Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
SAFETY i i Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FUMES AND GASEScan be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilat...
Page 4 - iii
SAFETY iii iii Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Jan ‘07 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U....
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Mar ‘93 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 préc...
Page 6 - b) radio and television transmitters and receivers
SAFETY v v Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Electromagnetic Compatibility (EMC) ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3 May1989 on the approximation of the laws of the Membe...
Page 7 - Methods of Reducing Emissions
SAFETY vi vi Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area ...
Page 8 - - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -; RETURN TO MAIN INDEX; Page; RETURN TO MAIN MENU
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I I DC-600 RETURN TO MAIN INDEX Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . ....
Page 9 - TABLE OF CONTENTS - INSTALLATION SECTION; Electrical Input Connections
TABLE OF CONTENTS - INSTALLATION SECTION A-1 A-1 Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS – DC-600; See the OPERATION section; INPUT - THREE PHASE ONLY
INSTALLATION A-2 A-2 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 60% Duty Cycle 122/61 122/61/49 6149 128/74/64 74/56 64 140/70 68 TECHNICAL SPECIFIC...
Page 11 - SAFETY PRECAUTIONS; LIMIT ON STACKING; STACKING HOLE
INSTALLATION A-3 A-3 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SAFETY PRECAUTIONS Read entire Installation Section before installingthe DC-600. ELE...
Page 12 - ELECTRICAL INPUT CONNECTIONS; FUSE AND WIRE SIZES; DO NOT; GROUND CONNECTION; INPUT POWER SUPPLYCONNECTIONS
ELECTRICAL INPUT CONNECTIONS Before installing the machine check that the input sup-ply voltage, phase, and frequency are the same as thevoltage, phase, and frequency as specified on thewelder Rating Plate located on the Case BackAssembly. Input power supply entry is through the holein the Case Back...
Page 13 - RECONNECT PROCEDURE; LINK; CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.; CAUTION
INSTALLATION A-5 A-5 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC RECONNECT PROCEDURE Multiple voltage machines are shipped connected tothe highest in...
Page 15 - GND; SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE
INSTALLATION A-7 A-7 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines L3L2L1 LINESI...
Page 16 - OUTPUT CONNECTIONS; Cable Size; CONNECTIONS; A. Connect Electrode and Work Leads to; Pull out the retractable strain relief loops.; Terminal
INSTALLATION A-8 A-8 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC OUTPUT CONNECTIONS See Table A.1 for recommended DC-600 cable sizes for combined len...
Page 18 - NOTES
Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC NOTES A-10 A-10 DC-600
Page 19 - TABLE OF CONTENTS - OPERATION SECTION; Design Features and Advantages
TABLE OF CONTENTS - OPERATION SECTION B-1 B-1 Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 20 - OPERATION; • Do not touch electrically live parts or
OPERATION B-2 B-2 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SAFETY PRECAUTIONS Read this entire section of operating instructionsbefore operating t...
Page 21 - GENERAL DESCRIPTION
OPERATION B-3 B-3 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC GENERAL DESCRIPTION The DC-600 is an SCR controlled three phase weldingand cutting powe...
Page 22 - WELDING CAPABILITY; SYMBOL
OPERATION B-4 B-4 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WELDING CAPABILITY The DC-600 has the following Output and Duty Cyclebased on operation...
Page 23 - CONTROLS AND SETTINGS; Input POWER ON/OFF Switch
OPERATION B-5 B-5 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC CONTROLS AND SETTINGS All operator controls and adjustments are located onthe Case Fron...
Page 24 - When this switch is in the REMOTE “; AUXILIARY POWER IN MS-RECEPTACLE
OPERATION B-6 B-6 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 3. OUTPUT CONTROL This control provides continuous control of themachine’s output volta...
Page 25 - CV INNERSHIELD; OPERATING STEPS
OPERATION B-7 B-7 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC REMOTE CONTROL OF MACHINEOPERATION The toggle switch on the control panel labeled “Remo...
Page 26 - same polarity as the work cable connection.; NA-3 AUTOMATIC WIRE FEEDER
OPERATION B-8 B-8 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 4. Connect the electrode cables to terminal polarity tobe used. 5. Connect the #21 work...
Page 27 - AND; NOTE
OPERATION B-9 B-9 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC 2. Connect the LN-8 or LN-9 Control Cable to the 14pin Amphenol of the DC-600. 3. Conne...
Page 29 - TABLE OF CONTENTS - ACCESSORIES SECTION
TABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 30 - ACCESSORIES; WIRE FEEDERS AND TRACTORS; Automatic Wire Feeders:; FIELD INSTALLED OPTIONS; used on other; FACTORY OR FIELD; WIRE
ACCESSORIES C-2 C-2 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC WIRE FEEDERS AND TRACTORS The DC-600 can be used to power any of the followingLincoln...
