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IDEALARC DC-600 - Red-D

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1. LINCOLN E IDEALARC 600 ELECTRICAL DIAGRAMS G 2 CONTROL PC BOARD G1504 4 AND ABOVE Identification Item G1504 BILL OF MATERIALS C16 eR be CAPACITOR PEMF 047 100V 10 e ER CAPACITOR ALEL 10 25V 75 10 C10 onde ep xen eu CAPACITOR TAEL 1 8 20V 1096 Q2 Gene CAPACITOR TAEL 4 7 35V 10 C5 OTA teehee ha hee CAPACITOR TAEL 18 15V 10 Rex CAPACITOR PEF 022 200V 10 C20 ssec xdi x CAPACITOR TAEL 2 7 50V 10 QT oo ee ee ad CAPACITOR ALEL 47 160V 50 20 CIT nec CAPACITOR ALEL 6 150V 50 10 eee ee CAPACITOR TAEL 0 47 50V 10 G26 Bee CAPACITOR ALEL 2 50V 75 10 SORT zx ke e dt SCR T202 4A 400V C106D C9 C21 C22 023 C24 C26 CAPACITOR CEMO 022 50V 20 C27 C28 C29 Identification Item R37 R40 R83 R89 RESISTOR MF 1 4W 68 1K 1 R6 R23 R48 R49 RESISTOR MF 1 4W 82 5K 1 R39 R63 R80 TRIMMER ST 1 2W 50K 10 LINEAR 26 38 TRIMME
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4. n seo A wy 280 1 am sox i gt TO S4A MODE SW rd 280 TO 224 IN VV MODE ONLY As 5 2227 n lt lt me 100 V 10 12v 03 BRE 1400 Mig 120 Be TO OUTPUT CONTROL POT E 5 y 256 2 lt 200 20w 222 OUTPUT STUD as 964 O lt s lt an Yoz 10V ma 184004 V 16V gt 5 21 x CONTROL Pce 4 T 0 REED S AR x V 220 TO COMMON WITH 220 OUTPUT CURRENT FLOW Y 7 m lov 2 IER 25v x POWER SUPPLY DA HA 5 1N4004 1m224 4 2 gle 04 244857 Y 1507 M VOLTAGE FEEDBACK 2220 1 e LI OUTPUT STUD 02 5 7 1 12 029 a 30v Nn e 4 CURRENT TO CASE OVERLOAD SWITCH len E 1 1604 5 4 rea RIZ 200v 22JK 22K R74 Jl TO 548 MODE SW 23 EN aul lj Die 3 m 1004 475K 232 TO COMMON eS gt ux V 5L jm224 IN VV MODE ONLY E 2 ai T aas lt e 56 o 600ma 2 jen E ne FAULT DETECT LEDA rer x 80 amp BI TO T S 3 1 80 81 amp 229 TO SAC IMODE SW 9 0c m 5 ras amp 80 TO 81 CVS MODE ALL OPEN CVI M
5. F 16 F 20 Firing Board Testi eene F 21 F 27 Control Board Test ee nh eene caes F 28 F 32 Static SCR Test eene nennen F 33 F 36 Active SCR tide nisin Dee edel oet Eee Des F 37 F 40 Oscilloscope W aveforms Normal Open Circuit V oltage W aveform Constant Current Mode F 41 Normal Maximum Open Circuit V oltage W aveform Constant V oltage Innershield Mode sess F 42 Normal Minimum Open Circuit V oltage W aveform Constant V oltage Innershield Mode F 43 Typical Output V oltage W aveform Machine Loaded Constant V oltage Innershield Mode F 44 Typical SCR Gate V oltage W aveform Maximum Output Setting Constant V oltage Innershield Mode F 45 Abnormal Open Circuit V oltage W aveform Constant V oltage Innershield Mode F 46 Replacement Procedures Input Contactor Cleaning and or Replacement _ F 47 F 48 SCR Output Bridge 2222220 00 eee F 49 Removal of Individual SCR Heat Sinks F 50 F 53 Removal of Lift Bail Assembly 2 000 F
6. 2 E 4 SCR Operation cei oec Reh dieto Ere red ele ieee E 5 Troubleshooting and Repair eere Section F How To Use Troubleshooting F 2 PC Board Troubleshooting Procedures sse F 3 Troubleshooting Guide F 4 F 52 Electrical Diagrams wc Section G e P 282 LINCOLN 5 IDEALARC DC 600 LINCOLN TABLE OF CONTENTS INSTALLATION SECTION beens Technical Specifications 2 Safety Precautions he A 3 Select Proper A 3 SLACKING meet Em A 3 ieu A 3 Electrical Input Connections A 4 Fuses and Wire 512 A 4 Ground Connection A 4 Input Power Supply Connections A 4 Reconnect Procedure ect tee A 5 Output Connections gt 8 Electrode and Work A 8 Connection for Wire Feeder Control
7. A 9 Connection for Stick Welding and Air Carbon Arc A 9 SECTION A 1 IDEALARC DC 600 we INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC DC 600 INPUT THREE PHASE ONLY Standard Voltage Input Current at Rated Output 208 230 416 460 575 3 60 125 113 63 57 45 RATED OUTPUT Duty Cycle Volts at Rated Amps 10096 44 6096 44 5096 44 OUTPUT Mode Current Maximum Open Auxiliary Power Range Circuit Voltage Constant Current 90 to 850 Amps 72 VNDC 115 VAC 8 Amps Constant Voltage 70 to 850 Amps 55 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage Fuse Input Ampere Type 75 C Type 75 C Frequency Super Lag Rating on Copper Wire in Copper Ground or Breaker Size Nameplate Conduit AWG Wire in Conduit IEC Sizes AWG IEC Sizes 208 60 230 60 416 60 460 60 575 60 Height 30 75 in 522 16 781 mm 237 kg LINCOLN 8 IDEALARC DC 600 INSTALLATION AS Read entire Installation Section before installing the IDEALARC DC 600 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK CAN KILL a Only qualified personnel should install o this machine Turn the input power OFF at the disconnect switch or fuse box before working on the equipment Do not touch electrically hot parts Always connect the IDEALARC DC 600 Gordo terminal to a good electrical earth ground Set the IDEALARC DC 600 Power ON OFF PUSH BUTTON to OFF position when connecting power cord to
8. B 7 NA 3 Automatic Wire B 7 NA 5 Automatic Wire B 9 LN 8 Semi Automatic Wire B 9 LN 7 amp LN 9 Semi Automatic Wire Feeders B 9 SECTION B 1 IDEALARC DC 600 OPERATING INSTRUCTIONS Read and understand entire section before operating machine SAFETY PRECAUTIONS A WARNING Es z yi PA 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 FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING CUTTING and GOUGING SPARKS can cause fire or explosion Keep flammable material away Do not weld cut or gouge on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual LINCOLN GENERAL DESCRIPTION The IDEALARC DC 600 is an SCR controlled three phase welding and cutting power source It uses a sin gle range potentiometer to control e Submerged Arc Semi Automatic or Automatic Welding e Open Arc Semi Automatic or Automatic Welding Stick Welding Stand
9. wj e n gt voz 1 FN ar sr 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 This diagram is intended to provide general information regarding PC board function Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine IDEALARC DC600 LINCOLN E
10. A qualified electrician should connect the input power supply leads 1 Follow all national and local electrical codes 2 Follow Input Supply Connection Diagram located on the inside of the machine 3 Use a three phase line 4 Remove Input Access Door at upper rear of machine 5 Connect the three phase AC power supply leads L1 L2 and to the input contactor terminals in the Input Box Assembly See Figure A 3 INPUT CONTACTOR CR1 INPUT POWER SUPPLY CABLE WITH BUSHING OR BOX CONNECTOR RECONNECT PANEL ASSEMBLY FIGURE A 3 Input Power Supply Connections LINCOLN 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 Follow The Input Connection Diagram located on the inside of Case Back Input Access Door These con nection diagrams for the following codes are listed below Multiple voltage machines are shipped connected to the highest input voltage listed on the machine s rating plate Before installing the machine check that the Reconnect Panel in the Input Box Assembly is con nected for the proper voltage 1 For codes 9773MSP 9910M 9776M 9780M see Figure A 4 A CAUTION 2 For code 9778M see Figure A 5 Failure to follow these instructions can cause immedi ate failure of components within the machine For code 9779M see Figure 4 For code 9774 s
11. INSTALLATION CONNECTION FOR 440 VOLTS 50 OR 60 HZ 460V 60HZ TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX DISCONNECT AND INSULATE THE H2 amp H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION CONNECT 11 12 amp L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES MOUNT THE LINKS IN THE POSITIONS SHOWN DOUBLE OR TRIPLE STACK THE LINKS IN THREE POSITIONS CONNECT THE FLEX LEAD AS SHOWN POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS INSTALLAND TIGHTEN ALLOF THE HEX NUTS CONNECTION FOR 380 VOLTS 50 OR 60 HZ TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX DISCONNECT AND INSULATE THE H2 amp H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION CONNECT 11 12 amp L3 INPUT SUPPLY LINES H1 AND CONTROL TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN CONNECT TERMINAL MARKED GROUND PER LOCAL AND NATIONAL ELECTRIC CODES MOUNT THE LINKS IN THE POSITIONS SHOWN DOUBLE UP THE LINKS IN TWO OF THE POSITIONS LOOP THE POSITIONS INSTALL AND TIGHTEN ALL OF THE HEX NUTS TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX DISCONNECT AND INSULATE THE H3 amp H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT L
12. NOTE If previous tests do not reveal the problem then the Control Board may be faulty Replace If LED 3 Does Not Glow But LED 1 Does Glow When ON PUSH BUTTON Is Pushed NOTE When this condition occurs the Fault Protection Relay CR2 is not receiving the 24 VDC supply voltage Therefore the Input Contactor CR1 cannot close Perform the following 1 Setand hold in the ON position the ON OFF PUSH BUTTON a f LED 4 glows or flickers Check the Weld Output Terminals associated wiring for a short condition See wiring diagram Check the Remote Control Circuit leads 75 76 77 They may be shorted to the negative welding voltage See wiring diagram b If the above procedures do not uncover the problem the Control Board may be faulty Replace If LED 5 Does Not Glow and Vary in Brightness Under the Following Conditions Machine is operating under load or ter minals 2 and 4 are jumpered togeth er on the terminal strip The OUTPUT CONTROL POTEN TIOMETER is rotated The WELD MODE SWITCH is in either CV position The OUTPUT CONTROL SWITCH is in the Output Control at DC 600 posi tion 1 Check the OUTPUT CONTROL POTENTIOMETER and associated wiring for loose or faulty connec tions a If all the above conditions are met the Control Board may be faulty Replace LINCOLN amp LINCOLN TROUBLESHOOTING amp REPAIR F 33 STATIC SCR TEST A WARNING Service and
13. The Shunt Assembly connects the positive Weld Output Terminal to the SCR Bridge Assembly Remove the small snubber lead from the left hand facing the front of the machine rear heat sink mounting bolt using a 1 2 socket wrench Clear all leads from any obstruc tions 10 11 Lift the SCR Bridge Assembly straight up and out of the machine being sure that no leads become tangled or hooked on the other machine parts a Be sure to locate the SCR Bridge Assembly on a stable work surface capable of hold ing the weight of the assembly Remove individual SCR Heat Sinks following the procedure described in A above Replace all insulating materials including the insulators on the frame rail and all insulating tubes when installing the SCR Output Bridge Assembly The Output Bridge assembly should be electrically isolated from ground Check with an analog ohm meter Minimum resistance is 500 000 ohms to ground F 53 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR LIFT BAIL REMOVAL INCLUDING MAIN TRANSFORMER CHOKE AND OUTPUT BRIDGE ASSEMBLY A 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 thr
14. Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the welder or cutter is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 1 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding or cutting must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being
15. LEAD 215 LEAD 204 LEAD 206 LEAD 231 LEAD 203 2 LEAD 207 a asco LEAD 208 LED7 LED8 LED9 LEAD 205 FIRING BOARD FOR CODES 9700 AND ABOVE G1486 5 AND HIGHER LED7 LED1 1 2 LEAD 203 FIRING BOARD LEAD 205 LEAD 215 LEAD 231 LED 5 FIRING BOARD FOR CODES BELOW 9700 G1486 4 AND LOWER G 1486 4 FIGURE F 7 Firing Board LED and Molex Plug Locations LINCOLN E IDEALARC DC 600 F 24 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR FIRING BOARD TEST TABLE F 1 LED 7 8 and 9 Check List LED 7 is OFF or is DIMMER than other LEDs LED 8 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 The proper AC voltage may not be reaching Firing Board _Check for loose or faulty connections Perform Main Transformer Test AC power is being supplied to the Firing Board from leads 205 and 206 connected to the phase angle winding in the Main Transformer LED 8 is OFF or is DIMMER than other LEDs LED 9 is ON The proper AC voltage may not be reaching Firing Board Check for loose or faulty connections Perform Main Transformer Test AC power is being supplied to the Firing Board from leads 207 and 208 connected to the phase angle winding in the Main Transformer LED 9 is OFF or
16. LED 6 G 1486 4 FIRING BOARD FOR CODES BELOW 9700 DC600 CONTROL G 1504 4 e e LED 1 LED 3 LED2 O LED4 LEDS LEAD 215 LED 2 CONTROL BOARD FOR CODES 9700 AND ABOVE LEAD 255 LEAD 256 CONTROL BOARD FOR CODES BELOW 9700 FIGURE F 12 Firing Board and Control Board Molex Plug Locations LINCOLN 8 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR F 35 STATIC SCR TEST REMOVE RED INSULATING 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 SCR 1 See Figure F 14 Use an NOTE DO NOT DISASSEMBLE analog ohmmeter Multimeter THE HEAT SINKS LINCOLN E IDEALARC DC 600 F 36 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR STATIC SCR TEST CATHODE FIGURE F 14 SCR 1 Test Points 5 Test for high or infinite resistance from the cathode to the anode of SCR 1 by reversing the leads See Figure F 14 high or infinite resistance is indicated for both tests 4 and 5 the SCR 1 is not shorted b If a low resistance is indicated in either strips 4 or 5 go to Step 6 Disconnect the snubber circuit See wiring diagram T Retest SCR 1 with the snubber cir cuit disconnected a If a low resistanc
17. NATIONAL NATIONAL 2 55 ELECTRICAL ELECTRICAL 2 CODE CODE 1 7 RECONNECT RECONNECT uo PANEL TO PRIMARY COILS TO PRIMARY COILS sw4 ae DUAL amp SINGLE VOLTAGE 380V OR TRIPLE VOLTAGE 222 2 Q o UNDER 300V 232 lt x H3 32 a e TO GROUND PER LL S TO GROUND PER NATIONAL 3 e 10 ys Q exi E um NATIONAL ELECTRICAL 2 a 76 2 ELECTRICAL CODE X2 r 31 75 77 80 81 M CODE RECONNECT lt gt 71 9 5 16 6 6 6 6 1 n aja on 280 mE PANEL SHOWN UE n m n n 80 81 PANEL CONNECTED T S 3 FOR 380V t T S 2 TO PRIMARY COILS TO PRIMARY COILS 255 PAS ot 235 m mmm 7 LIGHT J 235 aH 229 559 233 E 256 K 2 203p 75 UEGEND 255 349 232 1 PRIMARY EE 231 TK 4 sr C7 05 05 MFD 4 THERMOSTAT 238 56 32 593r 8 AMP SLOW BLOW FUSE 353 ok 233 lt 6 oh 226 1 R110K N A 1 PERMET To 7 34 72 224 R230 Qoow Pa 1 L 8 215 31 T1 MAIN POWER TRANSFORMER 13 T 9 10 43 T2 CONTROL TRANSFORMER LEADS 4 FRI K 10 280 1CR INPUT CONTACTOR THRU 9 210 K6 1 35 P E 4 12H30 2CR FAULT PROTECTION RELAY TO INPUT 215 215 P 2 D PANEL 210 13 49 220 3CR CURRENT ACTIVATED REED SWITCH 1 O 32A 1 CONTROL 222 4CR OUTPUT PILOT RELAY 7 8 9 O 1 D SW1 INPUT POWER im A RA H 10 11 12 LI 1 SW2 ELECTR
18. R2 3 ohms 10 watts To test SCRs construct the circuit outlined above Resistor values are plus or minus ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC FIGURE F 17 SCR Tester Circuit and SCR connections 4 Construct the circuit shown in Figure F 17 One 6 volt lantern bat tery can be used Set voltmeter scale low at approximately 0 5 volts or 0 10 volts a Test the voltage level of the battery Short leads A and C Close switch SW 1 Battery voltage should be 4 5 volts or higher If lower replace the battery IDEALARC DC 600 F 40 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST Connect the Tester to the SCR 1 as shown in Figure F 17 a Connect Tester lead A to the anode b Connect Tester lead C to the cathode c Connect Tester lead G to the gate Close switch SW 1 NOTE Switch SW 2 should be open Read meter for zero voltage a If the voltage reading is higher than zero the SCR is shorted Close or keep closed switch SW 1 Close switch SW 2 for 2 seconds and release and read meter a Ifthe voltage is 6 volts while the switch is closed and after the switch is open the SCR is functioning b If the voltages is 3 6 volts only when the switch is closed or there is no voltage when the switch is closed the SCR is defective NOTE Be sure battery is func tioning properly A low battery can affect the result
