGURE E.2 Input Line Voltage, Contactor and Main Transformer OUTPUT CONTROL 115 VAC CONTROL TRANSFORMER PROTECTION DEVICES & FAULT PROTECTION CIRCUTS 115 VAC MODE CONTACTOR SWITCH HOLD-IN CONTROL FIRING BOARD BOARD MAIN TRANSFORMER PILOT RELAY POSITIVE TERMINAL SHUNT PILOT RELAY...
  • Page 41 THEORY OF OPERATION FIGURE E.3 Output, Rectification, Control and Feedback OUTPUT CONTROL 115 VAC CONTROL TRANSFORMER PROTECTION DEVICES & FAULT PROTECTION CIRCUTS 115 VAC MODE CONTACTOR SWITCH HOLD-IN CONTROL FIRING BOARD BOARD MAIN TRANSFORMER PILOT RELAY POSITIVE TERMINAL SHUNT PILOT RELAY CONTACTOR TERMINAL...
  • Page 42 THEORY OF OPERATION FIGURE E.4 Protection Devices and Circuits (Contactor Hold-In) OUTPUT CONTROL 115 VAC CONTROL TRANSFORMER PROTECTION DEVICES & FAULT PROTECTION CIRCUTS 115 VAC MODE CONTACTOR SWITCH HOLD-IN CONTROL FIRING BOARD BOARD MAIN TRANSFORMER PILOT RELAY POSITIVE TERMINAL SHUNT PILOT RELAY CONTACTOR...
  • Page 43 THEORY OF OPERATION FIGURE E.5 SCR Operation INPUT CATHODE OUTPUT ANODE GATE NOTE: AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED. GATE SCR OPERATION A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the device used to control rather large currents to a load.
  • Page 44 NOTES IDEALARC ® DC-600...
  • Page 45 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 46: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 47: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - 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- CAUTION er failure analysis.
  • Page 48 6. The Control board may be faulty. Replace. CAUTION 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. IDEALARC ®...
  • Page 49 DC600. CAUTION 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. IDEALARC ®...
  • Page 50 6. Perform SCR Output Bridge Test. CAUTION 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. IDEALARC ®...
  • Page 51 6. Perform SCR Output Bridge Test. CAUTION 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. IDEALARC ®...
  • Page 52 Output Bridge Test. CAUTION 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. IDEALARC ®...
  • Page 53 CAUTION 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. IDEALARC ®...
  • Page 54 See wiring diagram. CAUTION 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. IDEALARC ®...
  • Page 55 4. The control board may be faulty. Replace. CAUTION 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. IDEALARC ®...
  • Page 56 5. The control board may be faulty. Replace. CAUTION 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. IDEALARC ®...

  • Page 57: Control Transformer (T2) Voltage Test

    CONTROL TRANSFORMER (T2) VOLTAGE TEST WARNING Service and repair should be performed only by 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 TROUBLESHOOTING AND REPAIR F-14 F-14 CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.1 - Control Transformer and Lead Locations PROCEDURE 1. Disconnect main AC input power to the machine. 5. Locate Control Transformer leads X1 and X2. 2. Remove the Top and Case Sides. a.
  • Page 59 TROUBLESHOOTING AND REPAIR F-15 F-15 CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) (continued) FIGURE F.2 - Control Transformer X1 and X2 Test Connections CONTROL INPUT TRANSFORMER CONTACTOR (CR1) METER INSULATED PROBE ALLIGATOR CLIP CABLE LEFT SIDE OF LIFT BAIL ASSEMBLY CASE BACK 6.
  • Page 60 NOTES F-16 F-16 IDEALARC ® DC-600...

