Lincoln Electric Idealarc DC600 9774 Service Manual
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Lincoln Electric Idealarc DC600 9774 Service Manual

Idealarc dc600 series multi-process welders
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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
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED
THROUGHOUT.
And, most importantly, think before
you act and be careful.
World's Leader in Welding and Cutting Products
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel (216) 481-8100
RETURN TO MAIN INDEX
IDEALARC DC-600
For use with machines having Code Numbers:
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
®
9773MSP
9774
9776M
9778M
9779M
9780M
9793MSP
9910M
Premier Manufacturer of Industrial Motors
SVM108-A
August, 1998

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  • Page 1 RETURN TO MAIN INDEX SVM108-A August, 1998 ® IDEALARC DC-600 For use with machines having Code Numbers: 9773MSP 9774 9776M 9778M 9779M 9780M 9793MSP 9910M 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 ...
  • 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 PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 SAFETY WELDING OR CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 5.a. Use only compressed gas cylinders contain- 4.a. Remove fire hazards from the welding or cut- ing the correct shielding gas for the process ting area. If this is not possible, cover them to used and properly operating regulators prevent the welding or cutting sparks from start- designed for the gas and pressure used.
  • Page 4 SAFETY ELECTRIC AND MAGNETIC FOR ENGINE powered equipment. FIELDS may be dangerous 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF).
  • Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety .........................i-iv Installation ......................Section A Technical Specifications ..................A-2 Safety Precautions ....................A-3 Select Proper Location .....................A-3 Electrical Input Connections ................... A-4 Reconnect Procedure ..................... A-5 Output Connections ..................A-8 - A-9 Operation ......................Section B Safety Precautions ....................

  • Page 7: Table Of Contents

    SECTION A-1 TABLE OF CONTENTS - INSTALLATION SECTION - INSTALLATION ............Section A Technical Specifications ..........A-2 Safety Precautions ............A-3 Select Proper Location............A-3 Stacking ..............A-3 Tilting.................A-3 Electrical Input Connections ......... A-4 Fuses and Wire Sizes ..........A-4 Ground Connection ..........A-4 Input Power Supply Connections......A-4 Reconnect Procedure ...........

  • Page 8: Technical Specifications

    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 Constant Current 72 VDC 115 VAC, 8 Amps...

  • Page 9: Safety Precautions

    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 weight three machines (1570 pounds/712 kilograms).

  • Page 10: Electrical Input Connections

    INSTALLATION ELECTRICAL INPUT CONNECTIONS GROUND CONNECTION Ground the frame of the machine. A ground Before installing the machine, check that the input sup- terminal marked with the symbol ( ) is located inside ply voltage, phase, and frequency are the same as the the Case Back of the machine near the input contactor.

  • 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 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 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. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN. INPUT CONTACTOR FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines...

  • 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 Parallel Cables Cable Size Lengths up to 150 ft.

  • Page 15: Connection For Stick Welding And Air Carbon Arc

    INSTALLATION Connection For Semi-Automatic or Automatic 1. Set ON/OFF PUSH BUTTON to OFF. Wire Feeder Control 2. Locate and open the hinged access door on the Front Case Assembly. NOTE: See the ACCESSORIES Section of this manu- al for specific instructions on connecting the following 3.

  • Page 16: Operation Section

    SECTION B-1 TABLE OF CONTENTS - OPERATION SECTION - OPERATION ............... Section B Safety Precautions ..............B-2 General Description ............... B-3 Recommended Processes and Equipment......B-3 Operational Features and Controls .........B-3 Design Features and Advantages ...........B-3 Welding Capacity ..............B-4 Controls and Settings ..............B-5 Operating Steps ..............

  • Page 17: Operating Instructions

    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 18: 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: • Submerged Arc Semi-Automatic or Automatic •...

  • Page 19: Welding Capability

    OPERATION • Auxiliary power source to provide 115-volt AC • Three circuit solid state control system provides power (1000 VA) to wire feeding equipment. maximum performance and circuit protection. • Multi-functional terminal strip for easy connection • Low profile case provides maximum use of space. of wire feeding control cables and switching •...

  • Page 20: 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. AMMETER 8. VOLTMETER WELDING MODE OUTPUT CONTROL (optional) (optional) SWITCH SWITCH ON/OFF PUSH BUTTON...