19. Test for 115 VAC between leads X1 and X2 NOTE If the main AC input supply voltage varies the Control Transformer voltage will vary by the same percentage a Connect one end of an insulat ed alligator clip to the X1 con nection at the Input Contactor CR1 interlock See Figure F 2 CONTROL TRANSFORMER LEFT SIDE OF LIFT BAIL ASSEMBLY b Connect the other end of the alligator clip to one of the meter probes Be sure that neither the alligator clip nor the meter probe touches any metal sur faces c Connect the other meter probe to the X2 connection at the secondary winding thermostat See Figure F 2 d Apply current Input Power to DC 600 INPUT CONTACTOR CR1 INSULATED ALLIGATOR CLIP CABLE CASE BACK FIGURE F2 Control Transformer X1 and X2 Test Connections 7 Read meter for 115 VAC a If 115 VAC is present the Control Transformer is func tioning properly b If 115 VAC IS NOT present go to Step 8 8 If 115 VAC is not present between leads X1 and X2 test for correct main AC input power to the Control Transformer primary windings H1 H2 H3 etc See Wiring Diagram a the correct main AC input power to the Control Trans for mer primary windings is pre sent AND the secondary volt age is not correct the Control Transformer may be faulty Replace F 15 IDEALARC DC 600 716 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST A WARNIN
20. WELDING PROBLEMS Poor arc starting when the DC600 is in the CV Sub Arc or CV Innershield Modes Make sure the proper welding procedures are being used wire feed speed arc voltage and wire size Check weld cables for loose or faulty connections Check the CR3 reed switch The voltage from lead 215 to lead 220 should be 8VDC when the DC600 is in an idle condition on but not welding When the machine is produc ing welding current the reed switch should close and the voltage from 215 to 220 should drop to zero Perform the Firing Board test Perform the SCR Output 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 216 383 2531 or 1 800 833 9353 LINCOLN IDEALARC DC 600 F 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines iie di 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 processes Check for the correct input volt ages on the three phase input lines at the DC600 Make sure the proper welding procedures are being used wire feed speed arc volt age and wire size Check the welding cab
21. 54 F 56 Removal of Transformer from Lift Bail Assembly F 57 F 59 Transformer Disassembly and Coil Replacement F 60 Retest After Repair F 61 F 62 LINCOLN E IDEALARC DC 600 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE IDEALARC DC 600 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into several main categories output problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks
22. 600 ACCESSORIES NOTE The instructions above are for connecting the stick polarity positive change the polarity turn the IDEALARC DC 600 OFF and reverse the cables NOTE When it is not necessary to have separate ground cables for stick and semi automatic or automatic welding connect a jumper from the MULTI PROCESS SWITCH Work terminal to the MULTI PROCESS SWITCH negative terminal See Figure C 4 To operate the MUL TI PROCESS SWITCH refer to the operating instructions on the switch nameplate UNDERCARRIAGE K817 K817R K842 The IDEALARC DC 600 is designed for use with the Lincoln K817 K817R or K842 Undercarriage Complete installation instructions are included with the undercarriage When any of the undercarriages are installed the IDEALARC DC 600 lift bail is no longer functional Do not attempt to lift the machine with the undercarriage attached The undercarriage is designed for moving the machine by hand only Mechanized towing can lead to injury and or damage to the IDEALARC DC 600 METERS Optional factory installed voltmeter and ammeter are available LINCOLN 8 ACCESSORIES CONNECTIONS FOR SEMI AUTO MATIC OR AUTOMATIC WIRE FEEDER CONTROL 1 Set the ON OFF PUSH BUTTON to OFF 2 Locate and open the hinged access door on the Front Case Assembly 3 Insert control cable through the strain relief box connector and pull enough cable through to reach the terminal strip 4
23. DC 600 E 4 THEORY OF OPERATION FIGURE E 4 Protection Devices and Circuits Contactor Hold In CONTROL TRANSFORMER PROTECTION DEVICES amp CIRCUTS CONTACTOR HOLD IN MAIN TRANSFORMER R E N N E T zb CONTACTOR TERMINAL STRIP PROTECTION DEVICES AND CIRCUITS CONTACTOR HOLD IN Two thermostats protect the DC 600 from excessive operating temperatures Excessive operating temper atures may be caused by a lack of cooling air or oper ating the machine beyond the duty cycle and output rating If excessive operating temperature should occur the thermostat s will deactivate the input con tactor turning the machine off The input contactor will remain open until the machine cools The machine can then be restarted by operating the start push but ton Upon restart if the fan does not turn or the air intake louvers are obstructed then the input power must be removed and the fan problem or air obstruction be corrected 115 VAC SCR BRIDGE OUTPUT CONTROL FAULT PROTECTION FIRING BOARD POSITIVE TERMINAL AOPuommn LATCHING RESISTOR NEGATIVE The DC 600 is also protected against high current overloads This electronic protection circuit senses an overload on the power source and opens the input con tactor should the overload remain for a predetermined time If the overload is great the machine will shut down immediately The input contactor will remain open until the start push
24. Disconnect main AC input power supply to the machine 2 Identify and label the following a The transformer secondary lead heavy aluminum conduc tor connected to the anode of the SCR heat sink for each assembly to be removed See Figure F 19 b The snubber leads for each SCR heat sink to be removed See Figure F 19 IDEALARC DC 600 3 Disconnect the transformer sec ondary lead to the anode of the heat sink assembly using 1 2 Socket wrench and 1 2 open end wrench 4 Disconnect the gate lead to the SCR a If the gate lead is cut it will have to be re soldered when the replacement SCR is installed b If anew snubber board is used install properly LINCOLN LINCOLN 8 TROUBLESHOOTING amp REPAIR 5 Remove the four thru bolts and associated nuts and washers hold ing the SCR heat sink to the bridge tie bars a The main mounting bolts that mount the SCR bridge assem bly to the frame rail may have to be loosened to slide the SCR Heat Sink out from under the buss jumper strap When all four thru bolts are removed the SCR Heat Sink directly above or below will be detached also Support the SCR Heat Sink above or below To hold the Heat Sink in place temporarily insert one of the thru bolts and replace the nut hand tight 6 Install the replacement SCR Heat Sink in reverse order of removal a Apply a thin layer of Lincoln E1868 Dow Corning 340 heat sink compound to all b
25. H THE MULTI PROCESS SWITCH He I N F ZNUSING A WIRE FEEDER K 317 OR K 318 B i I LEADS 210 8 215 ARE a Li CONNECTION DIAGRAM CONNECT ELECTRODE TE OUTPUT SHUNT TOGETHER AND WORK LEADS THESE TERMINALS 5 dig VsdMVrGagU AMBS 220 INSTEAD OF THE POWER SOURCE oy 2s 210 AA OUTPUT TERMINALS 220 output 215 THESE NOTES APPLY ONLY TO DC 600 WITH A 1 m MULTI PROCESS SWITCH INSTALLED SNUBBER c c c 215 1 1 mem mn md m m mem mm mem n mem o nim m 1 0 STICK ELECTRODE HOLDER OR 1 1 WORK 1 1 AIR CARBON ARC TORCH N D N E 1 D 1 ELECTRODE 1 TO WORK USED WITH STICK 1 L REUNIR OR AIR CARBON ARC m 4 3 OUTPUT RECTIFIER EL ES ERI EAE DU STICK WORK LEAD NOT OPTIONAL HEP G6 C GATE LEADS TO THOSE SITUATIONS WHERE IT IS NOT USEDOWHERDUMPERAS MULTI PROCESS CONNECTOR CAVITY NUMBERING SEQUENCE G4 P FIRING CIRCUIT NECESSARY HAVE SEPARATE GROUND nis 62 P C BOARD i VIEWED FROM COMPONENT SIDE OF BOARD CABLES FORIS TICK AND SEMEAUTOMATIG 4 WELDING ELECTRICAL SYMBOLS PER E1537 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosur
26. H4 R46 een Ed RESISTOR MF 1 4W 332 1 FAQS DDR wi RESISTOR MF 1 4W 33 2K 1 els EE RESISTOR MF 1 4W 392K 1 VAN ok bite head RESISTOR MF 1 4W 44 2K 1 R28 R87 R108 RESISTOR MF 1 4W 475 1 R15 R27 R41 R76 R91 R114 RESISTOR MF 1 4W 4 75K 1 R115 R12 R61 R93 R106 RESISTOR MF 1 4W 47 5K 1 13 62 120 RESISTOR MF 1 4W 475K 1 ee RESISTOR MF 1 4W 56 2K 1 69 100 109 RESISTOR MF 1 4W 681 196 R9 R34 R56 R57 R64 R71 R96 RESISTOR MF 1 4W 6 81K 1 01 02 03 04 07 09 010 019 DIODE AXLDS 1A 1000V 021 23 itus eed eee ZENER DIODE 0 4W 6 2V 5 1N821 DZ sete ett ZENER DIODE 1W 12V 5 1N4742A DZ5 ZENER DIODE 1W 15V 5 1N4744A 0713 0714 0715 ZENER DIODE 0 5W 3 0V 5 1N5225B 026 048 2 ZENER DIODE 0 5W 8 2V 5 1N5237B DZ2 DZ16 s ZENER DIODE 5W 10V 5 1N5347B DZ9 DZ12 ZENER DIODE 1W 30V 5 1N4751A isti ZENER DIODE 5W 16 0 16 5V 1N5353 DZ4 i cue ZENER DIODE 1W 9 9 10 4V 1N4740 Q1 Q2 Q4 Q8 Q10 TRANSISTOR NJF T206 40V 2N4857 Q3 Q5 Q6 Q11 TRANSISTOR N T226 0 5A 40V 2N4401 Q9 012 ero TRANSISTOR P T226 0 5A 40V 2N4403 TP Tuc con tore set ens MOV 150VRMS 45J 14MM CRIMPED 2 esce Peg reete MOV 320VRMS 160J 20MM LED1 LED2 LED3 LED4 LED5 LED T 1 3 4 RED HLMP 3003 R53 R54 R55 R111 R11
27. Open Circuit Voltage Control to the same dial setting as the Arc Voltage Control If this is a new welding procedure a good starting point is to set the Open Circuit Voltage Control to 6 NOTE The open circuit voltage of the IDEALARC DC 600 varies from approximately 16 volts to 56 volts in the CV Innershield or CV Submerged Arc modes The open circuit voltage is constant in the VV CC mode 3 Runa test weld Set proper current voltage and travel speed a For the best starting performance the NA 3 Open Circuit Voltage Control and Voltage Control setting should be the same Set the Inch Speed Control for the slowest inch speed possible b To adjust the Open Circuit Voltage Control to get the best starting performance make repeated starts observing the NA 3 voltmeter When the voltmeter pointer swings smoothly up to the desired arc voltage without undershooting or overshooting the desired arc voltage the Open Circuit Voltage Control is set properly If the voltmeter pointer overshoots the desired volt age and then returns back to the desired voltage the Open Circuit Voltage Control is set too high This can result in a bad start where the wire tends to Blast off If the voltmeter pointer hesitates before coming up to the desired voltage the Open Circuit Voltage Control is set too low This can cause the elec trode to stub 4 Start and make the weld a Cold starts For cold starts be sure the work piece is
28. SUPPLY S4 A 18J1 CURRENT REED SW CLOSED WITH OUTPUT CURRENT 3CR SET POINT CONTROL PCB 2J6 50818 SCR2 204 entu GATE DRIVE J7 A GATE DRIVE TO MAIN POWER l TRANSFORMER 206 106 SCR3 amp SCR4 205 7 5 Y FIRING CIRCUIT ag GATE DRIVE CONTROL 231 4J2 FIRING SIGNAL 1045 VOLTAGE FEEDBACK TO MAIN POWER 208 75 VAC Ce TRANSFORMER 207 SCR5 amp SCRE FIRING CIRCUIT SHUTDOWN CURRENT FEEDBACK OVEHEOAD DETEOT FIRING PCB Is S m m n 1401 243 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual IDEALARC DC600 222 OUTPUT STUD OUTPUT STUD 210 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD VOLTS J3 J6 J4 J7 1 12 14 gt 3 1 gt 4 2 5 8 6 gt 0 8 gt 12 CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD 1 11 92 DC 600 OPERATING SCHEMATIC 62299 LINCOLN P ELECTRICAL DIAGRAMS G 8 FIGURE G4 Control Board Schematic for G1504 4 and above
29. SWITCH be used This switch permits you to easily change the polarity of the connected wire feeding equipment or switch to stick welding or air carbon arc cutting NA 3 AUTOMATIC WIRE FEEDER 1 Setthe DC 600 Output Control Switch to Remote NOTE Later model NA 3 automatic wire feeders are capable of cold starts when the NA 3 Mode switch is in the CV or VV CC mode position Some earlier models are capable of cold starting only in the VV CC mode position Cold starting enables you to inch the wire down to the work automatically stop and automatically energize the flux hopper valve 2 Set the DC 600 welding mode switch for the desired process CV Submerged Arc CV Innershield mode or VV CC mode 3 Set the NA 3 mode Switch Position to either CV or VV CC to match the DC 600 mode selected in step 2 4 Refer to the NA 3 operators manual for instruc tions on how to use the NA 3 in conjunction with the DC 600 5 Follow the following guidelines for good arc striking detailed below for each welding mode GOOD ARC STRIKING GUIDELINES FOR THE NA 3 WITH THE IDEALARC DC 600 IN THE CV INNERSHIELD CV SUBMERGED ARC OR VV CC WELDING MODES Following are some basic arc striking techniques that apply to all wire feed processes Using these proce dures should provide trouble free starting These pro cedures apply to single solid wires and Innershield wires 1 the electrode to a sharp point LINCOLN 2 Set the NA 3
30. circuit voltage SCOPE SETTINGS 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 The machine was loaded with a resistance grid bank The grid bank meters read 200 amps at 28VDC Volts Div Horizontal Sweep Coupling Trigger Note Scope probes connected at machine ouput terminals probe to positive termi nal probe to negative terminal LINCOLN 8 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR F 45 TYPICAL SCR GATE VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MAXIMUM OUTPUT SETTING NO LOAD CH1 0 volts 2 volts 5ms This is the typical SCR gate pulse voltage waveform The machine was in an open cir cuit condition no load and operating proper ly Note that each vertical division represents 2 volts and that each horizontal division rep resents 5 milliseconds in time Volts Div Horizontal Sweep Coupling Trigger Note Scope probes connected at SCR gate and cathode probe to gate probe to cathode LINCOLN 2 IDEALARC DC 600 coe TROUBLESHOOTING amp REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD ONE OUTPUT SCR NOT FUNCTIONING 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
31. clean and the electrode makes posi tive contact with the work piece b Hot On the Fly starts For hot starts travel should begin before the wire contacts the work piece IDEALARC DC 600 Be OPERATION ARC STRIKING WITH IDEALARC DC 600AND THE NA 3 START BOARD When electrical strikeouts exceed 1 3 40 44 4mm an NA 3 Start Board may be required to improve arc strik ing When the NA 3 Start Board is used to improve arc striking use the following procedures 1 Set start time at 0 2 Set NA 3 start current and start voltage at mid range 3 Set the NA 3 output current and voltage to the proper settings for the welding procedure to be used 4 Turn the Start Board Timer to maximum 5 Set Start Board current and voltage control a Setthe Start Board current control to 1 1 2 dial numbers below that set on the NA 3 current control b Set the Start Board voltage control equal with the NA 3 voltage control setting NOTE These Start Board current and voltage set tings result in a start up current that is lower than the NA 3 current setting and approximately equal with the NA 3 voltage setting for the desired weld ing procedure IDEALARC DC 600 6 Establish the correct arc striking procedure with the NA 3 Start Board timer set at maximum a For the best starting performance the NA 3 Open Circuit Voltage Control and V oltage Control setting should be the same Set the Inch Speed Control for the slowes
32. igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 7 0 To avoid scalding do not remove the a AL pe M radiator pressure cap when the engine is TUN hot LINCOLN 79 8 a Electric current flowing through any conductor causes 2 ELECTRIC AND MAGNETIC FIELDS may be dangerous localized Electric and Magnetic Fields EMF Welding or cutting current creates EMF fields around welding or cutting cables and welding machines EMF fields may interfere with some pacema
33. in the order listed general these tests can be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate 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 trou bleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN LINCOLN 8 TROUBLESHOOTING amp REPAIR F 3 PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can e kill Have an electrician in
34. l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les IDEALARC DC 600 zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tou