  • Page 61: Main Transformer (T1) Voltage Test

    MAIN TRANSFORMER (T1) VOLTAGE TEST WARNING Service and repair should be performed only by 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 TROUBLESHOOTING AND REPAIR F-18 F-18 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.3 - Input Contactor, Reconnect Panel, and Primary Leads to Main Transformer Locations PROCEDURE 1. Set ON/OFF PUSH BUTTON to OFF 5. Set the ON/OFF PUSH BUTTON to ON. 2.
  • Page 63 TROUBLESHOOTING AND REPAIR F-19 F-19 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.4 - Main Secondary Lead Test Points 7. Read meter. 9. Read meter. a. If proper voltage is present for all three a. If proper voltage is present for all three phases, proper main AC input voltage is phases, the Contactor is working properly.
  • Page 64 TROUBLESHOOTING AND REPAIR F-20 F-20 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) Figure F.5 - Phase Angle Windings Test Points and Terminal Board location From Lead # To Lead # Expected VAC #203 #204 75 VAC #205 #206 75 VAC #207 #208 75 VAC 11.
  • Page 65 TROUBLESHOOTING AND REPAIR F-21 F-21 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.6 - Phase Angle Windings Test Points and Firing Board Location FIRING BOARD CONTROL BOARD TERMINAL STRIP PIN 9 PIN 4 (LEAD #207) (LEAD #204) PIN 8 PIN 3 (LEAD #208) (LEAD #206) PIN 7...
  • Page 66 NOTES F-22 F-22 IDEALARC ® DC-600...

  • Page 67: Firing Board Test

    FIRING BOARD TEST WARNING Service and repair should be performed only by 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 TROUBLESHOOTING AND REPAIR F-24 F-24 FIRING BOARD TEST (continued) TEST PROCEDURE FOR NOR- MAL FIRING BOARD OPERATION 1. Disconnect main AC input power to the IDE- ALARC DC-600. 2. Locate the Firing Board on the left side of Control Box facing the machine. 3.
  • Page 69 TROUBLESHOOTING AND REPAIR F-25 F-25 FIRING BOARD TEST (continued) FIGURE F.7 - Firing Board LED and Molex Plug Locations IDEALARC ® DC-600...
  • Page 70 TROUBLESHOOTING AND REPAIR F-26 F-26 FIRING BOARD TEST (continued) TABLE F.1 - LED 7, 8 and 9 Check List THEN LED 7 is ON AC power is being supplied to the Firing Board from leads #203 and #204 connected to the phase angle winding in the Main Transformer.
  • Page 71 TROUBLESHOOTING AND REPAIR F-27 F-27 FIRING BOARD TEST (continued) FIGURE F.8 - Jumper Wire Connection Points 7. Locate the terminal strip directly below the Control Box. 8. Connect a jumper wire from terminal #2 to ter- minal #4 on the terminal strip. See Figure F.8. NOTE: This jumper connection...
  • Page 72 TROUBLESHOOTING AND REPAIR F-28 F-28 FIRING BOARD TEST (continued) 9. Locate LEDs 1 to 6. Each LED should glow 13. Test for 10 VDC to 13 VDC between leads with equal brightness. #231 and #215 on the Firing Board in CV NOTE: LEDs 1 to 6 indicate that the gate firing mode.
  • Page 73 TROUBLESHOOTING AND REPAIR F-29 F-29 FIRING BOARD TEST (continued) 14. Test for approximately 5.8 VDC between leads 15. Test Output Pilot Control Relay (CR4) for prop- #231 and # 215 on the Firing Board in VV (CC) er operation by removing and replacing repeat- mode.
  • Page 74 NOTES F-30 F-30 IDEALARC ® DC-600...

  • Page 75: Control Board Test

    CONTROL BOARD TEST WARNING Service and repair should be performed only by 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 76 TROUBLESHOOTING AND REPAIR F-32 F-32 CONTROL BOARD TEST (continued) FIGURE F.9 - Control Board LED Locations TABLE F.2 - LED Function During Normal Operation LED # FUNCTION DURING NORMAL OPERATION (Machine is ON) Glows to display that 115 VAC is present between leads #255 and #256 at Plug J2 on Control Board.
  • Page 77 TROUBLESHOOTING AND REPAIR F-33 F-33 CONTROL BOARD TEST (continued) FIGURE F.10 - LED 1 Test Points CONTROL BOARD If LED 1 Does Not Glow When ON/OFF PUSH If 115 VAC is present AND LED 1 does not BUTTON is Set to ON glow, the Control Board may be faulty.
  • Page 78 TROUBLESHOOTING AND REPAIR F-34 F-34 CONTROL BOARD TEST (continued) FIGURE F.11 - LED 2 Open Circuit Voltage Test Points If LED 2 Does Not Light When Machine is 3. Read meter. Operating Under Load (or terMinals #2 and #4 are jumpered together on the terminal strip). a.
  • Page 79 TROUBLESHOOTING AND REPAIR F-35 F-35 CONTROL BOARD TEST (continued) b. If the open circuit voltage is not present at If LED 5 Does Not Glow and Vary in Brightness the Control Board, then check leads #222 Under the Following Conditions and #215 for loose or faulty wiring connec- tions.
  • Page 80 NOTES F-36 F-36 IDEALARC ® DC-600...