  • Page 21: Operating Steps

    OPERATION OPERATING STEPS REMOTE CONTROL OF MACHINE The following procedures are for using the IDEAL- OPERATION ARC DC-600 in the local control mode of operation. For remote control of the machine, see the Remote The toggle switch on the control panel labeled “Output Control of Machine Operation section.
  • Page 22 OPERATION SEMI-AUTOMATIC AND 2. Set the NA-3 Open Circuit Voltage Control to the AUTOMATIC WIRE FEEDING WITH same dial setting as the Arc Voltage Control. If this A IDEALARC DC-600 AND WIRE is a new welding procedure, a good starting point is to set the Open Circuit Voltage Control to # 6.
  • Page 23 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 NA-3 Start Board may be required to improve arc strik- Open Circuit Voltage Control and Voltage ing.
  • Page 24 OPERATION IDEALARC DC-600 POWER SOURCE LN-8 SEMI-AUTOMATIC WIRE FEEDER SETTING WHEN CONNECTED TO NA-5 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 follows for the best performance:...

  • Page 25: Connection For Wire Feeder Control

    Section C-1 TABLE OF CONTENTS - ACCESSORIES SECTION - ACCESSORIES ..............Section C Accessories..............C-2 Multi-Process Switch ............C-2 Undercarriage ..............C-4 Meters ................C-4 Connections for Wire Feeder Control ......C-5 NA-3................C-5 NA-5................C-6 LN-8 or LN-9 .............C-7 LN-7 ................C-8 IDEALARC DC-600...
  • Page 26 ACCESSORIES OPTIONS/ACCESSORIES 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 • Multi-Process Switch (K804) stick or air/carbon arc cables to the set of terminals on •...
  • Page 27 ACCESSORIES 5. Attach the MULTI-PROCESS SWITCH bracket 8. Connect the control leads from the MULTI- across the front of the machine with the flange PROCESS SWITCH to terminals #2 and #4 on the down. Use the long, self-tapping screws and lock IDEALARC DC-600's terminal strip.
  • Page 28 ACCESSORIES 13. Connect the wire feeder electrode and work NOTE: The instructions above are for connecting cables. See Figure C.4. the stick polarity positive. To change the polarity, turn the IDEALARC DC-600 OFF, and reverse the a. Insert the wire feeder electrode and work cables.
  • Page 29 ACCESSORIES CONNECTIONS FOR SEMI-AUTO- NA 3 WIRE FEEDER CONTROL MATIC OR AUTOMATIC WIRE CABLE FEEDER CONTROL AUTOMATIC CONTROL 1. Set the ON/OFF PUSH BUTTON to OFF. 2. Locate and open the hinged access door on the 21 4 2 31 32 75 76 77 80 81 Front Case Assembly.
  • Page 30 ACCESSORIES CONNECTING THE NA-5 TO THE 5. Extend wire feeder control cable lead # 21 so it can be connected directly to the work piece. IDEALARC DC-600 a. Make a bolted connection using AWG #14 or NOTE: For optimum performance use the NA-5 with larger insulated wire.
  • Page 31 ACCESSORIES CONNECTING THE LN-8 OR LN-9 TO THE LN8 OR LN 9 IDEALARC DC-600 WIRE FEEDER CONTROL 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...
  • Page 32 ACCESSORIES LN-7 IDEALARC DC-600 b. An S-16586- X remote voltage sensing work lead is available for this purpose. 1. Disconnect main AC input power to the c. Keep the #21 lead electrically separate from IDEALARC DC-600. the work cable circuit and connection. 2.

  • Page 33: Routine And Periodic Maintenance

    Section D-1 TABLE OF CONTENTS - MAINTENANCE SECTION - MAINTENANCE ..............Section D Safety Precautions ..............D-2 Routine and Periodic Maintenance ..........D-3 3-D Exploded View..............D-4 IDEALARC DC-600...
  • Page 34 MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. Only qualified personnel should perform this maintenance. Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. Do not touch electrically hot parts. __________________ IDEALARC DC-600...
  • Page 35 MAINTENANCE ROUTINE AND PERIODIC MAINTENANCE 1. Disconnect input AC power supply lines to the machine before performing periodic maintenance, tightening, cleaning, or replacing parts. Figure D.1 Perform the following daily: 1. Check that no combustible materials are in the welding or cutting area or around the machine. 2.
  • Page 36 MAINTENANCE FIGURE D.1 - General Assembly Exploded View IDEALARC DC-600...