35. mode 2 Set the IDEALARC CONTROL SWITCH DC 600 OUTPUT a LN 7 Use either an optional K775 Remote Control Box Assembly or set the IDEALARC DC 600 OUTPUT CONTROL SWITCH in the Local position b LN 9 Refer to the LN 9 Operator Manual for instructions of how to use the LN 9 IDEALARC DC 600 LINCOLN TABLE OF CONTENTS ACCESSORIES SECTION ACCESSORIES Ee Section C AGCCOSSOLIOS 2 C 2 Multi Process Switch C 2 Urdercatrlage 4 MEE ee iced 4 Connections for Wire Feeder Control C 5 C 5 NA 5 inrer des rue nere C 6 LNS Or EINE 9 etes C 7 ENS ue er LE C 8 Section C 1 IDEALARC DC 600 ACCESSORIES OPTIONS ACCESSORIES Y Multi Process Switch K804 Remote Control Box Assembly K775 X Undercarriages K817 K817R K842 Semi Automatic and Automatic Wire Feeders XY 7 Y LN 8 Semi Automatic Wire Feeders X LN 9 NA 3 5 Pautomatic Wire Feeders MULTI PROCESS SWITCH The MULTI PROCESS SWITCH gives you the ability to Y Switch between stick welding or air carbon arc cutting and using a semi automatic or automatic wire feeder Y Change the polarity of a semi automatic or auto matic wire feeder without changing any
36. power to the machine e Replace the Molex Plug J2 Test for continuity zero f Connect main AC input power ohms between lead 256 at to the machine Plug J2 on the Control Board and lead X2 at the secondary g Set the ON OFF PUSH BUT thermostat See Figure F 10 TON to ON NOTE Disconnect main AC h Read meter for 115 VAC input power to the machine CONTROL BOARD ON OFF PUSHBUTTON FIGURE F 10 LED 1 Test Points LINCOLN amp IDEALARC DC 600 LINCOLN 1 TROUBLESHOOTING amp REPAIR CONTROL BOARD TEST If LED 2 Does Not Light When Machine is Operating Under Load or terminals 2 and 4 are jumpered together on the terminal strip Test for the following open circuit voltages at the Weld Output Terminals 15 58 VDC when the WELDING MODE SWITCH is in either of the CV positions 75 VDC when the WELDING MODE SWITCH is in the VV CC position NOTE BE SURE TO OBSERVE POLARIT Y DC VOLTAGES BEING TESTED Touch the negative meter probe to the negative Weld Output Terminal and positive meter probe to the positive Weld Output Terminal 3 Read meter a f the open circuit voltage is present at the Weld Output Terminals then test for open circuit voltage the Control Board b Ifthe open circuit voltage is not present at the Weld Output Terminals then Check the Output Choke and associated heavy current car rying leads for loose or faulty connections Perfor
37. 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 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION The Static SCR Test is used to quickly determine if an SCR is shorted or leaky See the Waveform Section in this manual fo and_abnormal SCR waveforms MATERIALS NEEDED Analog Ohmmeter Multimeter IDEALARC DC 600 wiring diagrams See Electrical Diagrams Section of this Manual IDEALARC DC 600 F 34 TROUBLESHOOTING amp 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 G 1486 5 FIRING BOARD O Q LED 7 LED 8 LED 9 LEAD 203 LED1 LED2 LEAD 204 LEAD 206 O O O LEAD 215 FIRING BOARD 3 LEAD 205 LEAD 207 4 LEAD 208 LEAD 231 LED 4
38. should be 115VAC present at leads 31 and 4 at CR4 when 2 and 4 are jumpered together at the terminal strip a If the correct voltage is present and the relay does not activate the relay may be faulty Replace If the 115VAC is missing check the associated wiring for loose or faulty connections See wiring diagram cable connections Check the OUTPUT CON TROL POTENTIOMETER R1 and associated circuitry for loose or faulty connections See wiring diagram Perform Main Transforme Perform Firing Board test Perform Control Board test Perform SCR Output Bridge 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 216 383 2531 or 1 800 833 9353 LINCOLN amp IDEALARC DC 600 TROUBLESHOOTING amp REPAIR F 7 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 f remote control is being used Check OUTPUT CONTROL put and no control set OUTPUT CONTROL SWITCH SW3 and associat SWITCH SW3 in OUTPUT ed wiring CONTROL AT DC600 position and control weld output with the Check feedback leads 222 OUTPUT CONTROL POTEN negative output terminal TI
39. the Input Contactor plate 10 Insert the replacement Input Contactor and install it following the procedures in reverse order NOTE Be sure to reconnect all leads correctly LINCOLN amp TROUBLESHOOTING amp REPAIR F 49 SCR SCR OUTPUT BRIDGE REMOVAL A 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 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD MATERIALS NEEDED 9 16 socket wrench 1 2 socket wrench 1 2 open end wrench LINCOLN amp IDEALARC DC 600 F 50 TROUBLESHOOTING amp REPAIR SCR SCR OUTPUT BRIDGE REMOVAL A REMOVAL OF INDIVIDUAL SCR HEAT SINK SCR BRIDGE ASSEMBLY SNUBBER PC BOARD ASSEMBLY TRANSFORMER SECONDARY LEAD TRANSFORMER SECONDARY LEAD FIGURE F 19 Individual Heat Sink Removal NOTE If it is necessary to remove and replace only one or two individual SCRs and they are easy to work on use these procedures 1
40. the left cable from the MUL TI PROCESS SWITCH facing the front of the machine to the IDEALARC DC 600 negative output terminal See Figure C 4 IDEALARC DC 600 4 13 Connect the wire feeder electrode and work cables See Figure C 4 a Insert the wire feeder electrode and work cables through the strain relief loop on the left side of the IDEALARC DC 600 facing the front of the machine b Connect the wire feeder electrode and work cables to the electrode work terminals on the left side of the MUL TI PROCESS SWITCH NOTE When using Dual Process Kits K317 or K318 connect the electrode and work cables to these terminals instead of the power source output terminals See connection diagrams for details 14 Connect wire feeder control cable to the terminal strip of the IDEALARC DC 600 NOTE Connect the control cable ground lead to the frame terminal marked 2 NOTE See the connection diagram for the wire feeder being used for connection instructions 15 Connect stick or air carbon arc electrode and work cable See Figure C 4 a Insert the electrode and work cables through the strain relief loop on the right side facing the front of the machine of the IDEALARC DC 600 b Connect the electrode cable to the Positive terminal on the right side of the MUL TI PROCESS SWITCH c Connect the work cable to the Negative ter minal on the right side of the MUL TI PROCESS SWITCH IDEALARC DC
41. ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding or cut ting with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 3 b Do not weld or cut in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding or cutting can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 3 e Also see item 7b IDEALARC DC 600 SAFETY WELDING OR CUTTING ME SPARKS can cause fire or explosi
42. 2 R122 RESISTOR CC 1 2W 100 5 RTORA T is sene eee RESISTOR CC 1 2W 330 5 liess dos Uu een RESISTOR WW 5W 270 5 SQ RITI vegan RESISTOR WW 5W 150 5 SQ Ri sot alee toe es RESISTOR WW 10W 100 5 RESISTOR WW 20W 200 5 SQ uteri CONNECTOR MOLEX MINI PCB 10 PIN XT X2 aen be sete te IC OP AMP QUAD GEN PURPOSE 224N QUT eee pa eda ees PUT 2N6027 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting 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 Improper PC board repairs could result in damage to the machine LINCOLN P IDEALARC 600 G 3 ELECTRICAL DIAGRAMS FIRING PC BOARD G1486 5 AND ABOVE 1 N 1 1 AT Ili
43. 208 75 VAC Figure F 5 Phase Angle Windings Test Points and Terminal Board location LINCOLN E IDEALARC DC 600 TROUBLESHOOTING REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST b If the Firing Board number is 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 nected to the firing board Molex plugs See Figure F 6 d If the wiring is good then the Main Transformer may be faulty Replace FIRING BOARD CONTROL BOARD TERMINAL STRIP PIN 4 PIN 9 LEAD 204 LEAD 207 cs PIN 3 PIN 8 LEAD 206 LEAD 208 PIN 2 LEAD 203 From To Plug Lead Plug Pin Lead Expected VAC 4 3 8 J5 2 203 J5 204 75 VAG J5 7 205 J5 206 75 VAG 5 9 J5 J 207 208 75 VAG FIGURE F 6 Phase Angle Windings Test Points and Firing Board Location LINCOLN 8 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR F 21 FIRING BOARD TEST A 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 If for any reason you do not understand
44. 600 wiring diagrams See Electrical Diagrams Section of this Manual LINCOLN E IDEALARC DC 600 F 38 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST TEST PROCEDURE 1 Disconnect main AC input power to the machine 2 Disconnect all Molex Plugs from the Firing Board and Control Board See Figure F 15 G 1486 5 FIRING BOARD O LED 7 LED 8 LED 9 FIRING BOARD FOR CODES 9700 AND ABOVE 6 LEAD 203 LED1 LED2 LEAD 204 LEAD 206 LEAD 207 LEAD 208 LEAD 205 LEAD 215 LEAD 231 FIRING BOARD O LED 4 Q LED 6 FIRING BOARD FOR CODES BELOW 9700 DC600 CONTROL G 1504 4 LED 1 LED 3 G 1504 3 LED4 LED5 LED 2 CONTROL BOARD FOR CODES 9700 AND ABOVE LEAD 255 gt o LEAD 256 OO CONTROL BOARD FOR CODES BELOW 9700 FIGURE F 15 Firing Board and Control Board Molex Plug Locations LINCOLN amp IDEALARC DC 600 LINCOLN TROUBLESHOOTING amp REPAIR F 39 ACTIVE SCR TEST REMOVE RED INSULATING FIGURE F 16 Heat Sink Test Points 3 Remove the red insulating paint from the heat sink test points See FIGURE F 16 NOTE DO NOT DISASSEMBLE THE HEAT SINKS 6 VOLT LANTERN BATTERY sw2 R1 4 ohms 10 watts
45. A OoP PuocmmT SCR BRIDGE LATCHING RESISTOR NEGATIVE TERMINAL Transformer The transformer changes the high volt age low current input power to a low voltage high cur rent output The finishes or neutrals of the main sec ondary coils are connected together and the six starts of the secondary windings are connected to the rectifi er assembly In addition the main transformer also has an isolated 115VAC auxiliary winding that supplies 115VAC to operate the cooling fan and offers 8 amps of auxiliary power to operate wire feeding equipment The three 75VAC phase angle windings are also housed in the Main Transformer assembly These windings provide power and timing to the firing board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC DC 600 THEORY OF OPERATION E 3 FIGURE E 3 Output Rectification Control and Feedback CONTROL 115 VAC TRANSFORMER PROTECTION DEVICES amp CIRCUTS CONTACTOR HOLD IN MAIN TRANSFORMER R E T E 7 CONTACTOR TERMINAL STRIP REMOTE CONTROL OUTPUT RECTIFICATION CONTROL AND FEEDBACK The neutrals of the Main Transformer secondary wind ings are connected together and the six starts are con nected to the six SCR assemblies to form a six phase output This six phase AC output from the Main Transformer secondary is rectified and controlled through the SCR bridge Output current and voltage is sensed at the shunt a
46. CH POTENTIOMETER FIGURE B 1 CONTROL PANEL KEYS 1 ON OFF PUSH BUTTON This push button turns 5 CONTROL CIRCUIT POLARITY SWITCH This the machine ON or OFF toggle switch is used to set power source voltage sensing polarity to match the polarity to which the 2 OUTPUT CONTROL POTENTIOMETER This electrode is connected to the machine This pro control provides tapered continuous control of the vides the correct polarity at the terminal strip for machine output The control can be rotated from correct operation of the automatic wire feeding minimum to maximum while machine is under load equipment powered by the auxiliary power from to adjust the machine output the power source WELDING MODE SWITCH This toggle switch is 6 POWER SOURCE PILOT LIGHT The red neon used to select the proper welder performance light glows when the power source input contactor characteristics for the process being used There is energized are three modes CV Constant Voltage Innershield CV Constant Voltage Submerged 7T AMMETER An optional ammeter is Arc and VV Variable Voltage CC Constant available Current Submerged Arc 8 VOLTMETER An optional voltmeter is 4 OUTPUT CONTROL SWITCH This toggle switch available is used to switch between Output Control at DC 600 for local control of machine output and Output Control Remote for remote control of machine output LINCOLN OPERATING STEPS The following procedures are fo
47. CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H2 PILOT RECONNECT TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN 2 INSULATE UNUSED H3 H4 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 3 CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODE 4 CONNECT TRANSFORMER LEADS 1 amp 7 2 amp 8 3 amp 8 9 4 5 amp 6 TO RECONNECT PANEL 5 TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13 14 15 16 17 18 TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS FIGURE A 8 Reconnect Panel Board Positions for 230 460 575 VAC Machines LINCOLN 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 46m 150 ft 46m to 200 ft 61m 2 0 67 200 ft 61m to 250 ft 76m 7 3 0 85mm Connect Electrode and Work Leads to Output Terminals NEGATIVE POSITIVE OUTPUT TERMINAL OUTPUT TERMINAL 1 Set the ON OFF PUSH BUTTON to OFF 2 Locate the retractable strain relief loops directly below the output terminals in the lower right and lower left corners of the Case Front Assembly See Figure A 9 3 Pull out the retractable stra
48. Circuit When the OUTPUT CONTROL SWITCH SW 3 is in the Output Control at DC 600 position and the WELDING MODE SWITCH SW 4 is in the CV position the LED will glow brighter or dimmer as the OUTPUT CONTROL POTENTIOMETER is rotated If the pot is rotated clockwise open circuit voltage increased the LED will glow dimmer If the pot is rotated counter clockwise open circuit voltage decreased the LED will glow brighter When the WELDING MODE SWITCH SW 4 is in the VV CC position for stick welding the open circuit voltage is at maximum LED 5 will be very dim or not lit TABLE F 2 LED Function Description IDEALARC DC 600 F 30 TROUBLESHOOTING amp REPAIR CONTROL BOARD TEST TEST PROCEDURES If LED 1 Does Not Glow When ON OFF PUSH BUTTON is Set to ON 1 Test for 115 VAC between leads 255 and 256 at Plug J2 on the Control Board If 115 VAC is present AND LED 1 does not glow the Control Board may be faulty Replace If 115 VAC is not present Inspect leads 255 and 256 a Disconnect main AC input sup and associated wiring for loose ply power to the machine or faulty connections See wiring diagram b Locate the Control Board in the Control Box Test for continuity zero ohms between lead 256 at Disconnect Molex Plug J2 Plug J2 on the Control Board and the ON OFF PUSH BUT d Insert the probes into the Plug TON See Figure F 10 lead cavities for leads 255 and 256 NOTE Disconnect main AC input
49. Connect the automatic wire feeder control cable to the terminal strip See corresponding connection diagram in this Section of the manual or the instructions included with the wire feeder 5 Connect the wire feeder grounding wire to the chassis ground screw marked with the symbol 7 NOTE The IDEALARC DC 600 Auxiliary Power Circuit supplies 1 15 volt AC power to the wire feed ing equipment The circuit has a 1000 volt ampere rating An 8 amp slow blow fuse on the machineO s control panel protects the auxiliary power supply from excessive overloads CONNECTING THE NA 3 IDEALARC DC 600 1 Disconnect main AC input power to the IDEALARC DC 600 2 Set IDEALARC DC 600 ON OFF PUSH BUTTON to OFF 3 Connect the wire feeder control cable leads to the IDEALARC DC 600 terminal strip as shown in Figure C 5 4 Connect the wire feeder control cable ground lead to the frame terminal marked 7 NOTE The IDEALARC DC 600 must be properly grounded LINCOLN NEGATIVE POSITIVE ELECTRODE CABLE TO MATIC TO WORK AUTO EQUIPMENT FIGURE C 5 NA 3 WIRE FEEDER CONNECTION TO THE IDEALARC DC 600 5 Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape An S 16586 X remote voltage sensing work lead is available for this pu