Page 33 - TABLE OF CONTENTS - MAINTENANCE SECTION
TABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 34 - MAINTENANCE; Perform the following daily:; Main transformer and choke.; Do not touch electrically hot parts.
MAINTENANCE D-2 D-2 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC ROUTINE AND PERIODICMAINTENANCE 1. Disconnect input AC power supply lines to themachi...
Page 35 - TABLE OF CONTENTS-THEORY OF OPERATION SECTION; FIGURE E.1 BLOCK LOGIC DIAGRAM
TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 36 - THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic
THEORY OF OPERATION E-2 E-2 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC GENERAL DESCRIPTION The DC-600 is a three-phase, SCR controlled DCpower sourc...
Page 37 - RECTIFICATION; See; CONTROL BOARD; This
THEORY OF OPERATION E-3 E-3 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC FIRING CIRCUIT, CONTROL CIR-CUIT AND RECTIFICATION RECTIFICATION The “neutral...
Page 38 - THERMAL PROTECTION
THEORY OF OPERATION E-4 E-4 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC PROTECTIVE DEVICES ANDSHUTDOWN CIRCUITS THERMAL PROTECTION This welder has th...
Page 39 - SCR OPERATION
THEORY OF OPERATION E-5 E-5 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC SCR OPERATION A silicon controlled rectifier (SCR) is a three-terminaldevice used to...
Page 41 - TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR; Test Procedures; Removal and Replacement
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 F-1 Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 42 - TROUBLESHOOTING AND REPAIR; HOW TO USE TROUBLESHOOTING GUIDE
TROUBLESHOOTING AND REPAIR F-2 F-2 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC This Troubleshooting Guide is provided tohelp you locate and repair po...
Page 43 - PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING AND REPAIR F-3 F-3 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Sometimes machine failures appear to be due to PCboard failures. These...
Page 44 - Control Transformer Test.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perfor m the tests/repairs safely,contact the Lincoln E...
Page 49 - 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 50 - FIGURE F.1 – FIRING BOARD LEDs; PC BOARD TROUBLESHOOTING GUIDE (continued); FIRING BOARD; Test Conditions
FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8(206) 7(207) 6(208) 5 4321 16 (204)15 (203)1413 (231)12 (215)11109 FIGURE F.1 – FIRING BOARD LEDs PC BOARD TROUBLESHOOTING GUIDE (continued) FIRING BOARD 1. With DC-600 set for the Test Conditions all ten...
Page 51 - FIGURE F.2 – CONTROL BOARD LEDs
DC600 CONTROL G3409-1 LED1 LED5 LED2 LED3 LED4 LED6 J2 J3 J1 2 (256) (290) 7 (291) 8 1 (222)12 1 (210) 5 (231) (255) 6 1 FIGURE F.2 – CONTROL BOARD LEDs PC BOARD TROUBLESHOOTING GUIDE (continued) CONTROL BOARD 1. With the DC-600 set for the Test Conditions , all the LEDs except LED 4 should be lit. ...
Page 53 - 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 54 - FIGURE F.3 – FIRING BOARD; INTERNAL TRIGGER CIRCUIT TEST (continued); PROCEDURE
FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8(206) 7(207) 6(208) 5 4321 16 (204)15 (203)1413 (231)12 (215)11109 FIGURE F.3 – FIRING BOARD INTERNAL TRIGGER CIRCUIT TEST (continued) PROCEDURE 1. With the correct input power applied to the DC-600 and t...
Page 55 - FIGURE F.4 - TERMINAL STRIPS AND AMPHENOL
1 2 3 4 5 6 7 8 9 10 DC-600 21- 21+ 41 4 2 31 32 75 76 77 TS 2 TS 1 F = 7 6 G = 7 5 H = 2 1 I = 4 1 J = 3 1 K = 4 2 A = 3 2 B = G N D C = 2 D = 4 E = 7 7 L N M 14 PIN CONNECTOR 10 AMP CIRCUIT BREAKER OUTPUT TERMINALS SWITCH FIGURE F.4 - TERMINAL STRIPS AND AMPHENOL INTERNAL TRIGGER CIRCUIT TEST (con...
Page 57 - FIRING BOARD 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 58 - FIGURE F.6 FIRING BOARD; PC Board Troubleshooting Guide; Internal
FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8(206) 7(207) 6(208) 5 4321 16 (204)15 (203)1413 (231)12 (215)11109 FIGURE F.6 FIRING BOARD FIRING BOARD TEST (continued) PROCEDURE ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. 1. Discon...
Page 59 - CONTROL BOARD 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 60 - FIGURE F.7 CONTROL BOARD; Control; Internal Trigger Test
DC600 CONTROL G3409-1 LED1 LED5 LED2 LED3 LED4 LED6 J2 J3 J1 2 (256) (290) 7 (291) 8 1 (222)12 1 (210) 5 (231) (255) 6 1 FIGURE F.7 CONTROL BOARD CONTROL BOARD TEST (continued) PROCEDURE ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. 1. Turn the POWER Switch ON. LEDs 1 and 3 shouldt...