  • Page 37: Scr Operation

    Section E-1 TABLE OF CONTENTS - THEORY OF OPERATION SECTION - THEORY OF OPERATION SECTION ........ Section E Power Supply Operation ..........E-2 - E-5 Input Line Voltage, Connector and Main Transformer ..E-2 Output, Rectification,Control and Feedback ......E-3 Protection Devices and Circuits (Contactor Hold-In) ...E-4 SCR Operation ................E-5 OUTPUT CONTROL...
  • Page 38 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 39 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 40 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 41 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 42: Pc Board Troubleshooting Procedures

    SECTION F-1 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section..............Section F Safety Precautions....................F-2 How to Use Troubleshooting Guide...............F-2 PC Board Troubleshooting Procedures ..............F-3 Troubleshooting Guide................F-4 - F-12 Test Procedures Control Transformer Voltage Test ............F-13 - F-14 Main Transformer Voltage Test ............F-16 - F-20 Firing Board Test.................F-21 - F-27 Control Board Test ................F-28 - F-32...

  • Page 43: How To Use Troubleshooting Guide

    TROUBLESHOOTING & 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 44 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES - Remove the P.C. Board from the static-shield- WARNING ing bag and place it directly into the equipment. Don’t set the P.C. Board on or near paper, plas- ELECTRIC SHOCK can tic or cloth which could have a static charge. If kill.

  • Page 45: Troubleshooting Guide

    MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Major Physical Electrical Contact the Lincoln Electric Service Damage is Evident Dept. (216) 383-2531 or 1-800-833- 9353 (WELD) The Machine is dead- The Input 1. Check for blown or missing 1. The ON/OFF PUSHBUTTON contactor does not operate.
  • Page 46 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Input contactor (CR1) chatters. 1. The input line voltage may be 1. The pilot relay (CR2) may low.
  • Page 47 TROUBLESHOOTING & REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Machine input contactor operates 1. Install a jumper from #2 to #4 1. Check operation of output pilot machine weld on machine terminal strip.
  • Page 48 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Machine has maximum weld out- 1. If remote control is being used 1. Check OUTPUT CONTROL put and no control.
  • Page 49 TROUBLESHOOTING & REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Machine has minimum output and 1. If a remote control unit is NOT 1.
  • Page 50 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Machine shuts off (input contactor 1. Remove all welding cables and 1. Check for grounds and or drops out) when the welder output control cables from the DC 600.
  • Page 51 F-10 TROUBLESHOOTING & REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The weld output terminals are 1. Remove any external leads 1. Check for an internal short always electrically "hot".
  • Page 52 F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELDING PROBLEMS Poor arc starting when the DC600 1. Make sure the proper welding 1.
  • Page 53 F-12 TROUBLESHOOTING & REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELDING PROBLEMS Poor arc characteristics in all 1. Check for the correct input volt- 1.
  • Page 54 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 could result in danger to the technician or the 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 55 F-14 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST FIGURE F.1 - Control Transformer and Lead Locations TEST PROCEDURE 1. Disconnect main AC input power to 5. Locate Control Transformer leads the machine. X1 and X2. 2. Remove the Top and Case Sides. a.
  • Page 56 F-15 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST 6. Test for 115 VAC between leads X1 b. Connect the other end of the and X2. alligator clip to one of the meter probes. Be sure that neither NOTE: If the main AC input supply the alligator clip nor the meter voltage varies,...
  • Page 57 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 could result in danger to the technician or the 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-17 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST FIGURE F.3 - Input Contactor, Reconnect Panel, and Primary Leads to Main Transformer Locations TEST PROCEDURE 1. Set ON/OFF PUSHBUTTON to 4. Connect main AC input power to the machine. 2. Disconnect main AC input power 5.
  • Page 59 F-18 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST 7. Read meter. 9. Read meter. a. If proper voltage is present for a. If proper voltage is present for all three phases, proper main all three phases, the Contactor AC input voltage is being sup- is working properly.
  • Page 60 F-19 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST 11. Test for 115 VAC between leads 13. Test with an AC voltmeter for 75 #31 and #32 on the terminal board. VAC for each phase angle winding as shown in Figures F.5 and F.6. a.
  • Page 61 F-20 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST b. If the Firing Board number is c. If one or more of the above G-1486 - 5 or higher, test for 75 voltage tests are incorrect, VAC between the leads con- check for loose or faulty wiring.
  • Page 62 FIRING BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 63 F-22 TROUBLESHOOTING & REPAIR FIRING BOARD TEST TEST PROCEDURE FOR NORMAL FIRING BOARD OPERATION 1. Disconnect main AC input power to 4. Connect the correct main AC input power to the machine. the IDEALARC DC-600. 2. Locate the Firing Board on the left 5.
  • Page 64 F-23 TROUBLESHOOTING & REPAIR FIRING BOARD TEST FIGURE F.7 - Firing Board LED and Molex Plug Locations IDEALARC DC-600...
  • Page 65 F-24 TROUBLESHOOTING & REPAIR FIRING BOARD TEST 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 66 F-25 TROUBLESHOOTING & REPAIR FIRING BOARD TEST 7. Locate the terminal strip directly NOTE: This jumper connection ini- below the Control Box. tiates machine output. 8. Connect a jumper wire from termi- nal #2 to terminal #4 on the termi- nal strip.
  • Page 67 F-26 TROUBLESHOOTING & REPAIR FIRING BOARD TEST 9. Locate LEDs 1 to 6. Each LED should glow with equal brightness. 13. Test for 10 VDC to 13 VDC NOTE: LEDs 1 to 6 indicate that between leads #231 and #215 on the gate firing signals are being the Firing Board in CV mode.
  • Page 68 F-27 TROUBLESHOOTING & REPAIR FIRING BOARD TEST 14. Test for approximately 5.8 VDC 15. Test Output Pilot Control Relay between leads #231 and # 215 on (CR4) for proper operation by the Firing Board in VV (CC) mode. removing and replacing repeatedly the jumper wire from terminal # 2.