50. Contactor Reconnect Panel and primary leads to the Main Transformer for loose or faulty connections See Figure F 3 a Confirm that the Reconnect Panel is connected properly for the three phase main AC input power supplied to the machine See the Reconnect Panel Connection Diagram located on the inside of the Input Box Assembly Access Door the machine Set the ON OFF PUSHBUTTON to ON a Make sure the Input Contact CR1 energizes The fan runs Test with an AC voltmeter for prop er main AC input voltage to the line side of the Input Contactor CR1 See wiring diagram a L1toL2 b L2toL3 C L1toL3 IDEALARC DC 600 F 18 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST 7 Read meter a f proper voltage is present for all three phases proper main AC input voltage is being sup plied b If proper voltage is not present in any or all of the three phas es check input fuses and leads 8 Test with an AC voltmeter for prop er main AC input voltage from the output side of the Input Contactor CR1 See wiring diagram a to T2 b T2to T3 T1 to 9 Read meter a If proper voltage is present for all three phases the Contactor is working properly b If the proper voltage is not pre sent for any or all of the three phases the contactor may be faulty Replace 10 Test with an AC voltmeter for 52 VAC from each of the six m
51. Contactor CR1 in the Input Box CONTROL INPUT Drone ens di dees CR1 S Ye T Speo J AA FIGURE F 18 Input Contactor Cleaning and Removal MENT PROCEDURE 1 Disconnect main AC input power supply to the machine 2 Locate and get access to the Input Figure Ede Contactor CR1 in the Input Box See Fi F 18 Remove the Input Contractor cover ERE P 3 Disconnect the main power supply leads L1 L2 and L3 to the Input Contactor DO NOT APPLY 5 e INPUT POWER TO 4 Disconnectthe output leads T1 T2 THE MACHINE and T3 from the Input Contactor WITH THE INPUT CONTACTOR 5 Identify and label the leads con COVER PLATE nected to the Input Contactor coil REMOVED and interlock See wiring diagram 4 Blow out any dirt or dust in or 6 Disconnect the leads from the Input around the contacts with a low Contactor coil leads 271 amp 272 pressure air stream See wiring diagram Inspect the contacts for signs of 7 Disconnect the leads from the Input excessive wear pitting or contacts Contactor interlock leads 211 amp fused stuck to together 212 See wiring diagram a If any of these conditions are 8 Remove the three self tapping present replace the Input mounting screws using a 5 16 Contactor Assembly socket wrench See Figure F 18 Replace the Input Contactor cover 9 Remove
52. EAST 600 VOLT INSULATION CONNECT 11 12 amp L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN CONNECT TERMINAL MARKED TO GROUND PER LOCALAND NATIONAL ELECTRIC CODES MOUNT THE LINKS IN THE POSITIONS SHOWN LOOP THE FLEX LEAD IN THE POSITION SHOWN INSTALL AND TIGHTEN ALL OF THE HEX NUTS FIGURE A 5 Reconnect Panel Board Positions for 220 380 440 VAC Machines CONNECTION FOR 380 460 VOLTAGES DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION CONNECT H2 LEAD TO CONTACTOR CONNECTION FOR 500 575 VOLTAGES H3 DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION CONNECT H3 LEAD TO CONTACTOR CONNECT 11 12 amp L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR CONNECT L1 L2 amp L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN CONNECT TERMINAL MARKED CD TO GROUND PER NATIONAL ELECTRIC CODES REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN REPLACE AND TIGHTEN ALLHEX NUTS AS SHOWN CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN REPLACE AND TIGHTEN ALLHEX NUTS FIGURE A 6 Reconnect Panel Board Positions for 380 460 500 575 VAC Machines IDEALARC DC 600 LINCOLN SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE 1 TURN OFF THE IN
53. ENTS ELECTRICAL DIAGRAMS Control Board G1504 4 and above Firing Board Layout G1486 5 and above Wiring Diagram Codes 9773 9776 9778 9779 9780 9910 Wiring Diagram Code 9774 Operating Schematic Control Board G1504 4 and above Firing Board Schematic G1486 5 and above Section G IDEALARC DC600 ELECTRICAL DIAGRAMS G 1 CONTROL PC BOARD G1504 4 AND ABOVE Y 01 LEDS R122 DC600 CONTROL 61504 R120 473 i pee R112 J 78 R106 105
54. G 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 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltages are being a applied to the primary windings of the Main Transformer T1 b induced on the secondary winding auxiliary windings and phase angle windings MATERIALS NEEDED Volt Ohm Meter Multimeter IDEALARC DC 600 wiring diagram See Electrical Diagram Section of Manual LINCOLN 8 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR F 17 MAIN TRANSFORMER T1 VOLTAGE TEST INPUT SUPPLY INPUT OPENING RECONNECT TRANSFORMER PANEL ASSEMBLY LEADS LN CASE BACK SIDE VIEW 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 OFF Disconnect main AC input power from the machine Inspect the Input
55. IDEALARC DC 600 must be properly grounded 5 PERFORM THIS STEP ONLY IF THE LN 7 IS EQUIPPED WITH A METER KIT Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape NOTE If the work cable length is less than 25 feet and the connections to the work piece are secure then wire feeder control cable lead 21 can be connected directly to the DC 600 terminal strip LINCOLN 8 IDEALARC DC 600 LINCOLN TABLE OF CONTENTS SectionD 1 MAINTENANCE SECTION MAINTENANCE nissene aininn iaieiiea Section D Safety Precautions 2 D 2 Routine and Periodic Maintenance _ D 3 3 D Exploded D 4 IDEALARC DC 600 D 2 MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS A 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 LINCOLN IDEALARC DC 600 MAINTENANCE D 3 ROUTINE AND PERIODIC MAINTENANCE 1 Disconnect input AC power supply lines to the machine before performing periodic maintenance tightening cleaning or replacing parts See Figure D 1 Perform the following daily 1 Check that no combustible material
56. If any or all of LEDs 1 6 do not glow or do not change in brightness equally as the pot is turned go to Step 13 between leads 231 and 215 on the Firing Board in CV mode a Locate on the Firing Board the Molex Plug with leads 231 and 215 connected to it See Figure 7 b Set the ON OFF PUSH BUTTON to OFF c Remove the Molex Plug from the board d Insert the meter probes into the appropriate Plug lead cavities NOTE OBSERVE POLARITY DC VOLTAGES BEING TESTED e Connect the Molex Plug into the Firing Board f Set the WELDING MODE SWITCH in either of the CV positions g Set the ON OFF PUSHBUT TON to ON h Rotate the OUTPUT CON TROL POTENTIOMETER clockwise and counter clock wise The DC voltage between leads 231 and 215 should vary from 10 VDC to 13 VDC as the pot is turned from mini mum to maximum i If the voltage does NOT vary then the Control Board may be faulty Replace LINCOLN amp LINCOLN TROUBLESHOOTING amp REPAIR FIRING BOARD TEST 14 Test for approximately 5 8 VDC between leads 231 and 215 on the Firing Board in VV CC mode a Keep the meter probes insert ed into the Plug lead cavities for leads 231 and 215 b Keep the jumper connected at terminals 2 and 4 at the ter minal strip c Set the WELDING MODE SWITCH SW4 to the VV CC position d Rotate the OUTPUT CON TROL POTENTIOMETER clockwise and counter clock wise The DC voltag
57. L SWITCH Remote or Machine Control WELDING MODE SWITCH e CONTROL CIRCUIT POLARITY SWITCH e POWER SOURCE PILOT LIGHT DC AMMETER OPTIONAL DC VOLTMETER OPTIONAL DESIGN FEATURES AND ADVANTAGES The following list of design features will help you understand the machine s total capabilities and how you can take advantage of them to get maximum use of your machine e Excellent arc characteristics for optimum constant voltage submerged arc and Innershield welding performance Acontrol circuit designed to provide good starting for a large variety of processes and procedures e Output Control Potentiometer that provides easy single range continuous control e Output Control Switch that provides simple switch ing from local to remote control Red neon pilot light to confirm that the Input Contactor is energized Auxiliary power source to provide 115 volt AC power 1000 VA to wire feeding equipment Multi functional terminal strip for easy connection of wire feeding control cables and switching between CV Innershield and CV Submerged Arc welding when using the Dual Process or Dual Procedure Kits Recessed output terminals to avoid any person or object from accidentally coming into contact with the output terminals and labeled positive and neg ative for easy identification Thermostatically protected power source Electronic protection circuit to protect power source against overloads Input line voltage compensat
58. ODE 80 TO 229 VV MODE 020 5 194004 A nev A Pig 16V 229 lt e lt gt bes 028 1N4004 184004 un soom 2 22 r ATSR RIIS eis 3 150 032 s LUN 184004 14004 221K 2 zer gt i sa e mo e g La Y SHUTDOWN CIRCUIT 150 c Mar TO SHUNT 95 s 50 BOOAmps GENERAL_INFORMATION mr 10v ELECTRICAL SYMBOLS PER E1537 em 3 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED em a TESISIORS Ones t 1 48 UNLESS OTHERWISE SPECIFIED LABELS o DIODES 1 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE MT 42 O POWER SUPPLY SOURCE POINT COMMON CONNECTION 77 2 FRAME CONNECTION EARTH GROUND CONNECTION NOTES v WA SINCE COMPONENTS OR CIRCUITRY ON 4 PRINTED CIRCUIT BOARD MAY CHANGE IDEALARC DC 600 WITHOUT AFFECTING THE INTERCHANGEABILITt A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE MAGER CONTROL BOARD SCHEMATIC 1 30 92 62312 46 NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It not be totally applicable to your machine s specific PC board version This diagram is intended to provide general information regarding PC board function Linc
59. ODE POLARITY PRI CONNECTION i ON 380 OR SW4 WELDING MODE SHOWN IN STICK POSITION 2 6 TRIPLE VOLTAGE NOTES MACHINES T D UTZUT ES 74552216 N A LEADS 4 THRU 9 NOT PRESENT ON RECTIFIER G6 Ker 2 2 73237203 460V 380 500V amp 460 575V MACHINES 1 lt lt 3 3 gt 206 sEc ASSEMBLY e 24 3 N B FOR STICK WELDING OR AIR CARBON ARC 4 4 1 WITHOUT MULTI PROCESS SWITCH INSTALLED ECCE 5 s 215 e 6 nH DISCONNECT ALL ELECTRODE WORK AND D 62 i js 6 CONTROL LEADS TO ANY WIRE FEEDERS lt 1 r 205 JUMPER 2 TO 4 OUTPUT TERMINALS WILL US 1 lt r gt gt 208 NOW ENERGIZED PLACE MODE SWITCH 9 gt 207 IN VV FOR STICK CV 1 FOR AIR 2 1 2 Ja Acts 1014H 231 OUTPUT 11 CARBON ARC SEE OPERATING MANUAL CHOKE 5 4 17 1 lt 3 FOR FURTHER INSTRUCTIONS 1 5 12 4 GATE L lt 2 Cit e 6 i N C CENTER TERMINAL OF FUSE HOLDER LEADS TO 5 129 N D WELDING CABLE MUST BE OF THE PROPER FIRING e 8 J6 2 4 2 CAPACITY FOR THE CURRENT AND DUTY CYCLE pu Firing circuit 3 OF IMMEDIATE AND FUTURE APPLICATIONS SOARS SCR 2 T P C BOARD a ZATHIS DIAGRAM SHOWS THE STICK POLARITY r JA SNUBBERS 1 POSITIVE TO CHANGE THE POLARITY TURN 1 H 1 THE DC 600 OFF AND REVERSE THE LEADS AT roy
60. OMETER R1 at DC600 If 215 and 210 output the problem is solved check the shunt for loose or faulty con remote control unit or wire nections See wiring diagram feeder and associated control cable Check the 75 lead for conti nuity zero ohms from the OUTPUT CONTROL POTEN TIOMETER R1 to the control board plug 2J1 See wiring diagram Perform Firing Board test Perform Control Board test Perform SCR Output Bridge 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 216 383 2531 or 1 800 833 9353 LINCOLN E IDEALARC DC 600 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Observe Safety Guidelines detailed in the beginning of this manual Machine has minimum output and no control The machine does not have maxi mum weld output OUTPUT PROBLEMS If a remote control unit is NOT connected to the terminal strip 75 76 and 77 terminals the OUTPUT CONTROL SWITCH must be in the PUT CONTROL AT DC600 position If a remote control cable is con nected to terminals 75 76 and 77 the leads may be shorted to the positive weld output Make certain the Three Phase input voltage is correct and matches the mach
61. PUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 CONNECT TERMINAL MARKED CD TO GROUND PER NATIONAL ELECTRIC CODES 3 CONNECT THE L1 L2 amp L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN FIGURE A 7 Reconnect Panel Board Positions for Single Voltage Machines CONNECTION FOR 575 VOLTS 60 HZ 1 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H4 PILOT TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN 2 INSULATE UNUSED H2 H3 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 3 CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES 4 CONNECT TRANSFORMER LEADS 16 17 18 4 amp 13 5 amp 14 6 amp 15 TO RECONNECT PANEL 5 TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 1 2 3 7 8 9 TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS CONNECTION FOR 460 VOLTS 60 HZ 1 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H3 PILOT RECONNECT TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN 2 INSULATE UNUSED H2 H4 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 3 CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES 4 CONNECT TRANSFORMER LEADS 1 2 3 4 amp 7 5 88 6 amp 9 TO RECONNECT PANEL 5 TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13 14 15 16 17 18 TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS CONNECTION FOR 230 VOLTS 60 HZ 1
62. R ST 1 2W 1K 10 LINEAR 18 101 TRIMMER ST 1 2W 20K 10 LINEAR C18 au A nro cur i CAPACITOR PEF 0 1 100V 10 CM cri A el ces ten CAPACITOR PEF 0 22 100V 10 CB MTS CAPACITOR PEF 01 200V 10 02 63 CA4 oon CAPACITOR CD 02 600V 80 20 D5 D11 D12 D13 D14 D15 DIODE AXLDS 1A 400V D16 D17 D18 D20 D22 D23 D25 D26 D28 D29 D30 D31 D32 D33 D34 D35 D36 D37 D38 Jl wastes CONNECTOR MOLEX MINI PCB 1 4 PIN US techn eed CONNECTOR MOLEX MINI PCB 2 PIN GOLD R7 R22 R24 R29 R44 R45 RESISTOR MF 1 4W 1 00K 1 R102 R19 R58 R65 R81 R105 RESISTOR MF 1 4W 10 0K 1 20 21 50 RESISTOR MF 1 4W 100K 1 R25 R51 R67 R73 R77 R107 RESISTOR MF 1 4W 1 00M R121 47 110 117 RESISTOR MF 1 4W 1 30K 1 R16 R42 R118 R125 RESISTOR MF 1 4W 13 7K 1 R31 H85 R99 RESISTOR MF 1 4W 1 50K 1 R36 R94 R126 R127 RESISTOR MF 1 4W 15 0K 1 5 98 123 RESISTOR MF 1 4W 150K 1 R70 H86 22 ce eed ee ee RESISTOR MF 1 4W 1 82K 1 R8 R72 R78 R79 R88 R97 RESISTOR MF 1 4W 2 21K 1 R103 R43 R68 R82 R90 R92 RESISTOR MF 1 4W 22 1K 1 5 52 RESISTOR MF 1 4W 221K 1 R24 ix bie bn RESISTOR MF 1 4W 24 3K 196 R30 R82 R104 RESISTOR MF 1 4W 267 1 RIZ eel ccm thoes Ere RESISTOR MF 1 4W 3 01K 1
63. RBON ARC TORCH N E TO WORK USED WITH STICK OR AIR CARBON ARC LI OPTIONAL USER SUPPLIED JUMPER FOR OUTPUT RECTIFIER OPTIONAL STICK WORK LEAD NOT ASSEMBLY G6 GATE LEADS TO THOSE SITUATIONS WHERE IT 15 NOT USED WHEN TUMBERLIS CONNECTOR CAVITY NUMBERING SEQUENCE G4 gt FIRING CIRCUIT ECESSARY TO HAVE SEPARATE GROUND USER VIEWED FROM COMPONENT SIDE OF BOARD 62 gt pe BOARD CABLES FOR STICK AND SEMI AUTOMATIC 4 WELDING ELECTRICAL SYMBOLS PER E1537 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels IDEALARC DC600 ELECTRICAL DIAGRAMS FIGURE G3 Operating Schematic N A ON 440 460V MACHINES CR1 IS A DC CONTACTOR AND D1 amp TPI ARE ADDED AS SHOWN INPUT L3 POWER 12 L1 GROUND Ta 1CR 1CR 1CR START STOP 211 wale 212 55 271 i 31 32A 09 09 10 5 4 AC 1CR R 210 pie 78 a 207 To OUTPUT CHOKE H2 id FIRING 1 FIRING FIRING H1 5 P 273 272 N MAIN POWER 204 PCB PCB PCB CONTROL SECONDARY PRIMARY TRANSFORMER TRANSFORMER THERMOSTATS FAN MOTOR TO AUX WINDING F1 120VAC LC OUTPUT SCR BRIDGE 256 255 215 POWER
64. RC DC 600 ON OFF PUSH BUTTON to OFF Connect the wire feeder control cable leads to the IDEALARC DC 600 terminal strip as shown in Figure C 7 Connect the wire feeder control cable ground lead to the frame terminal marked NOTE The IDEALARC DC 600 must be properly grounded Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpose c Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 21 lead to work cable for ease of use NOTE Using the extended 21 lead eliminates the need to use the LN 9 s remote work lead accessory which has a direct work lead jack Connect LN 9 wire feeder control jumpers on Voltage Control board See LN 9 Operator s Manual a White jumper on V oltage Control Board to pin S b Blue jumper on Voltage Control Board to pin B LINCOLN NEGATIVE POSITIVE ELECTRODE CABLE TO WIRE TO WORK FEEDER FIGURE C 7 LN 8 OR LN 9 WIRE FEEDER CONNECTION TO THE IDEALARC DC 600 NOTE On earlier units the blue jumper on V oltage Control Board is connected to Pin B on Start Board NOTE The connection diagram shown in Figure C 7 shows the electrode connected
