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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 4
5 6
2
9
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
SERVICE MANUAL
World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
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 a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” 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. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-
FORMED ONLY BY QUALIFIED INDIVIDUALS.
1.f. Maintain the electrode holder, work clamp, welding or cutting 3.b. Do not weld or cut in locations near chlorinated hydrocarbon
cable and welding or cutting machine in good, safe operating vapors coming from degreasing, cleaning or spraying
condition. Replace damaged insulation. operations. The heat and rays of the arc can react with
solvent vapors to form phosgene, a highly toxic gas, and
1.g. Never dip the electrode in water for cooling. other irritating products.
1.h. Never simultaneously touch electrically “hot” parts of 3.c. Shielding gases used for arc welding or cutting can displace
electrode holders connected to two welders because voltage air and cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
3.d. Read and understand the manufacturer’s instructions for this
1.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
1.j. Also see Items 4.c. and 6. your welding distributor or from the manufacturer.
IDEALARC DC-600
SAFETY ii
4.b. Where compressed gases are to be used at the job site, 5.c. Cylinders should be located:
special precautions should be used to prevent hazardous • Away from areas where they may be struck or subjected to
situations. Refer to “Safety in Welding and Cutting” (ANSI physical damage.
Standard Z49.1) and the operating information for the
equipment being used. • A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
4.c. When not welding or cutting, make certain no part of the
electrode circuit is touching the work or ground. Accidental 5.d. Never allow the electrode, electrode holder or any other
contact can cause overheating and create a fire hazard. electrically “hot” parts to touch a cylinder.
4.d. Do not heat, cut or weld tanks, drums or containers until the 5.e. Keep your head and face away from the cylinder valve outlet
proper steps have been taken to insure that such procedures when opening the cylinder valve.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 5.f. Valve protection caps should always be in place and hand
been “cleaned”. For information, purchase “Recommended tight except when the cylinder is in use or connected for
Safe Practices for the Preparation for Welding and Cutting of use.
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society 5.g. Read and follow the instructions on compressed gas
(see address above). cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
4.e. Vent hollow castings or containers before heating, cutting or Cylinders,” available from the Compressed Gas Association
welding. They may explode. 1235 Jefferson Davis Highway, Arlington, VA 22202.
4.f. Sparks and spatter are thrown from the welding and cutting
arc. Wear oil free protective garments such as leather gloves,
heavy shirt, cuffless trousers, high shoes and a cap over
FOR ELECTRICALLY
your hair. Wear ear plugs when welding or cutting out of posi- powered equipment.
tion or in confined places. Always wear safety glasses with 6.a.Turn off input power using the disconnect
side shields when in a welding or cutting area. switch at the fuse box before working on
the equipment.
4.g. Connect the work cable to the work as close to the welding
or cutting area as practical. Work cables connected to the 6.b. Install equipment in accordance with the U.S. National
building framework or other locations away from the welding Electrical Code, all local codes and the manufacturer’s
area increase the possibility of the welding or cutting current recommendations.
passing through lifting chains, crane cables or other alternate
circuits. This can create fire hazards or overheat lifting 6.c. Ground the equipment in accordance with the U.S. National
chains or cables until they fail. Electrical Code and the manufacturer’s recommendations.
IDEALARC DC-600
SAFETY iii
____________________________________________________ 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
7.d. Keep all equipment safety guards, covers side, the work cable should also be on your right side.
and devices in position and in good repair.
Keep hands, hair, clothing and tools away 8.d.4. Connect the work cable to the workpiece as close as
from V-belts, gears, fans and all other possible to the area being welded.
moving parts when starting, operating or
repairing equipment. 8.d.5. Do not work next to welding or cutting power source.
____________________________________________________
7.f. 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.
___________________________________________________
IDEALARC DC-600
SAFETY iv
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
a. Les circuits à l’électrode et à la piéce sont sous tension la zone de travail qu’il est pratique de le faire. Si on place la
quand la machine à souder est en marche. Eviter toujours masse sur la charpente de la construction ou d’autres endroits
tout contact entre les parties sous tension et la peau nue éloignés de la zone de travail, on augmente le risque de voir
ou les vétements mouillés. Porter des gants secs et sans passer le courant de soudage par les chaines de levage,
trous pour isoler les mains. câbles de grue, ou autres circuits. Cela peut provoquer des
b. Faire trés attention de bien s’isoler de la masse quand on risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher met- câbles jusqu’à ce qu’ils se rompent.
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble de galvanisées plombées, ou cadmiées ou tout autre métal qui
soudage et la machine à souder en bon et sûr état defonc- produit des fumeés toxiques.
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à soud- du solvant pour produire du phosgéne (gas fortement toxique)
er parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
courant pour soudage semi-automatique, ces precautions le code “Code for safety in welding and cutting” CSA Standard
pour le porte-électrode s’applicuent aussi au pistolet de W 117.2-1974.
soudage.