  • Page 81: Static Scr Test

    STATIC SCR TEST WARNING Service and repair should be performed only by 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 82 TROUBLESHOOTING AND REPAIR F-38 F-38 STATIC SCR TEST (continued) PROCEDURE 2. Disconnect all Molex Plugs from the Firing 1. Disconnect main AC input power to the Board and Control Board. See Figure F.12. machine. FIGURE F.12 - Firing Board and Control Board Molex Plug Locations IDEALARC ®...
  • Page 83 TROUBLESHOOTING AND REPAIR F-39 F-39 STATIC SCR TEST (continued) FIGURE F.13 - Heat Sink Test Points 3. Remove the red insulating paint from the heat 4. Test for high or infinite resistance from the sink test points. See FIGURE F.13. anode to the cathode of SCR 1.
  • Page 84 TROUBLESHOOTING AND REPAIR F-40 F-40 STATIC SCR TEST (continued) FIGURE F.14 - SCR 1 Test Points 5. Test for high or infinite resistance from the 7. Retest SCR 1 with the snubber circuit discon- cathode to the anode of SCR 1 by reversing nected.

  • Page 85: Active Scr Test

    ACTIVE SCR TEST WARNING Service and repair should be performed only by 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 86 TROUBLESHOOTING AND REPAIR F-42 F-42 ACTIVE SCR TEST (continued) PROCEDURE 1. Disconnect main AC input power to the 2. Disconnect all Molex Plugs from the Firing machine. Board and Control Board. See Figure F.15. FIGURE F.15 - Firing Board and Control Board Molex Plug Locations IDEALARC ®...
  • Page 87 TROUBLESHOOTING AND REPAIR F-43 F-43 ACTIVE SCR TEST (continued) FIGURE F.16 - Heat Sink Test Points. 3. Remove the red insulating paint from the heat sink NOTE: DO NOT DISASSEMBLE THE HEAT SINKS. test points. See FIGURE F.16. FIGURE F.17 - SCR Tester Circuit and SCR connections. 4.
  • Page 88 TROUBLESHOOTING AND REPAIR F-44 F-44 ACTIVE SCR TEST (continued) 5. Connect the Tester to the SCR 1 as shown in 10. Open switch SW-1. Figure F.17. 11. Reconnect the Tester leads. See Figure F.17. a. Connect Tester lead (A) to the anode. a.
  • Page 89 TROUBLESHOOTING AND REPAIR F-45 F-45 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE - NO LOAD 0 volts 50 volts This is the typical DC open circuit voltage waveform generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
  • Page 90 TROUBLESHOOTING AND REPAIR F-46 F-46 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MAXIMUM OUTPUT SETTING - NO LOAD 0 volts 50 volts This is the typical DC open circuit voltage waveform generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
  • Page 91 TROUBLESHOOTING AND REPAIR F-47 F-47 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MINIMUM OUTPUT SETTING - NO LOAD LINE 0 volts 20 volts This is the typical DC open circuit voltage waveform generated from a properly operat- ing machine. Note that each vertical division represents 20 volts and that each horizontal division represents 2 milliseconds in time.
  • Page 92 TROUBLESHOOTING AND REPAIR F-48 F-48 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED CONSTANT VOLTAGE INNERSHIELD MODE CH 1 0 volts 20 volts This is the typical DC open circuit voltage waveform generated from a properly operat- ing machine. Note that each vertical division represents 20 volts and that each horizontal division represents 2 milliseconds in time.
  • Page 93 TROUBLESHOOTING AND REPAIR F-49 F-49 TYPICAL SCR GATE VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MAXIMUM OUTPUT SETTING - NO LOAD 0 volts 2 volts This is the typical SCR gate pulse voltage waveform. The machine was in an open cir- cuit condition (no load) and operating proper- ly.
  • Page 94 TROUBLESHOOTING AND REPAIR F-50 F-50 ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD ONE OUTPUT SCR NOT FUNCTIONING CH 1 0 volts 20 volts This is NOT the typical DC output voltage waveform. One output SCR is not function- ing. Note the “gap” in the waveform. One SCR gate is disconnected to simulate an open or non-functioning output SCR.