65. STOR WW 20W 250 5 SQ 071 072 073 ZENER DIODE 1W 20V 5 1N4747A TETSTBPOTBS aet fe seni td MOV 150VRMS 45J 14MM LED1 LED2 LED3 LED4 LED5 LED T 1 3 4 RED HLMP 3003 LED6 LED7 LED8 LED9 R58 R59 R60 R61 R62 R63 RESISTOR CC 1 2W 5 1 5 R10 R11 R12 R13 R14 R15 RESISTOR CC 1 2W 82 5 HZR8IR9 Lee EDS RESISTOR WW 5W 1 5K 596 SQ JG eie et CONNECTOR MOLEX MINI PCB 4 PIN dap E CONNECTOR MOLEX MINI PCB 8 PIN 1 902 0037 ere Ret et eld PUT 2N6027 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting 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 Improper PC board repairs could result in damage to the machine LINCOLN IDEALARC 600 NOTES LINCOLN IDEALARC 600 ELECTRICAL DIAGRAMS G 5 FIGURE G1 Wiring Diagram for Codes 9773 9776 9778 9779 9780 9910 380 500V amp 460 575V te SHOWN CONNECTED SUPPLY FOR LOW VOLTAGE LINES SINGLE VOLTAGE OVER 300 V TO EXCEPT 380V SUEPLY LINES OUTPUT CONTROL TO GROUND PER TO GROUND PER 215
66. 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 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 SERVICE MANUAL LINCOLN je World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors Sales and Service through Subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 SAFETY A WARNING WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 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
67. WELDING OR AIR CARBON ARC SEG nits 4 3r 204 WITHOUT A MULTI PROCESS SWITCH INSTALLED Lie F 543 215 DISCONNECT ALL ELECTRODE WORK AND jeg ee CONTROL LEADS TO ANY WIRE FEEDERS i iis 7 205 JUMPER 2 TO 4 OUTPUT TERMINALS WILL 15 Acke 8 208 NOW BE ENERGIZED PLACE MODE SWITCH 37 5 2 B H ec 2 9 492 207 IN VV FOR STICK AND CV I FOR AIR i ake 3 1044 231 OUTPUT Boxee 4 11 gt CARBON SEE OPERATING MANUAL 5 CHOKE C T 5 12223 FOR FURTHER INSTRUCTIONS 15 Ee I N C CENTER TERMINAL OF FUSE HOLDER ke7 1 gt X N D WELDING CABLE MUST BE OF THE PROPER pe Acke 8 64 2 CAPACITY FOR THE CURRENT AND DUTY CYCLE I FIRING 2596 OF IMMEDIATE AND FUTURE APPLICATIONS SCR i P C BOARD T N E A THIS DIAGRAM SHOWS THE STICK POLARITY SNUBBERS POSITIVE TO CHANGE THE POLARITY TURN THE DC 600 OFF AND REVERSE THE LEADS AT ray THE MULTI PROCESS SWITCH CR3 1 USING A WIRE FEEDER K 317 OR K 318 il i 1 LEADS 210 amp 215 ARE CONNECTION DIAGRAM CONNECT ELECTRODE 211 OUTPUT SHUNT AND WORK LEADS TO THESE TERMINALS ml TWISTED TOGETHER INSTEAD OF THE POWER SOURCE 210 OUTPUT TERMINALS 215 220 A THESE NOTES APPLY ONLY 00 600 WITH OUTPUT 219 MULTI PROCESS SWITCH INSTALLED SNUBBER TO STICK ELECTRODE HOLDER OR AIR CA
68. XIMUM OUTPUT SETTING NO LOAD CH1 dl HHHH volts 50 volts 2ms This is the typical DC open circuit voltage SCOPE SETTINGS 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 Volts Div Horizontal Sweep Coupling Trigger Note Scope probes connected at machine ouput terminals probe to positive termi nal probe to negative terminal LINCOLN 8 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR F 43 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MINIMUM OUTPUT SETTING NO LOAD LINE N N V N HH N A 0 volts 20 volts 2ms This is the typical DC open circuit voltage SCOPE SETTINGS 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 Volts Div Horizontal Sweep Coupling Trigger Note Scope probes connected at machine ouput terminals probe to positive termi nal probe to negative terminal LINCOLN 9 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CONSTANT VOLTAGE INNERSHIELD MODE CH 1 0 volts 20 volts 2ms This is the typical DC open
69. ain transformer secondary leads to the common buss connected to the output choke See Figure F 4 If one or more of the above voltage tests are incorrect check for loose or faulty wiring If the wiring is good then the Main Transformer may be faulty Replace MAIN TRANSFORMER SECONDARY LEADS FIGURE F 4 Main Secondary Lead Test Points LINCOLN amp TROUBLESHOOTING amp REPAIR F 19 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 Open the Front Panel Assembly Door to gain access NOTE If the main AC input supply to the terminal board voltage varies the Main Transformer voltages will vary pro b If the above voltage test is portionately incorrect check for loose or faulty wiring a f the Firing Board number is G 1486 4 or lower test for 75 c If the wiring is good then the VAC between the leads con Main Transformer may be nected to the terminal strip faulty Replace located on the right side of the Control Box See Figure F 5 12 Remove the six screws from the Control Box Cover with a 5 16 nut driver and flip the cover down It does not have to be completely removed to perform the tests FIRING BOARD CONTROL BOARD TERMINAL 0 0 0 E From Lead To Lead Expected VAC 203 204 75 VAC 205 206 75 VAC 207
70. ain trans former coil it is necessary to remove the secondary coil first Remove the secondary coil by breaking the seal caused by the epoxy paint and lifting the coil up away from the main transformer coil a If the secondary coil is not being replaced do not cut the lead to the secondary coil With the lead attached lift the coil off the main transformer coil and bend the coil and lead to the side Remove the main transformer coil a Take out the insulated wedges that help keep the coil firmly seated on the iron E If these do not dislodge easily it will be necessary to force the coil off the iron E 4 Replace the coil s a Be sure to replace all insulated wedges b Using a high temperature industrial epoxy such as Lincoln E 1603 glue the pri mary coils in place by applying the epoxy to the coil side and cell insulation opposite the wedges Using a high tempera ture industrial epoxy Such as Lincoln E 1603 glue the sec ondary coils in place from the iron to the coil sides Test for correct operation before replacing the transformer assembly back into the machine a The primary coils should be ground tested at 2700VAC for 1 second The secondary coils should be ground tested at 1500VAC for 1 second The primary to secondary insulation should be tested at 2700VAC for 1 second LINCOLN amp TROUBLESHOOTING amp REPAIR F 61 RETEST AFTER REPAIR Should a machine under test be rejecte
71. ard on All Machines e Air Carbon Arc Cutting Carbon Rod Sizes up to 3 8 Diameter The IDEALARC DC 600 has a three position Welding Mode Switch to enable the user to operate in one of three modes e Constant Voltage CV Innershield e Constant Voltage CV Submerged Arc Variable Voltage VV Constant Submerged Arc Current The IDEALARC DC 600 can be easily connected to wire feeding equipment including e Semi automatic wire feeders LN 7 LN 8 and LN 9 Automatic wire feeders NA 3 and NA 5 Tractors LT 56 and LT 7 The optional Multi Process Switch allows the user to switch between semi automatic or automatic welding and stick welding or air carbon arc cutting without dis connecting the wire feeder equipment control elec trode and work leads RECOMMENDED PROCESSES AND EQUIPMENT The IDEALARC DC 600 is recommended for the fol lowing welding or cutting processes within its output capacity of 70 amps to 850 amps in the Constant Voltage mode and 90 amps to 850 amps in the Variable Voltage Constant Current mode e Submerged Arc Semi Automatic or Automatic Welding e Open Arc Semi Automatic or Automatic Welding Stick Welding Standard on All Machines e Air Carbon Arc Cutting Carbon Rod Sizes up to 3 8 Diameter LINCOLN OPERATIONAL FEATURES AND CONTROLS The IDEALARC DC 600 comes with the following standard controls e ON OFF PUSH BUTTON e OUTPUT CONTROL POTENTIOMETER OUTPUT CONTRO
72. blem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims IDEALARC DC 600 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROU BLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Contact the Lincoln Electric Service Dept 216 383 2531 or 1 800 833 9353 WELD Major Physical or Electrical Damage is Evident The Machine is dead The Input contactor does not operate Check for blown or missing fuses in input lines Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel The ON OFF PUSHBUTTON S1 may be faulty Check for proper operation See wiring diagram The Control Transformer T2 may be faulty Perform the Control Transformer Test The primary or secondary thermostats may be open Check or replace Also check the associated wiring See wiring diagram The pilot relay CR2 may be faulty Check or replace See wiring diagram The input contactor coil may be open See wiring diagram The Control board may be faulty Re
73. button is operated The Remote Control circuit is also protected from grounds or voltage intrusions If the 75 76 or 77 leads come in contact with either of the machine s out put cables the DC 600 will only operate at a minimum output or the input contactor will open NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC DC 600 THEORY OF OPERATION E 5 FIGURE E 5 SCR Operation CATHODE OUTPUT NOTE AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large currents to a load An SCR acts very much like a switch When a gate sig nal is applied to the SCR it is turned ON and there is current flow from anode to cathode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cathode thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes current only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the on state and the remainder of the time in the off state The amount of time spent in the ON state is con trolled by t
74. d 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 Input volts Phase Hertz 208 3 60 230 3 60 380 3 60 416 3 60 460 3 60 550 3 60 575 3 60 200 3 50 220 3 50 260 3 50 346 3 60 380 3 50 400 3 50 415 3 50 440 3 50 500 3 50 550 3 50 OPEN CIRCUIT VOLTAGES Variable Voltage 74 70 DC Variable Voltage 71 67 DC Auxiliary Output 31 32 123 117 AC Auxiliary Output 31 32 118 112 AC LINCOLN jo IDEALARC DC 600 F 62 TROUBLESHOOTING amp 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 AT MINIMUM OUTPUT SETTINGS Variable Voltage 75 Amps 24 26VDC Variable Voltage 75 Amps 24 26VDC Constant Voltage Innershield 100 Amps 11 5 12 5VDC Constant Voltage Innershield 100 Amps 11 5 14 5VDC MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT SETTINGS Variable Voltage 750 Amps 44 50VDC Constant Voltage Innershield 750 Amps 44 50VDC LINCOLN 8 IDEALARC DC 600 LINCOLN ELECTRICAL DIAGRAMS SECTION TABLE OF CONT
75. de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de
76. e between leads 231 and 215 should be constant at approximately 5 8 VDC This voltage should not vary when the pot is turned e Remove probes inserted into the Molex Plug lead cavities of lead 231 and 215 15 16 17 Test Output Pilot Control Relay CR4 for proper operation by removing and replacing repeatedly the jumper wire from terminal 2 This should cause the relay con tacts to open and close The con tacts can be seen closing and opening through the clear plastic relay case or can be heard opening and closing a f the Output Control Relay CR4 does not close when energized check for loose or faulty wiring Remove the jumper from terminals 2 and 4 on the terminal strip Replace the Firing Board if the above voltage and control relay tests were passed It may be faulty F 27 IDEALARC DC 600 F 28 TROUBLESHOOTING amp REPAIR CONTROL BOARD TEST A 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 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 tec
77. e is still indi cated SCR 1 is faulty Replace If one SCR is shorted they may all appear shorted The SCRs will have to be test ed separately by disconnecting the secondary leads from the bridge assembly b If a very high or infinite resis tance is indicated with the snubber circuit disconnected replace the snubber circuit Repeat Steps 3 to 7 for SCRs 2 6 Replace all Molex Plugs on the Firing Board and Control Board NOTE To further check the SCR s Function use an SCR tester and proceed to active SCR Test TROUBLESHOOTING amp REPAIR F 37 ACTIVE SCR TEST A 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 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION The Active SCR Test will determine if the device is able to be gated ON and conduct current from anode to cathode MATERIALS NEEDED An SCR Tester as specified in this procedure IDEALARC DC
78. e or faulty wiring between pilot relay CR2 and input contactor CR1 coil connections The input contactor CR1 may be faulty Replace The CR1 interlock may be faulty Replace if necessary The ON OFF PUSHBUTTON may be faulty Check or replace Check internal remote control circuit leads 75 76 and 77 and switch SWS for grounds or shorts The control board may be faulty Replace A 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 216 383 2531 or 1 800 833 9353 LINCOLN IDEALARC DC 600 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Machine input contactor operates but machine has no weld output Fan runs and pilot light glows OUTPUT PROBLEMS Install a jumper from 2 to 4 on machine terminal strip If machine weld output is restored the problem is in the wire feed er or control cable If remote control is not being used make certain the OUT PUT CONTROL SWITCH SW3 is in the OUTPUT CON TROL AT DC 600 position Check 8AMP fuse in the front panel Replace if blown Check for loose or faulty weld Check operation of output pilot relay CR4 There
79. e panels IDEALARC DC600 ELECTRICAL DIAGRAMS G 6 FIGURE G2 Wiring Diagram for Code 9774 236 21 OUTPUT S CONTROL 237 SINGLE VOLTAGE 4408460v TE ES swa un TO GROUND PER i ssl NATIONAL lt 9 ELECTRICAL CODE 224 E 4 TO PRIMARY COILS O Q 76 77 80 87 6 6 IDEALARC DC 600 400 460V WIRING DIAGRAM 235 LEGEND PRIMARY 226 C7 05 05 MFD THERMOSTAT F1 8 SLOW BLOW FUSE R1 10K N A 1 2 3 32A 31 THERMOSTAT T1 MAIN POWER TRANSFORMER 13 o o 2 CONTROL TRANSFORMER LEADS 4 PRI F F F 10 1CR INPUT CONTACTOR THRU 9 i 203 5 207 210 eee N us 2CR FAULT PROTECTION RELAY TO INPUT cor Se ars S 2157 215p 2 CURRENT ACTIVATED REED SWITCH PANEL 1o A D 208 1 CONTROL 1423 222 4CR OUTPUT PILOT RELAY 7 8 9 P TU SUED SW1 INPUT POWER THERE d SW2 ELECTRODE POLARITY PRI ELE AE SWS OUTPUT CONTROL 10 Pt ON 380 OR 224 SW4 WELDING MODE SHOWN IN STICK POSITION amm NOTES MACHINES TO OUTPUT G3 p4 X T 7 T 216 N A LEADS 4 THRU 9 ARE NOT PRESENT ON n RECTIFIER e ex 2 2 209 460V 380 500V amp 460 575V MACHINES EN Ome SO ASSEMBLY j4 343 N B FOR STICK
80. ect the electrode cables to terminal polarity to be used 3 Set the CONTROL CIRCUIT POLARITY SWITCH to the same polarity as the electrode cable con nection 4 Set the OUTPUT CONTROL SWITCH to REMOTE 5 Set the IDEALARC DC 600 WELDING MODE SWITCH to the position that matches the welding process being used a For submerged arc welding set WELDING MODE SWITCH TO CV SUBMERGED ARC position b For all open arc welding processes set WELD ING MODE SWITCH TO CV INNERSHIELD position LINCOLN LN 8 SEMI AUTOMATIC WIRE FEEDER To use the LN 8 Semi Automatic Wire Feeder with IDEALARC DC 600 1 Set the IDEALARC DC 600 WELDING MODE SWITCH to either CV Innershield mode or CV Submerged Arc mode depending on the welding process being used 2 Set the IDEALARC DC 600 OUTPUT CONTROL SWITCH to the REMOTE position 3 Set the LN 8 W elding Mode Switch to the CV posi tion The LN 8 Welding Mode Switch is located on the variable voltage CC board 4 Refer to the LN 8 Operator Manual for instruc tions on how to use the LN 8 LN 7 AND LN 9 SEMI AUTOMATIC WIRE FEEDERS OR OTHER CONSTANT WIRE FEEDERS To use the LN 7 LN 9 or other constant wire feed speed semi automatic wire feeders with IDEALARC DC 600 Set the IDEALARC DC 600 WELDING MODE SWITCH to either CV Innershield mode or CV Submerged Arc mode depending on the welding process being used NOTE These semi automatic wire feeders cannot be used in the VV CC