Page 61 - 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 62 - FIGURE F.8 - INPUT CONTACTOR AND RECONNECT PANEL; MAIN TRANSFORMER VOLTAGE TEST (continued); Disconnect the main input power from the DC-600.; ELECTRIC SHOCK; • Do not touch electrically hot parts.
L3 T3 L2 T2 L1 T1 FIGURE F.8 - INPUT CONTACTOR AND RECONNECT PANEL MAIN TRANSFORMER VOLTAGE TEST (continued) PROCEDURE 1. Disconnect the main input power from the DC-600. 2. Inspect the input contactor, reconnect panel andprimary leads to the main transformer for loose orfaulty connections. See Figu...
Page 63 - FIGURE F.9 – TRANSFORMER SECONDARIES; All of the secondary voltages will vary if the; RECEPTACLE; Wiring Diagram; FIGURE F.10 – AUXILIARY VOLTAGES
A A A SECONDARY LEADS (6 PLACES) COMMON BUSS FIGURE F.9 – TRANSFORMER SECONDARIES MAIN TRANSFORMER VOLTAGE TEST (continued) PROCEDURE 9. Test with an AC voltmeter for approximately 55 VACfrom each of the six main transformer secondaryleads to the common bus connected to the outputchoke. See Figure F...
Page 64 - FIGURE F.11 – FIRING BOARD
FIRING BOARD G3742-[ ] LED7 LED8 LED9 LED1 LED2 LED3 LED4 LED5 LED6 LED10 J5 J6 J7 J4 J8 (205) 8(206) 7(207) 6(208) 5 4321 16 (204)15 (203)1413 (231)12 (215)11109 FIGURE F.11 – FIRING BOARD MAIN TRANSFORMER VOLTAGE TEST (continued) PROCEDURE ELECTRIC SHOCK can kill. • Do not touch electrically hot p...
Page 65 - 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 66 - Input Contactor Test
A PowerSwitch Secondary Thermostat Control Transformer L3 T3L2 T2 L1 T1 H2, H3 or H4 (see Input Diagram) H1 FIGURE F.12 - CONTROL TRANSFORMER CONTROL TRANSFORMER TEST (continued) PROCEDURE 1. With the Input Power OFF, remove the case top,right side panel and the input access door. TheControl Transfo...
Page 67 - INPUT CONTACTOR 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 68 - FIGURE F.13 – INPUT CONTACTOR; VOLTAGE TEST; CONTACT TEST
L3 T3 L2 T2 L1 T1 W (L 3 ) T3 U (L 1 ) V T2 (L 2 ) T1 CR 1 Contactor Coil Terminals Apply External 120vac Here 272 271 Cover Plate Screws FIGURE F.13 – INPUT CONTACTOR INPUT CONTACTOR TEST (continued) PROCEDURE VOLTAGE TEST 1. Disconnect the input power and remove the InputAccess Panel from the rear...
Page 69 - SCR BRIDGE 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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 70 - FIGURE F.14 – SCR BRIDGE ASSEMBLY; STATIC TEST; Disconnect the input power from the DC-600.
ANODE CATHODE REMOVEINSULATINGPAINT FIGURE F.14 – SCR BRIDGE ASSEMBLY SCR BRIDGE TEST(continued) PROCEDURE STATIC TEST 1. Disconnect the input power from the DC-600. 2. Remove the top and side panels and drop thenameplate to access the PC Boards. 3. Unplug the Molex connectors from both the ControlB...
Page 71 - FIGURE F.15 – ACTIVE SCR TEST; ACTIVE TEST; Figure
FIGURE F.15 – ACTIVE SCR TEST SCR BRIDGE TEST(continued) PROCEDURE ACTIVE TEST 1. With the circuit shown in Figure F.17. One 6-voltlantern battery can be used. Set the voltmeterscale low, at approximately 0-5 volts or 0-10 volts. a. Test the voltage level of the battery. Short leads (A) and (C). Clo...
Page 72 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; volts
This is the typical DC open circuitvoltage waveform generated from aproperly operating machine. Notethat each vertical division represents50 volts and that each horizontal divi-sion represents 2 milliseconds intime. Note: Scope probes connected atmachine output terminals: (+) probeto positive termin...
Page 73 - MAXIMUM OUTPUT SETTING – NO LOAD
This is the typical DC open circuitvoltage waveform generated from aproperly operating machine. Notethat each vertical division represents50 volts and that each horizontal divi-sion represents 2 milliseconds intime. Note: Scope probes connected atmachine output terminals: (+) probeto positive termin...