IDEALARC DC-600
v
Page
Safety .........................................................................................................................i-iv
Installation ..........................................................................................................Section A
Technical Specifications .......................................................................................... A-2
Safety Precautions .................................................................................................. A-3
Select Proper Location .............................................................................................A-3
Electrical Input Connections ................................................................................... A-4
Reconnect Procedure ............................................................................................. A-5
Output Connections ....................................................................................... A-8 - A-9
Operation ............................................................................................................Section B
Safety Precautions ................................................................................................. B-2
General Description ................................................................................................ B-3
Recommended Processes and Equipment ..............................................................B-3
Operational Features and Controls .........................................................................B-3
Design Features and Advantages ...........................................................................B-3
Welding Capability .................................................................................................. B-4
Controls and Settings ..............................................................................................B-5
Operating Steps ...................................................................................................... B-6
Welding Procedure Recommendations .................................................................. B-6
Accessories ........................................................................................................Section C
Accessories .....................................................................................................C-2 - C-8
Maintenance........................................................................................................Section D
Safety Precautions ...................................................................................................D-2
Routine and Periodic Maintenance ..........................................................................D-3
3-D Exploded View ...................................................................................................D-4
Electrical Diagrams............................................................................................Section G
Parts Manual..............................................................................................................P-282
IDEALARC DC-600
SECTION A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
IDEALARC DC-600
A-2 INSTALLATION
TECHNICAL SPECIFICATIONS - IDEALARC DC-600
208/230/416/460/575/3/60 125/113/63/57/45
RATED OUTPUT
Duty Cycle AMPS Volts at Rated Amps
100% 600 44
60% 680 44
50% 750 44
OUTPUT
Mode Current Maximum Open Auxiliary Power
Range Circuit Voltage
PHYSICAL DIMENSIONS
Height Width Depth Weight
IDEALARC DC-600
INSTALLATION A-3
Read entire Installation Section before installing DO NOT stack the IDEALARC DC-600 on another type
the IDEALARC DC-600. of machine.
• Do not touch electrically hot parts. 4. Repeat process for third machine.
• Always connect the IDEALARC
DC-600 grounding terminal to a good electrical earth ground. NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
• Set the IDEALARC DC-600 Power ON/OFF PUSH BUTTON to Figure A.1.
OFF position when connecting power cord to input power.
__________________
SELECT PROPER LOCATION
STACKING HOLE
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 PINS
STACKING
TILTING
IDEALARC DC-600
A-4 INSTALLATION
Before installing the machine, check that the input sup- Ground the frame of the machine. A ground
ply voltage, phase, and frequency are the same as the terminal marked with the symbol ( ) is located inside
machine’s voltage, phase, and frequency as specified the Case Back of the machine near the input contactor.
on the machine’s rating plate on the Case Front Access to the Input Box Assembly is at the upper rear
Assembly Control Panel. Input power supply entry is of the machine. See your local and national electrical
through the hole in the Case Back Assembly. See codes for proper grounding methods.
Figure A.2 for the location of the machine’s input cable
entry opening, Input Contactor (CR1), and reconnect INPUT POWER SUPPLYCONNECTIONS
panel assembly for dual voltage machines.
A qualified electrician should connect the input power
supply leads.
FIGURE A.2 - Rear Panel
1. Follow all national and local electrical codes.
INPUT SUPPLY
CABLE ENTRY 2. Follow Input Supply Connection Diagram located
INPUT on the inside of the machine.
OPENING
CONTACTOR (CR1)
3. Use a three-phase line.
RECONNECT
PANEL ASSEMBLY 4. Remove Input Access Door at upper rear of
machine.
INPUT
CONTACTOR (CR1)
IDEALARC DC-600
RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different
voltage, remove input power and change the position
Multiple voltage machines are shipped connected to of the reconnect board on the Reconnect Panel.
the highest input voltage listed on the machine’s rating Follow The Input Connection Diagram located on the
plate. Before installing the machine, check that the inside of Case Back Input Access Door. These con-
Reconnect Panel in the Input Box Assembly is con- nection diagrams for the following codes are listed
nected for the proper voltage. below.
U 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.
GND H1 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H2 H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT
TRANSF.
L1 U L1 U
GND H1 GND H1
H3 LINK H2 LINK
TAPE TAPE
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT 1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION. LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR. 2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN. AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES. 4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN 5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS ALL HEX NUTS
FIGURE A.6-Reconnect Panel Board Positions for 380/460, 500/575 VAC Machines
IDEALARC DC-600
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI
2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
LINES
INPUT L2
V 3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
CONTACTOR
L1 U
GND
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
6. Tighten the output terminal nut with a wrench. FIGURE A.9 - Output Terminals.
IDEALARC DC-600
Connection For Semi-Automatic or Automatic 1. Set ON/OFF PUSH BUTTON to OFF.