81. ee Figure A 7 5 For code 9793MSP see Figure A 8 6 For codes not listed see the Input Connection Diagram pasted on the inside of the Case Back Input Access Door CONNECTION FOR HIGHEST RATING PLATE VOLTAGE 50 OR 60 HZ 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX jojw oF 2 DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT d 600 VOLT INSULATION cmm FR CONNECT L1 2 amp L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOW 4 CONNECT TERMINAL MARKED j TO GROUND PER LOCALAND NATIONAL ELECTRIC CODES H2 e 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE SECURE THE REMAINING HEX NUTS IN PLACE CONNECTION FOR LOWEST RATING PLATE VOLTAGE 50 OR 60 HZ LINK L3 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX LINES 2 DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION INPUT L1 Jr U 3 CONNECT 11 12 amp L3 INPUT SUPPLY LINES Ht AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN GND fs H1 4 CONNECT TERMINAL MARKED GROUND PER LOCALAND NATIONAL ELECTRIC CODES H2 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS PILOT Ea FIGURE A 4 Reconnect Panel Board Positions for Dual Voltage Machines LINCOLN
82. electrical cable connections See Figure C 1 POSITIVE NEGATIVE fe e STICK OR AIR CARBON ARC CABLES WIRE FEEDER CABLES FIGURE C 1 MULTI PROCESS SWITCH IDEALARC DC 600 The MULTI PROCESS SWITCH has two sets of output terminals You connect the wire feeder unit cables to the set of terminals on the left side of the box and the stick or air carbon arc cables to the set of terminals on the right side facing the front of the machine as shown in Figure C 1 When the MULTI PROCESS SWITCH is in the Stick or Air Carbon Arc position only those terminals are energized The wire feeder nozzle or gun and electrode are not electrically hot when in this mode Follow these steps to install the MUL TI PROCESS SWITCH 1 Confirm that the IDEALARC DC 600 ON OFF PUSH BUTTON is in the OFF position 2 Disconnect main AC input power to the IDE ALARC DC 600 3 Open the terminal strip access door located on the Case Front Assembly 4 Remove the two front middle screws that secure the two side panels of the machine See Figure C 2 REMOVE SCREWS TO MOUNT MULTI PROCESS SWITCH POSITIVE STICK OR AIR CARBON ARC NEGATIVE A FIGURE C 2 SIDE PANEL REMOVAL LINCOLN 8 ACCESSORIES 5 Attach the MUL TI PROCESS SWITCH bracket across the front of the machine with the flange down Use the long self tapping screws and lock washers provided The bracket sho
83. for positive polarity To change polarity a Set the IDEALARC DC 600 ON OFF PUSH BUTTON to OFF b Move the electrode cable to the Negative output terminal c Move the work cable to the Positive output terminal d Set the IDEALARC DC 600 CONTROL CIR CUIT POLARITY SWITCH to NEGATIVE IDEALARC DC 600 ER 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 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 use 3 Connect the wire feeder control cable leads to the IDEALARC DC 600 terminal strip as shown NOTE The connection diagram shown in Figure C 8 Figure C 8 shows the electrode connected for positive polarity To change polarity LN 7 WIRE a Set the IDEALARC DC 600 ON OFF PUSH BUTTON to OFF b Move the electrode cable to the Negative output terminal c Move the work cable to the Positive output terminal d Set the IDEALARC DC 600 CONTROL CIRCUIT POLARITY SWITCH to NEGATIVE NEGATIVE POSITIVE CABLE TO LN TO WORK CONDUCTOR BLOCK FIGURE C 8 LN 7 WIRE FEEDER CONNEC TION TO THE IDEALARC DC 600 4 Connect the wire feeder control cable ground lead to the frame terminal marked 2 NOTE The
84. g arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding or cutting out of posi tion or in confined places Always wear safety glasses with side shields when in a welding or cutting area Connect the work cable to the work as close to the welding or cutting area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding or cutting current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 4 h Also see item 7c IDEALARC DC 600 CYLINDER may explode if damaged 9 Use only compressed gas cylinders contain ing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condi tion Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot pa
85. he Gate LINCOLN An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard PN junction between gate and cathode the voltage between these terminals must be slightly greater than 0 6V Once the SCR has fired it is not necessary to continue the flow of gate current As long as current continues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC supply voltage passes through zero into the negative portion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output IDEALARC DC 600 TABLE OF CONTENTS SECTION TSI TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Sectian eene Section F Safety Precautions iresi reien er cr ec sees E ERE F 2 How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures 2 F 3 Troubleshooting Guide F 4 F 12 Test Procedures Control Transformer V oltage Test F 13 F 14 Main Transformer V oltage
86. hnical trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION This test will determine if the Control Board is receiving the correct voltages and feedback signals MATERIALS NEEDED Analog Volt Ohm Meter Multimeter IDEALARC DC 600 wiring diagrams See Electrical Diagrams Section of this Manual LINCOLN IDEALARC DC 600 LINCOLN TROUBLESHOOTING amp REPAIR F 29 CONTROL BOARD TEST See Table F 2 for LED function during normal operation See Figure F 9 for LED loca tion on Control Board LEAD 256 d DC600 CONTROL LEAD 255 G 1504 3 ES xi LEAD 421 LED 4 LED 5 LEAD 222 CONTROL BOARD FOR CODES 9700 AND ABOVE FEED m LEAD 255 lt LEAD 256 CONTROL BOARD FOR CODES BELOW 9700 FIGURE F9 Control Board LED Locations LED FUNCTION DURING NORMAL OPERATION Machine is ON 1 Glows to display that 115 VAC is present between leads 255 and 256 at Plug J2 on Control Board Glows to display that output voltage feedback is being supplied to the Control Board Terminals 2 and 4 on the terminal strip must be jumped together Glows to display that power is applied to fault protection relay CR2 ES DOES NOT GLOW Glows only if there is a fault condition Glows to display a control signal lead 231 is being supplied to the Firing
87. ia gta E iD p rs gt ts E ON 4 ZEN can 8 620 e 2 gt lt czognz Siv LOOPNI 929 210 vOOPNI use vOOPNI 20 gt Lue M HC moz 4 5 d 9 gus 5 MUI 10090 voornl d 224 28 28 062 de wal vty Ld zu 94 sn vOOPNI LOOPNE xt 47 3001 OVAGL LOOPNI M2 8 8 8 MS 10091 ed xt ua 052 gt e lt 4 su gt lt 902 ar ON ar st LOOPNI A sa 5 z EN 27x e 31v5 or 24 lt 3 lt 5 voopni 3 8 3149 s ev 5 anis inaro 5 512 e e 4 9 gt ce Siz 002 m D 002 D m Sp 29 S Mog 29218 8 v2 051 ast 9 Ost 25 59 lj 22 e L e 5 9 2E rs rs D 1 10 z 03 tan cr 318vN3 1102412 WEE P e 25 2 19 1001 LOOPNI avy wu vOOVNI vOOvNI 220 02 _9vu t e mM nz L e T 7495 2 1 149S 2OObNI 5 120 28 28 052 vOOPNE 5 14 oly lt lt A 1031 vOObNI 5 LOOPNI lt 24 4 m cnt 910 9 LOOPNI 610 Y MS lt 2OOPNI 191 1 00 052 gt lt 14
88. ice department for technical trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltage is being a applied to the primary of the control transformer b induced on the secondary winding of the control transformer MATERIALS NEEDED Volt Ohm Meter Multimeter IDEALARC DC 600 wiring diagrams See Electrical Diagram Section of Manual IDEALARC DC 600 F 14 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST SECONDARY WINDING THERMOSTAT X2 LEAD LOCATION NOT SHOWN INPUT CONTACTOR X1 LEAD LOCATION 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 Lead X1 is connected to the Input Contactor CR1 interlock 3 Locate the Control Transformer located underneath the Input T2 on the left side of the Input Contactor See Figure F 1 Box facing the back the of the machine See Figure F 1 b Lead X2 is connected to the secondary winding thermostat 4 Locate the Control Transformer pri See Figure F 1 mary leads H1 H2 H3 etc See wiring diagram NOTE Unused leads should be taped a Inspect for broken or incorrect connections LINCOLN amp TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST 6
89. im TIS g 5 AS PN A z 2 J Q e fe Dj Lod a LINCOLN IDEALARC 600 ELECTRICAL DIAGRAMS G 4 FIRING PC BOARD G1486 5 AND ABOVE Identification Item C1 C2 C3 C4 C5 C6 C7 CAPACITOR PEMF 0 15 200V 10 C8 C9 C10 C11 C12 SCR1 SCR2 SCR3 SCRA SCR5 SCR T202 4A 400V C106D SCR6 C13 C14 C15 C16 C17 C18 CAPACITOR CEMO 022 50V 2096 C19 C20 C21 C22 C23 C24 C25 C26 C27 J5 icm e terrd CONNECTOR MOLEX MINI PCB 12 PIN JA vitet CONNECTOR MOLEX MINI PCB 6 PIN R16 R17 R18 R19 R20 R21 RESISTOR MF 1 4W 1 00K 1 R22 R23 R24 R25 R26 R27 RESISTOR MF 1 4W 150 1 R34 R35 R36 R37 R38 R39 R40 R41 R42 RESISTOR MF 1 4W 1 50K 1 R28 R29 R30 R31 R32 R33 RESISTOR MF 1 4W 267 1 R52 R53 R54 R46 R47 R48 RESISTOR MF 1 4W 2 67K 1 55 56 957 ees wee RESISTOR MF 1 4W 26 7K 1 64 65 66 RESISTOR MF 1 4W 332K 1 HA3 HAA RAS RESISTOR MF 1 4W 475 1 R49 R50 R51 TRIMMER ST 1 2W 100K 10 LINEAR D7 D8 D9 D22 D23 D24 D25 DIODE AXLDS 1A 400V D26 D27 D28 D29 D30 D31 D32 D33 D34 D35 D36 D37 D38 D39 01 02 03 04 05 06 010 011 DIODE AXLDS 1A 1000V D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 R1 R2 R3 R4 R5 R6 RESI
90. in relief loops 4 Insert the electrode lead through the loop directly below the desired polarity positive or negative Pull through enough cable to reach the output terminals sue STRAIN Nr di 5 Connect electrode lead to the desired terminal RELIEF LOOPS positive negative 6 Tighten the output terminal nut with a wrench FIGURE A 9 Output Terminals 7 Connect the work lead to the other output terminal following steps 4 6 LINCOLN 8 IDEALARC DC 600 Connection For Semi Automatic or Automatic Wire Feeder Control NOTE See the ACCESSORIES Section of this manu al for specific instructions on connecting the following semi automatic and automatic wire feeders Semi Automatic Wire Feeders NA 3 Jautomati Wire Feeders e 1 7 e 1 56 Tractors Connection for Stick Welding and Air Carbon Arc Cutting Operation A WARNING THE OUTPUT TERMINALS ARE ENERGIZED AT ALL TIMES WHEN THE IDEALARC DC 600 IS CON NECTED FOR STICK WELDING AND AIR CARBON ARC CUTTING LINCOLN B 1 Set ON OFF PUSH BUTTON to OFF 2 Locate and open the hinged access door on the Front Case Assembly 3 f necessary disconnect all wire feeder control cable connections from the DC 600 terminal strip 4 Remove the leads from the unit by pulling them through and out of the strain relief loops 5 Connect a jumper wire from terminal 2 to terminal 4 on the terminal strip 6 Setthe Welding Mode Switch to the VV posi
91. ine s voltage phase and frequency as specified on the machine s rating plate on the Case Front Assembly Control Panel Input power supply entry is through the hole in the Case Back Assembly See Figure A 2 for the location of the machine s input cable entry opening Input Contactor CR1 and reconnect panel assembly for dual voltage machines FIGURE A 2 Rear Panel INPUT SUPPLY CABLE ENTRY OPENING INPUT CONTACTOR CR1 RECONNECT PANEL ASSEMBLY FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Technical page of this manual for the machine being used They are also called inverse time or ther mal magnetic circuit breakers DO NOT use fuses or circuit breakers with a lower amp rating than recommended This can result in nui sance tripping caused by inrush current even when machine is not being used for welding at high output currents Use input and grounding wire sizes that meet local electrical codes or see the Technical Specification page in this manual IDEALARC DC 600 INSTALLATION GROUND CONNECTION Ground the frame of the machine A ground terminal marked with the symbol is located inside the Case Back of the machine near the input contactor Access to the Input Box Assembly is at the upper rear of the machine See your local and national electrical codes for proper grounding methods INPUT POWER SUPPLYCONNECTIONS
92. ine rating and the reconnect panel Check all Three Phase input lines at the DC600 Make sure input voltages match machine rating and recon nect panel Put OUTPUT CONTROL SWITCH SW3 OUT PUT CONTROL AT DC600 position If problem is solved then check remote control unit or wire feeder Check the OUTPUT CON TROL POTENTIOMETER R1 and associated wiring Check the OUTPUT CON TROL SWITCH 5 3 the WELDING MODE SWITCH SW4 and associated wiring Perform the Control Board test Perform the Firing Board test Perform the SCR Output 5 Perform the Main Transformer test Check the OUTPUT CON TROL POTENTIOMETER R1 and associated wiring for loose or faulty connec tions See wiring diagram Perform Control Board test Perform Firing Board test Perform test Perform SCR Output Bridge test A 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 216 383 2531 or 1 800 833 9353 IDEALARC DC 600 LINCOLN amp TROUBLESHOOTING amp REPAIR F 9 TROUBLESHOOTING GUIDE _ Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Machine shuts off input contactor drops out when the welder output terminals are
93. input power SELECT PROPER LOCATION Place the IDEALARC DC 600 where clean air can freely circulate in through the front intake and out through the rear louvers Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Not following these precautions can result in the nuisance shutdown of the machine because of excessive operating temperatures STACKING Three IDEALARC DC 600 machines can be stacked DO NOT stack more than three machines in one grouping LINCOLN DO NOT stack the IDEALARC DC 600 on another type of machine Follow these guidelines when stacking 1 Select a firm level surface capable of sup porting the total weight of up to three machines 1570 pounds 712 kilograms 2 Setthe bottom machine in place 3 Stack the second machine on top of it by aligning the two holes in the base rails of the second machine with the two pins on top front of the bottom machine 4 Repeat process for third machine NOTE The machines must be stacked with the Case Front of each machine flush with each other See Figure A 1 STACKING HOLE STACKING PINS FIGURE A 1 Stacking IDEALARC DC 600 machines TILTING The IDEALARC DC 600 must be placed on a stable level surface so it will not topple over IDEALARC DC 600 A 4 ELECTRICAL INPUT CONNECTIONS Before installing the machine check that the input sup ply voltage phase and frequency are the same as the mach
94. ion to provide an essentially constant output SCR electronically controlled welder output pro vides extra long life especially for highly repetitive welding applications Three circuit solid state control system provides maximum performance and circuit protection Low profile case provides maximum use of space Convenient access to all controls Output lead strain relief loops to prevent terminal and cable damage Easily removed case side even when stacked Outdoor operation because enclosure is designed with air intake louvers that keep dripping water from entering the unit Transformer SCR bridge and choke have special corrosion resistant paint for added protection 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 Duty DuyCyde vals 5096 50 60 Based on 10 min 6096 50 60 Based on 10 min LINCOLN 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 7 AMMETER 8 VOLTMETER 3 WELDING MODE 4 OUTPUT CONTROL optional optional SWITCH SWITCH 1 ON OFF PUSH BUTTON 6 POWER SOURCE PILOT LIGHT 5 CONTROL CIRCUIT 2 OUTPUT CONTROL POLARITY SWIT
95. is DIMMER than other LEDs The proper AC voltage may not be reaching Firing Board Check for loose or faulty connections Perform Main Transformer Test LINCOLN amp LINCOLN TROUBLESHOOTING amp REPAIR F 25 FIRING BOARD TEST Locate the terminal strip directly NOTE This jumper connection ini below the Control Box tiates machine output Connect a jumper wire from termi nal 2 to terminal 4 on the termi nal strip See Figure F 8 O O O O O O O 214 2 31 32 75 76 77 80 81 FIGURE F 8 Jumper Wire Connection Points IDEALARC DC 600 F 26 TROUBLESHOOTING amp 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 IDEALARC DC 600 NOTE LEDs 1 to 6 indicate that the gate firing signals are being generated to send to each of the SCRs Set the OUTPUT CONTROL SWITCH SWS in the Output Control at DC 600 position Set the WELDING CONTROL SWITCH in either of the CV posi tions Rotate the OUTPUT CONTROL POTENTIOMETER As the pot is turned clockwise the LEDs glow brighter As the pot is turned counter clockwise the LEDs dim a If the LEDs glow and change in brightness equally as the pot is turned and the problem contin ues then the SCR Bridge may be faulty Perform SCR Bridge test b