  • Page 69: 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 could result in danger to the technician or the 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-29 TROUBLESHOOTING & REPAIR CONTROL BOARD TEST See Table F.2 for LED function during normal operation. See Figure F.9 for LED loca- tion on Control Board. FIGURE F.9 - Control Board LED Locations 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 71: Test Procedures

    F-30 TROUBLESHOOTING & REPAIR CONTROL BOARD TEST TEST PROCEDURES If LED 1 Does Not Glow When If 115 VAC is present AND LED ON/OFF PUSH BUTTON is Set to ON 1 does not glow, the Control Board may be faulty. Replace. 1.
  • Page 72 F-31 TROUBLESHOOTING & REPAIR CONTROL BOARD TEST If LED 2 Does Not Light When b. If the open circuit voltage is not Machine is Operating Under Load (or present at the Weld Output terminals #2 and #4 are jumpered Terminals, then together on the terminal strip).
  • Page 73 F-32 TROUBLESHOOTING & REPAIR CONTROL BOARD TEST b. If the open circuit voltage is not a. If LED 4 glows or flickers, present at the Control Board, then check leads #222 and • Check the Weld Output #215 for loose or faulty wiring Terminals associated connections.

  • Page 74: 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 could result in danger to the technician or the 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 75 F-34 TROUBLESHOOTING & REPAIR STATIC SCR TEST TEST PROCEDURE 1. Disconnect main AC input power to 2. Disconnect all Molex Plugs from the machine. the Firing Board and Control Board. See Figure F.12. FIGURE F.12 - Firing Board and Control Board Molex Plug Locations. IDEALARC DC-600...
  • Page 76 F-35 TROUBLESHOOTING & REPAIR STATIC SCR TEST FIGURE F.13 - Heat Sink Test Points. 3. Remove the red insulating paint 4. Test for high or infinite resistance from the heat sink test points. See from the anode to the cathode of FIGURE F.13.
  • Page 77 F-36 TROUBLESHOOTING & REPAIR STATIC SCR TEST FIGURE F.14 - SCR 1 Test Points. 5. Test for high or infinite resistance 7. Retest SCR 1 with the snubber cir- from the cathode to the anode of cuit disconnected. SCR 1 by reversing the leads. See Figure F.14.