  • Page 95: Input Contactor (Cr1) Cleaning/Replacement

    INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT WARNING Service and repair should be performed only by 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 96 TROUBLESHOOTING AND REPAIR F-52 F-52 INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) CLEANING PROCEDURE CONTACTOR REPLACEMENT PROCEDURE 1. Disconnect main AC input power supply to the machine. 1. Disconnect main AC input power supply to the machine. 2. Locate and get access to the Input Contactor (CR1) in the Input Box.

  • Page 97: Scr/Scr Output Bridge

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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 98 TROUBLESHOOTING AND REPAIR F-54 F-54 SCR / SCR OUTPUT BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 - Individual Heat Sink Removal NOTE: If it is necessary to remove and replace only 3. Disconnect the transformer secondary lead to the one or two individual SCRs and they are easy anode of the heat sink assembly using 1/2"...
  • Page 99 TROUBLESHOOTING AND REPAIR F-55 F-55 SCR / SCR OUTPUT BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) 5. Remove the four thru bolts and associated nuts 6. Install the replacement SCR Heat Sink in reverse and washers holding the SCR heat sink to the order of removal.
  • Page 100 TROUBLESHOOTING AND REPAIR F-56 F-56 SCR / SCR OUTPUT BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) 5. Remove the bolt that connects the Shunt 8. Lift the SCR Bridge Assembly straight up and Assembly (heavy copper) lead to the SCR out of the machine being sure that no leads Bridge Assembly.

  • Page 101: Lift Bail Removal (Including Main Transformer, Choke And Output Bridge Assembly

    CHOKE AND OUTPUT BRIDGE ASSEMBLY) WARNING Service and repair should be performed only by 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 102 TROUBLESHOOTING AND REPAIR F-58 F-58 LIFT BAIL REMOVAL (INCLUDING MAIN TRANSFORMER, CHOKE AND OUTPUT BRIDGE ASSEMBLY) (continued) FIGURE F.21 - Lift Bail Removal LIFT BALE RESISTOR SHUNT 1. Disconnect gate leads. 3. Disconnect the leads from the secondary ther- mostat. See wiring diagram. a.
  • Page 103 TROUBLESHOOTING AND REPAIR F-59 F-59 LIFT BAIL REMOVAL (INCLUDING MAIN TRANSFORMER, CHOKE AND OUTPUT BRIDGE ASSEMBLY) (continued) 5. Disconnect leads #215 and #216 from Relay 13. Disconnect lead #272 from Input Contactor CR4 and lead #231 from the splice connector. (CR1) coil.
  • Page 104 NOTES F-60 F-60 IDEALARC ® DC-600...