96. kers and welders or cutters having a pacemaker should consult their physician before welding or cutting Exposure to EMF fields in welding or cutting may have other health effects which are now not known All welders or cutters should use the following procedures in order to minimize exposure to EMF fields from the welding or cutting circuit 8 d 1 Route the electrode and work cables together Secure them with tape when possible 8 d 2 Never coil the electrode lead around your body 8 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding or cutting power source IDEALARC DC 600 SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention
97. les for loose or faulty connections 1 Check the WELDING MODE SWITCH SW4 and the asso ciated wiring for loose or faulty connections See wiring dia gram Check the reed switch The voltage from lead 215 to lead 4220 should be 8VDC when the DC600 is in an idle condition When the machine is producing welding current the reed switch CR3 should close and the voltage from 215 to 220 should drop to zero Perform the Firing Board test Perform the SCR Output The control board may be faulty Replace A 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 216 383 2531 or 1 800 833 9353 LINCOLN amp IDEALARC DC 600 LINCOLN TROUBLESHOOTING amp REPAIR F 13 CONTROL TRANSFORMER T2 VOLTAGE TEST A 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 If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric serv
98. m the Transformer Test Perform the Firing Board Test Perform the SCR Output Bridge Test 4 Test for open circuit voltage at the Control Board a Insert meter probes in to Plug lead cavities to test for open circuit voltage from lead 222 at Plug J1 on the Control Board to lead 215 at Plug J3 on Control Board See Figure 11 LEAD 256 DC600 CONTROL S LEAD 255 G 1504 4 r G 1504 3 LED 1 F 31 LEAD 222 LED 4 LED 5 LEAD 215 a 2 CONTRO L BOARD FOR CODES 9700 AND ABOVE LED2 LEAD 255 2 E LEAD 4256 O4 LEAD 222 E E C 2 CONTROL BOARD FOR CODES BELOW 9700 FIGURE F 11 LED 2 Open Circuit Voltage Test Points IDEALARC DC 600 F 32 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR CONTROL BOARD TEST b Ifthe open circuit voltage is not present at the Control Board then check leads 222 and 215 for loose or faulty wiring connections See wiring dia gram 5 Test for continuity zero ohms between the negative output termi nal and lead 222 at Plug J1 on the Control Board a f more than zero ohms is mea sured the lead may be faulty 6 Test for continuity zero ohms between the positive output termi nal and lead 215 at Plug J3 on the Control Board a If more than zero ohms is mea sured the lead may be faulty
99. made electrically hot 2 to 4 closure at terminal strip The DC600 will NOT shut off when the Stop button is pushed OUTPUT PROBLEMS Remove all welding cables and control cables from the DC 600 Jumper 2 to 4 at the terminal strip If the machine does NOT shut off and normal open circuit voltage is present at the welder output terminals the problem is external to the DC600 Either the remote leads 75 76 or 77 are grounded to the nega tive output cable or there is a short on the welding output ter minals If the machine still shuts off when all control and welding cables are removed then the problem is internal to the DC600 Contact your local Lincoln Authorized Field Service Facility Check for grounds and or shorts in the 75 76 77 cir cuit See wiring diagram Check for grounds and shorts in the welder output terminals and associated leads See wiring diagram Check the output shunt and associated leads See wiring diagram Perform the Control Board The input contactor CR1 contacts may be stuck closed Check and replace if necessary The Interlock contacts Part of CR1 may be faulty Replace if necessary The ON OFF PUSHBUT TON may be faulty Check or 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 bef
100. nd output terminals This feed back information is processed in the control board The control board compares the commands of the Mode switch and the Output Control Potentiometer or Remote Control with the feedback information and sends the appropriate signal to the Firing Board The Firing Board is a three phase circuit Each phase provides two firing pulses one for each of the two Silicon Controlled Rectifiers SCR controlled by that phase The firing circuit supplies the proper amount of FAULT PROTECTION OUTPUT CONTROL FIRING BOARD POSITIVE TERMINAL AOoPuommT SCR BRIDGE LATCHING RESISTOR NEGATIVE TERMINAL energy to the gates of the power SCHs When this energy is applied at the correct time the SCR will turn ON The amount of ON time versus OFF time determines the output of the machine See SCR Operation The Pilot Relay signals the Firing Board circuit to sup ply gate pulses to the SCR Bridge Closing of the Pilot Relay a dry closure of leads 2 and 4 also brings the Latching Resistor into the machine output circuit The Latching Resistor provides a pre load for the SCR Bridge A Choke is connected between the neutral connection of the Main Transformer secondaries and the negative output terminal This large inductor stores energy and provides filtering for the output of the DC 600 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion LINCOLN 8 98 IDEALARC
101. nd the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD MATERIALS NEEDED 9 16 socket wrench 9 16 open end wrench 1 2 socket wrench 1 2 open end wrench 3 8 socket wrench LINCOLN E IDEALARC DC 600 F 58 TROUBLESHOOTING amp REPAIR TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY TRANSFORMER REMOVAL PROCEDURE IDEALARC DC 600 OUTPUT CHOKE LEAD THROUGH BOLT 4 7 lt X9 LIFT BAIL ACCESS TO BOLT h 2755 SELF TAPPING BOLTS FIGURE F 22 Transformer Bail Assembly Removal 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 socket wrench rear of the transformer Remove the two bolts and nuts 5 Remove the six transformer sec connecting the Output Choke leads to the copper strap and the main secondary common buss lead using a 9 16 socket wrench and a 9 16 open end wrench a Identify and label the small snubber leads Remove the four nuts mounting the Output Choke to the transformer through bolts using a 9 16 socket wrench ondary leads from the SCR Output Bridge Assembly using a 1 2 sock et wrench and a 1 2
102. ntrol capabilities or a remote control device such as a K775 must be connected to terminals 75 76 and 77 Refer to Accessories Section for wire feeder remote information WELDING PROCEDURE RECOMMENDATIONS Select Welding Mode Switch position based on type of welding to be done 1 Innershield Welding Other Open Arc Processes Use the CV Innershield mode 2 Submerged Arc Welding Use the CV Submerged Arc mode f performing high speed welding switch between the CV Submerged Arc and the CV Innershield mode and use the mode that produces the best welding results 3 Air Carbon Arc Cutting Stick Welding High Current Large Puddle Submerged Arc Welding Use the VV CC mode When the IDEALARC DC 600 is used for Air Carbon Arc cutting the OUT PUT CONTROL POTENTIOMETER should be set to 9 initially Based on the size of the carbon being used or the process turn the potentiometer to a lower setting as required by the process You can use carbon rods up to 3 8 in diameter at cur rents as high as 750 amps with excellent arc con trol The welder protection circuit protects the machine from extremely high short circuiting pulses LINCOLN OPERATION iid SEMI AUTOMATIC AND AUTOMATIC WIRE FEEDING WITH A IDEALARC DC 600 AND WIRE FEEDERS When using the IDEALARC DC 600 with semi auto matic or automatic wire feeding equipment and for stick welding or air carbon arc cutting it is recom mended that the optional MULTI PROCESS
103. oln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LELECTRIC IDEALARC DC600 G 9 ELECTRICAL DIAGRAMS FIGURE G5 Firing Board Schematic for G1486 5 and above 4881 926 21 1 OILVW3H2S Quvog SNIUIJ NO 123NNO2 GNNOYD Hi1HV3 NOILO3NNOD BNVHS LY NOLL23NNO2 gt 1404 32405 14406 u3MOd 13M 07170 03141934S 351 0 553740 1 530010 513971 031312395 361 10 SS31NN Mp SWUO 540151538 031312345 351MH3H10 553191 05 220 034 SuoLlOVdY 21513 34 57108 5 1951815373 NOILVNHOJNI 1 83 39 824 9Nl HIJ JAVIS WOYs G3AOW3Y SI JTIHM 82d ONI U J 33159 JHL NI SNIVN3H SindinO 1311 8 4 01 S3NIHOVN JMI OML 5824 1J3NNOJ 01 035 S G N 3002 NOWAOD v 9 51081802 30 AYLINDYID YO 51 3 04 02 12VX3 JHL MOHS LON MVHOVIO 5 31374WO2 V 30 A111IBV3ONVH2H3INI 3 1 9 112333 1nOHLIM 30 2 AVA 08908 1102812 Q31NIBd V AYLINIBII NO SIN3NOdNOO 3941 V N S310N 82d 1051 02 WOHJ WNOIS gt
104. ols which come in contact with the P C Board must be either conductive anti static or static dissipative Remove the P C Board from the static shield ing bag and place it directly into the equipment Don t set the P C Board on or near paper plas tic or cloth which could have a static charge If the P C Board can t be installed immediately put it back in the static shielding bag If the P C Board uses protective shorting jumpers don t remove them until installation is complete If you return a P C Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board trou bleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and sub stitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the pro
105. olted electrical connections on the aluminum heat sinks F 51 IDEALARC DC 600 F 52 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR SCR SCR OUTPUT BRIDGE REMOVAL SCR BRIDGE ASSEMBLY REMOVAL OF COMPLETE BRIDGE ASSEMBLY SNUBBER PC BOARD ASSEMBLY 7 NA PR Ry N AN See w Te SS SS 2 TRANSFORMER SECONDARY LEAD Wi FIGURE F 20 SCR Output Bridge Removal NOTE If it is necessary to remove and replace the entire SCR Output Bridge Assembly use these procedures 1 Disconnect the Gate Lead Molex Plug J4 from the Firing Board later models a f working on an earlier model and there is no Gate Lead Molex Board identify and label the six Gate leads and cut or unsolder the leads from their respective snubber boards 2 Remove the four self tapping bolts that mount the SCR Bridge Assembly to the horizontal rails using a 9 16 socket wrench See Figure F 20 a Note placement of insulting washers tubes and pads so they can be replaced correctly Identify and label the six trans former secondary heavy alu minum leads that connect to the anodes of the SCR Head Sink Assemblies See Figure F 20 Remove the transformer secondary leads using a 1 2 socket wrench LINCOLN amp LINCOLN TROUBLESHOOTING amp REPAIR SCR SCR OUTPUT BRIDGE REMOVAL 5 Remove the bolt that connects the Shunt Assembly heavy copper lead to the SCR Bridge Assembly
106. on 4 a Remove fire hazards from the welding or cut ting area If this is not possible cover them to prevent the welding or cutting sparks from start ing a fire Remember that welding or cutting sparks and hot materials from welding or cutting can easily go through small cracks and openings to adjacent areas Avoid welding or cut ting near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding or cutting make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding and cuttin
107. open end wrench a Identify and label all leads including the small snubber leads b Clear the secondary leads so they are free to move when the transformer is removed LINCOLN amp TROUBLESHOOTING amp REPAIR F 59 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 NOTE There is one bolt on each transformer side of the transformer that must be removed by inserting the wrench 2 Cut or unsolder all leads through the hole in Lift Bail a Cut the secondary leads 7 Remove the Lift Bail and Output These must be re TIG welded Bridge Assembly from the trans to the new transformer coils former by lifting the Lift Bail up slightly and sliding the Lift Bail 3 Remove the four nuts from the towards the SCR Bridge through bolts that hold the trans former together 4 Attach a hoist to the top of the E Iron and lift from assembly LINCOLN 9 IDEALARC DC 600 F 60 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY COIL REMOVAL PRIMARY TRANSFORMER COILS SECONDARY _ TRANSFORMER COILS INSULATION THROUGH BOLT Figure F 23 Transformer coil removal Label and cut leads to the coil s being removed See Figure F 23 NOTE To remove a m
108. or non functioning output SCR Each vertical division represents 20 volts and each horizontal division represents 2 milliseconds in time Volts Div Horizontal Sweep Coupling Trigger Note Scope probes connected at machine ouput terminals probe to positive termi nal probe to negative terminal LINCOLN 8 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR F 47 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 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD MATERIALS NEEDED Phillips head screwdriver 5 16 socket wrench Flat head screw driver Low pressure air source LINCOLN amp IDEALARC DC 600 ae TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT CLEANING PROCEDURE CONTACTOR REPLACE IDEALARC DC 600 Disconnect main AC input power supply to the machine Locate and get access to the Input
109. ore you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Observe Safety Guidelines detailed in the beginning of this manual The weld output terminals are always electrically hot A CAUTION OUTPUT PROBLEMS Remove any external leads hooked to 2 and 4 on the ter minal strip If the problem dis appears the fault is in the con trol cable or wire feeder If some open circuit voltage is present over 3VDC after per forming Step 1 then the prob lem is within the DC600 Check for an internal short between leads 2 and 4 See wiring diagram The Pilot Relay CR4 may be stuck closed Check or replace Perform Firing Board test Perform Control Board test Perform the SCR Output Bridge test The SCR Snubber s may be leaky Check or replace See wiring diagram 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 216 383 2531 or 1 800 833 9353 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR 11 TROUBLESHOOTING GUIDE _ Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION
110. oughout this manual 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD LINCOLN 8 IDEALARC DC 600 LINCOLN TROUBLESHOOTING amp REPAIR LIFT BAIL REMOVAL INCLUDING MAIN TRANSFORMER CHOKE AND OUTPUT BRIDGE ASSEMBLY REMOVAL PROCEDURE SHUNT FIGURE F 21 Lift Bail Removal 1 Disconnect gate leads a On later models remove gate lead Molex Plug J5 from the Firing Board On earlier models identify and label the six gate leads and cut or unsolder the leads from their respective Snubber Board 2 Disconnect the Shunt lead from the SCR Bridge Assembly See Figure 21 3 Disconnect the leads from the sec ondary thermostat See wiring dia gram 4 Disconnect auxuliary winding leads a On later models remove Molex Plug J5 from the Firing Board On earlier models disconnect the following leads from the ter minal strip in the Control Box 31 32A 203 204 205 206 207 and 208 IDEALARC DC 600 F 56 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR LIFT BAIL REMOVAL INCLUDING MAIN TRANSFORMER CHOKE AND OUTPUT BRIDGE ASSEMBLY Disconnect leads 215 and 216 from Relay CR4 and lead 231 from
111. place A 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 216 383 2531 or 1 800 833 9353 LINCOLN amp IDEALARC DC 600 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE F 5 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Input contactor CR1 chatters Input contactor pulls in when start button is pressed but immediately drops out when start button is released OUTPUT PROBLEMS The input line voltage may be low Check all three phases Make sure input line voltage matches machine rating and the reconnect panel is connect ed correctly for the line voltage Make sure input line voltage matches machine rating and the reconnect panel is connect ed correctly for the line voltage Remove all external wires attached to terminal strip 2 4 31 32 75 76 77 If contactor CR1 functions correctly there may be a ground or negative intrusion on the remote control leads 75 76 or 77 There may also be a short at the welder output terminals If the problem persists after per forming steps 1 and 2 the problem is in the DC600 The pilot relay CR2 may have bad contacts Check or replace relay Check for loos