  • Page 78: 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 could result in danger to the technician or the 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 79 F-38 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST TEST PROCEDURE 1. Disconnect main AC input power to 2. Disconnect all Molex Plugs from the machine. the Firing Board and Control Board. See Figure F.15. FIGURE F.15 - Firing Board and Control Board Molex Plug Locations. IDEALARC DC-600...
  • Page 80 F-39 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST FIGURE F.16 - Heat Sink Test Points. 3. Remove the red insulating paint NOTE: DO NOT DISASSEMBLE from the heat sink test points. See THE HEAT SINKS. FIGURE F.16. FIGURE F.17 - SCR Tester Circuit and SCR connections. 4.
  • Page 81 F-40 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST 10. Open switch SW-1. 5. Connect the Tester to the SCR 1 as shown in Figure F.17. 11. Reconnect the Tester leads. See Figure F.17. a. Connect Tester lead (A) to the anode. a.

  • Page 82: Normal Open Circuit Voltage Waveform

    F-41 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE - NO LOAD 0 volts 50 volts This is the typical DC open circuit voltage SCOPE SETTINGS waveform generated from a properly operat- ing machine. Note that each vertical division Volts/Div .
  • Page 83 F-42 TROUBLESHOOTING & REPAIR 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 SCOPE SETTINGS waveform generated from a properly operat- ing machine. Note that each vertical division Volts/Div .
  • Page 84 F-43 TROUBLESHOOTING & REPAIR 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 SCOPE SETTINGS waveform generated from a properly operat- ing machine. Note that each vertical division Volts/Div .
  • Page 85 F-44 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED CONSTANT VOLTAGE INNERSHIELD MODE CH 1 0 volts 20 volts This is the typical DC open circuit voltage SCOPE SETTINGS waveform generated from a properly operat- ing machine. Note that each vertical division Volts/Div .

  • Page 86: Typical Scr Gate Voltage Waveform

    F-45 TROUBLESHOOTING & REPAIR 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 SCOPE SETTINGS waveform. The machine was in an open cir- cuit condition (no load) and operating proper- Volts/Div .
  • Page 87 F-46 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD ONE OUTPUT SCR NOT FUNCTIONING CH 1 0 volts 20 volts SCOPE SETTINGS This is NOT the typical DC output voltage waveform. One output SCR is not function- ing.
  • Page 88 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 could result in danger to the technician or the 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 89 F-48 TROUBLESHOOTING & REPAIR INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT CLEANING PROCEDURE CONTACTOR REPLACE- MENT 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 90 SCR / SCR OUTPUT BRIDGE REMOVAL WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 91 F-50 TROUBLESHOOTING & REPAIR SCR / SCR OUTPUT BRIDGE REMOVAL A. REMOVAL OF INDIVIDUAL SCR HEAT SINK FIGURE F.19 - Individual Heat Sink Removal NOTE: If it is necessary to remove and 3. Disconnect the transformer sec- replace only one or two individual ondary lead to the anode of the SCRs and they are easy to work on, heat sink assembly using 1/2"...
  • Page 92 F-51 TROUBLESHOOTING & REPAIR 5. Remove the four thru bolts and 6. Install the replacement SCR Heat associated nuts and washers hold. Sink in reverse order of removal. ing the SCR heat sink to the bridge tie bars. a. Apply a thin layer of Lincoln E1868 (Dow Corning 340) heat a.
  • Page 93 F-52 TROUBLESHOOTING & REPAIR SCR / SCR OUTPUT BRIDGE REMOVAL B. REMOVAL OF COMPLETE BRIDGE ASSEMBLY FIGURE F.20 - SCR Output Bridge Removal NOTE: If it is necessary to remove and 2. Remove the four self-tapping bolts replace the entire SCR Output Bridge that mount Bridge...
  • Page 94 F-53 TROUBLESHOOTING & REPAIR SCR / SCR OUTPUT BRIDGE REMOVAL 5. Remove the bolt that connects the 8. Lift the SCR Bridge Assembly Shunt Assembly (heavy copper) straight up and out of the machine lead to the SCR Bridge Assembly. being sure that no leads become The Shunt Assembly connects the tangled or hooked on the other...
  • Page 95 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 could result in danger to the technician or the 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 F-55 TROUBLESHOOTING & REPAIR LIFT BAIL REMOVAL (INCLUDING MAIN TRANSFORMER, CHOKE, AND OUTPUT BRIDGE ASSEMBLY) REMOVAL PROCEDURE FIGURE F.21 - Lift Bail Removal 1. Disconnect gate leads. 3. Disconnect the leads from the sec- ondary thermostat. See wiring dia- a. On later models, remove gate gram.
  • Page 97 F-56 TROUBLESHOOTING & REPAIR LIFT BAIL REMOVAL (INCLUDING MAIN TRANSFORMER, CHOKE, AND OUTPUT BRIDGE ASSEMBLY) 5. Disconnect leads #215 and #216 13. Disconnect lead #272 from Input from Relay CR4 and lead #231 Contactor (CR1) coil. from the splice connector. 14.
  • Page 98 TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 99 F-58 TROUBLESHOOTING & REPAIR TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY TRANSFORMER REMOVAL PROCEDURE FIGURE F.22 Transformer Bail Assembly Removal 1. Remove the four screws that con- 4. Lift the Output Choke straight up nect the top and side baffles until the through bolts are cleared around the Output Choke using a and then move it out toward the 3/8"...
  • Page 100 F-59 TROUBLESHOOTING & REPAIR TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY 6. Remove the four self-tapping bolts TRANSFORMER that hold the Lift Bail to the trans- DISASSEMBLY former base using a 9/16" socket wrench. See Figure F.22. 1. Identify and label all leads to the transformer.
  • Page 101 F-60 TROUBLESHOOTING & REPAIR TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY COIL REMOVAL Figure F.23 Transformer coil removal. 1. Label and cut leads to the coil(s) 4. Replace the coil(s). being removed. See Figure F.23. a. Be sure to replace all insulated NOTE: To remove a main trans- wedges.