  • Page 105: Transformer Removal From Lift Bail Assembly

    TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY PROCEDURE WARNING Service and repair should be performed only by 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 106 TROUBLESHOOTING AND REPAIR F-62 F-62 TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY PROCEDURE (continued) FIGURE F.22 Transformer Bail Assembly Removal 1. Remove the four screws that connect the top 4. Lift the Output Choke straight up until the and side baffles around the Output Choke through bolts are cleared and then move it out using a 3/8"...
  • Page 107 TROUBLESHOOTING AND REPAIR F-63 F-63 TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY PROCEDURE (continued) 6. Remove the four self-tapping bolts that hold TRANSFORMER DISASSEMBLY the Lift Bail to the transformer base using a 9/16" socket wrench. See Figure F.22. 1. Identify and label all leads to the transformer. NOTE: There is one bolt on each side of the trans- 2.
  • Page 108 TROUBLESHOOTING AND REPAIR F-64 F-64 TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY PROCEDURE (continued) Figure F.23 Transformer Coil Removal PRIMARY TRANSFORMER COILS INSULATION WEDGES E IRON SECONDARY TRANSFORMER COILS THROUGH BOLT 1. Label and cut leads to the coil(s) being 4. Replace the coil(s). removed.
  • Page 109 TROUBLESHOOTING AND REPAIR F-65 F-65 RETEST AFTER 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 IDLE AMPS AND WATTS Input volts/Phase/Hertz Maximum Idle Amps...
  • Page 110 TROUBLESHOOTING AND REPAIR F-66 F-66 RETEST AFTER REPAIR (Continued) 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. MAXIMUM ACCEPTABLE OUTPUT VOLTAGE —...
  • Page 111 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (Codes 9773, 9775, 9776, 9778, 9779, 9780, 9781, 9782, 9910, 10282, 10283, 10410, 10411, 10412, 10413, 10414, 10416, 10417) (L8750) .
  • Page 112 ELECTriCaL DiaGrams WiriNG DiaGram - (CODEs 9773, 9775, 9776, 9778, 9779, 9780, 9781, 9782, 9910,10282, 10283, 10410, 10411, 10412, 10413, 10414, 10416, 10417) (L8750) 380/500V. & 460/575V. SINGLE VOLTAGE OVER 300 V. (SHOWN CONNECTED OUTPUT SUPPLY SUPPLY (EXCEPT 380V.) FOR LOW VOLTAGE) LINES LINES CONTROL...
  • Page 113 ELECTriCaL DiaGrams WiriNG DiaGram - (CODEs 9774, 9777, 10419) (L8751) SINGLE VOLTAGE 440&460v OUTPUT CONTROL N.C. T2 H1 START SUPPLY STOP LINES TO GROUND PER NATIONAL ELECTRICAL 21 4 2 31 32 CODE 271A T.S.3 T.S.2 LEGEND PILOT C7 .05 +.05 MFD LIGHT D1 INPUT CONTACTOR BRIDGE (ONLY 272A...
  • Page 114 ELECTriCaL DiaGrams WiriNG DiaGram - (CODE 9793) (L8752) WIRING DIAGRAM (230/460/575) 230/460/575V. N.A. OUTPUT (SHOWN CONNECTED CONTROL FOR LOW VOLTAGE) SUPPLY LINES TO GROUND PER N.C. T2 H1 NATIONAL START STOP ELECTRICAL CODE RECONNECT PANEL CR 1 TO PRIMARY COILS 21 4 2 31 32 15,14,13...
  • Page 115 ELECTriCaL DiaGrams WiriNG DiaGram - (CODE 9832) (L7779) OUTPUT 380/500V. & 460/575V. CONTROL SINGLE VOLTAGE OVER 300 V. (SHOWN CONNECTED SUPPLY SUPPLY (EXCEPT 380V.) FOR LOW VOLTAGE) LINES LINES TO GROUND PER TO GROUND PER NATIONAL NATIONAL N.C. ELECTRICAL ELECTRICAL T2 H1 CODE CODE...
  • Page 116 ELECTriCaL DiaGrams WiriNG DiaGram - (CODEs 10407, 10408, 10409, 10415) (L10575) 380/500V. & 460/575V. SINGLE VOLTAGE OVER 300 V. (SHOWN CONNECTED SUPPLY SUPPLY (EXCEPT 380V.) FOR LOW VOLTAGE) LINES LINES OUTPUT TO GROUND PER TO GROUND PER T2 H1 NATIONAL CONTROL NATIONAL START...
  • Page 117 ELECTriCaL DiaGrams WiriNG DiaGram - CODE 10418) (L10576) SINGLE VOLTAGE 440&460v OUTPUT CONTROL T2 H1 START SUPPLY STOP N.C. LINES TO GROUND PER NATIONAL ELECTRICAL CODE LEGEND C7 .05 +.05 MFD 21 4 2 31 32 D1 INPUT CONTACTOR BRIDGE (ONLY N.G.
  • Page 118 GENERAL INFORMATION FIRING PCB ELECTRICAL SYMBOLS PER E1537. 14J1 CAPACITORS= MFD/VOLTS CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) EQUIP. Ch'ge.Sht.No. DC-600 THE LINCOLN ELECTRIC CO. TYPE 3-8-91N OPERATING SCHEMATIC CLEVELAND, OHIO U.S.A. SUBJECT 1-17-92E NONE REF. G1527-1 SCALE SHT.
  • Page 119 FIRING PCB GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537. 14J1 CAPACITORS= MFD/VOLTS CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) EQUIP. Ch'ge.Sht.No. DC-600 THE LINCOLN ELECTRIC CO. TYPE 11-8-96J OPERATING SCHEMATIC CLEVELAND, OHIO U.S.A. SUBJECT NONE REF. G2259 SCALE SHT.
  • Page 120 G-10 G-10 ELECTriCaL DiaGrams sChEmaTiC - CONTrOL BOarD (G2312) ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: EQUIPMENT TYPE:...
  • Page 121 G-11 G-11 ELECTriCaL DiaGrams sChEmaTiC - FiriNG BOarD (L8337) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. iDEaLarC ® DC-600...

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