112. r using the IDEAL ARC DC 600 in the local control mode of operation For remote control of the machine see the Remote Control of Machine Operation section Before operating the machine make sure you have all materials needed to complete the job Be sure you are familiar with and have taken all possible safety pre cautions before starting work It is important that you follow these operating steps each time you use the machine 1 Turn on the main AC power supply to the machine 2 Setthe CONTROL CIRCUIT POLARITY SWITCH to the appropriate position Set toggle to Electrode Negative position if the electrode is connected to the negative output terminal Set toggle to Electrode Positive position if the electrode is connected to the positive output terminal 3 Set the WELDING MODE SWITCH to welding process being used CV Innershield CV Submerged Arc VV CC 4 Pushthe ON OFF PUSH BUTTON to the ON posi tion The red neon light glows The fan starts 5 Set Output Control Potentiometer to desired volt age or current 6 Make the weld NOTE Terminal 2 and 4 must be connected together to energize the machine output REMOTE CONTROL OF MACHINE OPERATION The toggle switch on the control panel labeled Output Control at DC 600 Output Control Remote gives the operator the option of controlling the machine out put from a remote location If in the Remote position a wire feeder with remote co
113. rminal marked 5 NOTE The IDEALARC DC 600 must be properly grounded IDEALARC DC 600 ACCESSORIES 5 Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpose c Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 21 lead to work cable for ease of use 6 Connect NA 5 wire feeder control jumpers on Voltage Control Board See NA 5 Operator s Manual a Connect red jumper on V oltage Control Board to pin S b Connect white jumper on V oltage Control Board to pin B NOTE The connection diagram shown in Figure C 6 shows the electrode connected for positive polarity To change polarity a Set the IDEALARC DC 600 ON OFF PUSH BUTTON to OFF b Move the electrode cable to the Negative output terminal c Move the work cable to the Positive output terminal d Set the IDEALARC DC 600 CONTROL CIRCUIT POLARITY SWITCH to NEGATIVE NOTE For proper NA 5 operation the electrode cables must be secured under the clamp bar on the left side of the NA 5 Control Box LINCOLN 8 ACCESSORIES CONNECTING THE LN 8 OR LN 9 TO THE IDEALARC DC 600 1 Disconnect AC input power to the IDEALARC DC 600 Set the IDEALA
114. rpose Keep the 21 lead electrically separate from the work cable circuit and connection Tape the 21 lead to work cable for ease of use NOTE The connection diagram shown in Figure C 5 shows the electrode connected for positive polarity To change polarity a Set the IDEALARC DC 600 ON OFF PUSH BUTTON to OFF Move the electrode cable to the Negative output terminal Move the work cable to the Positive output terminal Set the IDEALARC DC 600 CONTROL CIR CUIT POLARITY SWITCH to NEGATIVE Reverse the leads at the back of the ammeter and voltmeter on the wire feeder automatic control box IDEALARC DC 600 C 6 CONNECTING THE NA 5 TO THE IDEALARC DC 600 NOTE For optimum performance use the NA 5 with IDEALARC DC 600 codes 8288 and above 1 Disconnect main AC input power to the IDEALARC DC 600 2 Set the IDEALARC DC 600 ON OFF PUSH BUTTON to OFF 3 Connect the wire feeder control cable leads to the IDEALARC DC 600 terminal strip as shown in Figure C 6 LN8 OR LN9 NEGATIVE POSITIVE ELECTRODE CABLE TO WIRE FEEDER TO WORK FIGURE C 6 NA 5 WIRE FEEDER CONNEC TION TO THE IDEALARC DC 600 NOTE If using a K215 control cable connect con trol cable leads 75 76 and 77 to the matching 75 76 and 77 terminals on the terminal strip of the IDEALARC DC 600 4 Connect the wire feeder control cable ground lead to the frame te
115. rts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations LINCOLN 7 7 74 7 0 SAFETY FOR ENGINE powered equipment Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 7 c Do not add the fuel near an open flame welding or cutting arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
116. s are in the welding or cutting area or around the machine 2 Remove any debris dust dirt or materials that could block the air flow to the machine for cooling 3 Inspect the electrode cables for any slits or punctures in the cable jacket or any condition that would affect the proper operation of the machine Perform Periodically Clean the inside of the machine with low pressure air stream Clean the following parts Refer td Figure Main transformer and choke Electrode and work cable connections e SCR rectifier bridge and heat sink fins e Control board Firing board Fan Assembly NOTE The fan motor has sealed bearings which require no maintenance LINCOLN E IDEALARC DC 600 MAINTENANCE D 4 TRANSFORMER ASSEMBLY REAR PANEL ASSEMBLY gt m m lt LL O O a z lt BASE FAN SIDES LIFT BAIL CHOKE SCR gt d BRIDGE ASSEMBLY FRONT PANEL AND CONTROL ASSEMBLY CASE LINCOLN FIGURE D 1 General Assembly Exploded View IDEALARC DC 600 TABLE OF CONTENTS Section E 1 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 Contac
117. s of the test Repeat Battery Test Procedure in Step 4 if needed 10 11 12 13 14 15 16 Open switch SW 1 Reconnect the Tester leads See a Connect Tester lead A to the cathode b Connect Tester lead C to the anode c Disconnect Test lead G from the gate Close switch SW 1 Read meter for zero voltage a Ifthe voltage is zero the SCR is functioning b If the voltage is higher than zero the SCR is shorted Perform the Active Test Procedure outlined in Steps 5 13 for SCRs 2 6 Replace all SCR assemblies that do not pass the above tests Replace all Molex Plugs onto the Firing Board and Control Board LINCOLN amp TROUBLESHOOTING amp REPAIR F 41 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE NO LOAD H1 C HHH 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 Note Scope probes connected at machine ouput terminals probe to positive termi nal probe to negative terminal LINCOLN ams SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger IDEALARC DC 600 is TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MA
118. stall and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid problems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical abili ty that the PC board is the most likely com ponent causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly con nected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures P C Board can be dam aged by static electricity Remove your body s sta tic charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations Reusable Container Do Not Destroy If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time To
119. t Connections 2 2 4 100 4 Reconnect Procedure er A A 5 Output Connections 0 222 0 00 eene nennen A 8 A 9 Operation Section Safety PreCautions 2 General Description nennt nenne 3 Recommended Processes and B 3 Operational Features and Controls B 3 Design Features and Advantages sss eene nennen B 3 Welding Capability nnne nnne B 4 Gontrols and Settings 5 nae tie pane B 5 Operating SIleps iuit eee tere e nd Ace eet ata B 6 Welding Procedure Recommendations B 6 liec cm Section C ACGCOSSOTIOS inodo quilt Oi m SD eve C 2 C 8 Lr Section D Safety Precautions c eR e Meee eee Ed D 2 Routine and Periodic Maintenance sse enn D 3 3 D Exploded View dee iv eee D 4 Theory of nunne nnnn mnnn Section E Power Supply
120. t autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety EP i iv Installation 12 cii a tr Me ee ee Section A Technical Specifications icd ane A 2 Saltety Precautions 3 au ence Rua A 3 Select Proper Location accio aiaiai iaiia A 3 Electrical Inpu
121. t inch speed possible b To adjust the Open Circuit V oltage Control to get the best starting performance make repeated starts observing the NA 3 voltmeter When the voltmeter pointer swings smoothly up to the desired arc voltage without undershooting or overshooting the desired arc voltage the Open Circuit Voltage Control is set properly If the voltmeter pointer overshoots the desired volt age and then returns back to the desired voltage the Open Circuit V oltage Control is set too high This can result in a bad start where the wire tends to Blast of f If the voltmeter pointer hesitates before coming up to the desired voltage the Open Circuit V oltage Control is set too low This can cause the elec trode to stub Set NA 3 Start Board current and voltage as close to the welding procedure current and voltage as possible NOTE The Start Board current and voltage should be as close as possible to the welding pro cedure current and voltage while still getting satis factory starts d Setthe start time to as low a time as possible while still getting satisfactory starts 7 Start and make the weld LINCOLN 8 OPERATION B3 IDEALARC DC 600 POWER SOURCE SETTING WHEN CONNECTED TO NA 5 WIRE FEEDER When using the IDEALARC DC 600 with the NA 5 wire feeder set the controls on the IDEALARC DC 600 as follows for the best performance 1 Turn OFF main AC input power supply to the IDE ALARC DC 600 2 Conn
122. the splice connector Disconnect leads 211 and 212 from the ON OFF PUSH BUTTON Disconnect lead 256 from the PILOT LIGHT Disconnect lead 271 from relay CR2 located in the Control Box Remove resistor R2 from the hori zontal rail See Figure F 21 Cut and remove all cable ties and unbundle all wires Label and cut fan motor leads Separate leads 271 211 and X2 from the harness 13 14 15 16 17 Disconnect lead 272 from Input Contactor CR1 coil Disconnect the heavy copper lead from the negative Weld Output Terminal Identify label and disconnect the Main Transformer leads from the Reconnect Panel and the three leads that go to the Input Contactor Remove the four mounting nuts that hold the Lift Bail Assembly to the Base Lift the Bail Assembly carefully straight up and out of the machine using a hoist Be sure all leads are free to move with the assembly LINCOLN amp TROUBLESHOOTING amp REPAIR F 57 TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY A 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 If for any reason you do not understa
123. the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical trou bleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION This test determines whether or not the Firing Board is receiving the correct voltages and gate signals The LEDs Light Emitting Diodes will help you determine if the Firing Board is generating gate signals to the main SCRs MATERIALS NEEDED Volt Ohm Meter Multimeter IDEALARC DC 600 wiring diagram and Firing Board schematic drawing See Electrical Drawing Section of Manual LINCOLN E IDEALARC DC 600 F 22 IDEALARC DC 600 TROUBLESHOOTING amp REPAIR FIRING BOARD TEST TEST PROCEDURE FOR NORMAL FIRING BOARD OPERATION 1 Disconnect main AC input power to the IDEALARC DC 600 Locate the Firing Board on the left side of Control Box facing the machine Perform a visual inspection of the Firing Board to see if there are any loose or faulty connections Connect the correct main AC input power to the machine Set the ON OFF PUSHBUTTON to ON Locate LEDs 7 8 and 9 on the Firing Board See Figure F7 Each LED should be ON and be equally bright Use Table F 1 to check the operation of each LED LINCOLN amp TROUBLESHOOTING amp REPAIR F 23 FIRING BOARD TEST G 1486 5 FIRING BOARD
124. tion for both stick welding and air carbon arc cutting NOTE To use the IDEALARC DC 600 for both stick welding air carbon arc cutting AND semi automatic automatic welding the optional Multi Process Switch K804 must be used See the Section of this manual for instructions on installing and using the Multi Process Switch When the Multi Process Switch is not used all control work and elec trode leads from semi automatic or automatic wire feeders must be disconnected from the IDEALARC DC 600 before connecting the machine for stick weld ing or air carbon arc cutting LINCOLN TABLE OF CONTENTS OPERATION SECTION rh teen E kd ee E de Ra RS Section B Safety Precautions 444 6000000 0 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 2 0 0000 4 Controls and Settings B 5 Operating Steps 0 4204 4 0 6 Remote Control of Machine B 6 Welding Procedure Recommendations B 6 N B 9 Semi Automatic and Automatic Wire Feeding with a DC 600 and Wire
125. tor Hold In E 4 1 5 OUTPUT CONTROL CONTROL 115 VAC TRANSFORMER PROTECTION DEVICES amp FAULT PROTECTION CIRCUTS CONTROL FIRING BOARD BOARD MAIN TRANSFORMER m POSITIVE TERMINAL oma AOoPuommT JQomzzo 1 CONTACTOR AOoPuommqT MI S SCR BRIDGE LATCHING RESISTOR REMOTE CONTROL NEGATIVE TERMINAL FIGURE E 1 Block Logic Diagram LINCOLN amp 9 98 IDEALARC DC 600 E 2 THEORY OF OPERATION FIGURE E 2 Input Line Voltage Contactor and Main Transformer L 115 VAC PROTECTION DEVICES amp CIRCUTS CONTRO TRANSFORMER CONTACTOR HOLD IN R E T pu 7 CONTACTOR TERMINAL STRIP REMOTE CONTROL INPUT LINE VOLTAGE CONTAC TOR AND MAIN TRANSFORMER The desired three phase input power is connected to the DC 600 through an Input Contactor located in the input box at the rear of the machine Two phases of the input line are also connected to the Control Transformer which supplies power to the Contactor Hold In Circuit The Contactor Hold In Circuit will dis able the Input Contactor if the DC 600 is overloaded or overheated A Reconnect Panel allows the user to configure the machine for the desired input voltage This AC input voltage is applied to the primary of the Main FIRING BOARD OUTPUT CONTROL FAULT PROTECTION CONTROL BOARD POSITIVE TERMINAL Aop PuommqT
126. uld be on the outside of the side panel See Figure C 3 NOTE If the machine does not have any holes in the front of the machine use the switch template and drill two 153 diameter holes 6 Position the MUL TI PROCESS SWITCH at the front of the machine See Figure C 3 MULTI PROCESS Simen S SELE TAPPING BRACKET CONTROL DRILL 153 LEADS HOLE IF NEEDED MULTI PROCESS SWITCH WIRE FEED CONTROL CABLE FIGURE C 3 ATTACHING THE MULTI PROCESS SWITCH BRACKET 7 Route the MULTI PROCESS SWITCH control leads through the strain relief box connectors and into the terminal strip wire feeder control cable is routed through the strain relief box con nector also See Figure C 3 LINCOLN 12 Connect the control leads from the MUL TI PROCESS SWITCH to terminals 2 and 4 on the IDEALARC DC 600 s terminal strip Position the MUL TI PROCESS SWITCH flush with the front of the machine about 2 lower than the bracket Slide the switch straight up to the brack et Check that the bottom of the switch is hooked behind the top of the bottom louver Connect the right cable from the MUL TI PROCESS SWITCH facing the front of the machine to the IDEALARC DC 600 positive output terminal See Figure C 4 ELECTRODE ELECTRODE CABLE CABLE WIRE STICK AIR CARBON FEEDER ARC WELDING EQUIPMENT JUMPER IF NEEDED SEE INSTRUCTIONS FIGURE C 4 MULTI PROCESS SWITCH CABLE CONNECTIONS Connect
127. welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding or cutting cable and welding or cutting machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 4 c and 6 LINCOLN ARC RAYS can burn 2 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or cutting or observing open arc welding or cutting Headshield and filter lens should conform to ANSI Z87 standards 2 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 3 a Welding or cutting may produce fumes and B gases hazardous to health Avoid breathing these fumes and gases When welding or cutting keep your head out of the fume Use enough

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