  • Page 102: Retest After Repair

    F-61 TROUBLESHOOTING & REPAIR 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 103 F-62 TROUBLESHOOTING & REPAIR 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. MAXIMUM ACCEPTABLE OUTPUT VOLTAGE —...
  • Page 104 Section G TABLE OF CONTENTS - ELECTRICAL DIAGRAMS - ELECTRICAL DIAGRAMS SECTION ...... Section G Control Board Layout............G-1 (G1504-4 and above) Firing Board Layout ............G-3 (G1486-5 and above) Wiring Diagram ............G-5 (Codes 9773,9776,9778,9779,9780,9910) Wiring Diagram ..............G-6 (Code 9774) Operating Schematic ............G-7 Control Board Schematic..........G-8 (G1504-4 and above) Firing Board Schematic ...........G-9...
  • Page 105 ELECTRICAL DIAGRAMS CONTROL PC BOARD (G1504-4 AND ABOVE) IDEALARC-600...
  • Page 106 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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 107 ELECTRICAL DIAGRAMS FIRING PC BOARD (G1486-5 AND ABOVE) IDEALARC-600...
  • Page 108 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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 109 NOTES IDEALARC-600...
  • Page 110 ELECTRICAL DIAGRAMS FIGURE G1 - Wiring Diagram for Codes 9773, 9776, 9778, 9779, 9780, 9910 3 8 0 / 5 0 0 V . & 4 6 0 / 5 7 5 V . S I N G L E V O L T A G E O V E R 3 0 0 V . ( S H O W N C O N N E C T E D 2 3 6 O U T P U T...
  • Page 111 ELECTRICAL DIAGRAMS FIGURE G2 - Wiring Diagram for Code 9774 T P 1 2 3 6 O U T P U T S U P P L Y C O N T R O L L I N E S 2 1 0 2 3 7 2 1 5...
  • Page 112 ELECTRICAL DIAGRAMS FIGURE G3 - Operating Schematic 2 7 1 2 7 1 A N . A . O N 4 4 0 / 4 6 0 V M A C H I N E S , C R 1 I S A D C C O N T A C T O R A N D D 1 &...
  • Page 113 FIGURE G4 - Control Board Schematic for G1504-4 and above NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version.
  • Page 114 FIGURE G5 - Firing Board Schematic for G1486-5 and above NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version.

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