Page 74 - MINIMUM OUTPUT SETTING – NO LOAD
This is the typical DC open circuitvoltage waveform generated from aproperly operating machine. Notethat each vertical division represents20 volts and that each horizontal divi-sion represents 2 milliseconds intime. Note: Scope probes connected atmachine output terminals: (+) probeto positive termin...
Page 75 - TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
This is the typical DC open circuitvoltage waveform generated from aproperly operating machine. Notethat each vertical division represents20 volts and that each horizontal divi-sion represents 2 milliseconds intime. The machine was loaded with aresistance grid bank. The grid bankmeters read 650 amps...
Page 76 - TYPICAL SCR GATE VOLTAGE WAVEFORM
This is the typical DC open circuitvoltage waveform. The machine wasin an open circuit condition (no load)and operating properly. Note thateach vertical division represents 2volts and that each horizontal divisionrepresents 5 milliseconds in time. Note: Scope probes connected atSCR gate and cathode:...
Page 77 - ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
This is NOT the typical DC open cir-cuit voltage waveform. One outputSCR is not functioning. Note the“gap” in the waveform. One SCRgate is disconnected to simulate anopen or non-functioning output SCR.Each vertical division represents 20volts and each horizontal division rep-resents 2 milliseconds i...
Page 80 - FIGURE F.16 – CONTACTOR; CLEANING PROCEDURE; Replace the input contactor cover plate.
L3 T3 L2 T2 L1 T1 W (L3) T3 U (L1) V T2 (L 2 ) T1 CR 1 Contactor Coil Terminals Apply External 120vac Here 272 271 Cover Plate Screws FIGURE F.16 – CONTACTOR INPUT CONTACTOR CLEANING/REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-40 F-40 DC-600 Retur n to Section T OC Retur n to Sect...
Page 81 - Transformer Removal and Replacement Procedure; first to provide easier; SCR RECTIFIER BRIDGE
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 82 - FIGURE F.17 – RECTIFIER ASSEMBLY; REMOVAL PROCEDURE; NOTE: Before removing the Rectifier Assembly pay
"C" LEAD, RED(6 PLACES) "A" LEAD, WHITE(6 PLACES) GATE LEAD CONNECTOR OUTPUT SNUBBER A A A A A A A A A A A A A A A A LEFT SIDE OF CHOKE TO LEFT SIDE OF CHOKE OUTPUT SHUNT 210 215 MOUNTING BOLTS (4) SECONDARY LEAD (6 PLACES) BUSHING CONNECTION STRAP FIGURE F.17 – RECTIFIER ASSEMBLY SC...
Page 83 - FIGURE F.18 – RECTIFIER REPLACEMENT; REPLACEMENT PROCEDURE; NOTE: Any instructions packaged with the replace-
Thread Forming Screw Plain Washer Insulator Insulator Insulator Plain Washer Lock Washer 5/16-18 Hex Nut Rectifer Mounting Bracket Bridge Mounting Bracket Fig. 18 ‘A’ Fig. 18 ‘B’ Transformer Secondary Lead ‘A’ Lead from Snubber Heat Sink Negative Output Lead Output Snubber Lead Choke Lead Lock Washe...
Page 85 - MAIN TRANSFORMER AND CHOKE
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 87 - FIGURE F.20 – TRANSFORMER REMOVAL; SCR; NOTE: The hole in the lift bale assembly is to
FIGURE F.20 – TRANSFORMER REMOVAL MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT (continued) REMOVAL PROCEDURE (cont.) 12. Disconnect the five (5) #215 and the two(2) #210 leads from the Shunt, noting their positions forreassembly. . NOTE: It is important that the twisted pair (feed- back leads)...
Page 88 - FIGURE F.21 – CHOKE TIG WELD; NOTE: Cover the transformer assembly with
WELD W W XXXXXXXXXXX XXXXXXXXXXX XXXXXXXXXXX FIGURE F.21 – CHOKE TIG WELD MAIN TRANSFORMER AND CHOKE REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Place the flat washers and the choke on top of the transformer and the lift bale assembly over both. 2. Install the four thread cutting bo...
Page 89 - RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS
TROUBLESHOOTING AND REPAIR F-49 F-49 DC-600 Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Section T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC RETEST AFTER REPAIR Should a machine under test be rejected for any ...
Page 91 - TABLE OF CONTENTS - DIAGRAM SECTION
TABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC Retur n to Master T OC DC-600 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 92 - ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAMS G-2 WIRING DIAGRAM - G3506 E N -1 70 S O L ID E D G E G3506 DC-600 W IRING DIAGRAM NONE - DO NOT SCALE THIS DRAWING EQUIPMENT TYPE: SUBJECT: SCALE: UF CRM38710 1 PAGE ___ OF ___ 1 ENGINEERING CONTROLLEDMANUFACTURER: No THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCO...
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