Wire Feeder Control
2. Locate and open the hinged access door on the
NOTE: See the ACCESSORIES Section of this manu- Front Case Assembly.
al for specific instructions on connecting the following
semi-automatic and automatic wire feeders: 3. If necessary, disconnect all wire feeder control
cable connections from the DC-600 terminal strip.
•
•
•
LN-7
LN-8
LN-9 } Semi-Automatic Wire Feeders
4. Remove the leads from the unit by pulling them
through and out of the strain relief loops.
__________________
TABLE OF CONTENTS SECTION B-1
- OPERATION SECTION -
IDEALARC DC-600
OPERATING INSTRUCTIONS
Read and understand entire section before operating machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
can kill.
ARC RAYS
can burn.
_____________________________________
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.
_____________________________________
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.
5 6
1. ON/OFF
4 7
PUSH
BUTTON
3 8
2 9
1 10
6. POWER
SOURCE
PILOT
LIGHT
5. CONTROL CIRCUIT 2. OUTPUT CONTROL
POLARITY SWITCH POTENTIOMETER
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.
3. 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 7. AMMETER: An optional ammeter is
Arc, and VV (Variable Voltage) CC (Constant available.
Current) Submerged Arc.
SEMI-AUTOMATIC AND
2. Set the NA-3 Open Circuit Voltage Control to the
AUTOMATIC WIRE FEEDING WITH same dial setting as the Arc Voltage Control. If this
A IDEALARC DC-600 AND WIRE is a new welding procedure, a good starting point
is to set the Open Circuit Voltage Control to # 6.
FEEDERS
NOTE: The open circuit voltage of the
When using the IDEALARC DC-600 with semi-auto- IDEALARC DC-600 varies from approximately 16
matic or automatic wire feeding equipment and for volts to 56 volts in the CV Innershield or CV
stick welding or air/carbon arc cutting, it is recom- Submerged Arc modes. The open circuit voltage is
mended that the optional MULTI-PROCESS SWITCH constant in the VV(CC) mode.
be used. This switch permits you to easily change the
polarity of the connected wire feeding equipment or 3. Run a test weld. Set proper current, voltage, and
switch to stick welding or air/carbon arc cutting. travel speed.
NA-3 AUTOMATIC WIRE FEEDER a. For the best starting performance, the NA-
3 Open Circuit Voltage Control and Voltage
1. Set the DC-600 Output Control Switch to Remote. Control setting should be the same. Set the
NOTE: Later model NA-3 automatic wire feeders Inch Speed Control for the slowest inch speed
are capable of cold starts when the NA-3 Mode possible.
switch is in the CV or VV(CC) mode position.
Some earlier models are capable of cold starting b. To adjust the Open Circuit Voltage Control to
only in the VV(CC) mode position. Cold starting get the best starting performance, make
enables you to inch the wire down to the work, repeated starts observing the NA-3 voltmeter.
automatically stop, and automatically energize the
flux hopper valve. When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
2. Set the DC-600 welding mode switch for the overshooting the desired arc voltage, the Open
desired process: CV Submerged Arc, CV Circuit Voltage Control is set properly.
Innershield mode or VV(CC) mode.
If the voltmeter pointer overshoots the desired volt-
3. Set the NA-3 mode Switch Position to either CV or age and then returns back to the desired voltage,
VV(CC) to match the DC-600 mode selected in the Open Circuit Voltage Control is set too high.
step 2. This can result in a bad start where the wire tends
to "Blast off."
4. Refer to the NA-3 operators manual for instruc-
tions on how to use the NA-3 in conjunction with If the voltmeter pointer hesitates before coming up
the DC-600. to the desired voltage, the Open Circuit Voltage
Control is set too low. This can cause the elec-
5. Follow the following guidelines for good arc striking trode to stub.
detailed below for each welding mode.
4. Start and make the weld.
GOOD ARC STRIKING GUIDELINES FOR THE NA-3
WITH THE IDEALARC DC-600 IN THE CV a. Cold starts. For cold starts, be sure the work
INNERSHIELD, CV SUBMERGED ARC OR VV(CC) piece is clean and the electrode makes posi-
WELDING MODES. tive contact with the work piece.
Following are some basic arc striking techniques that b. Hot "On the Fly" starts. For hot starts, travel
apply to all wire feed processes. Using these proce- should begin before the wire contacts the work
dures should provide trouble-free starting. These pro- piece.
cedures apply to single, solid wires and Innershield
wires.
IDEALARC DC-600
B-8 OPERATION
ARC STRIKING WITH IDEALARC DC-600AND THE 6. Establish the correct arc striking procedure with
NA-3 START BOARD the NA-3 Start Board timer set at maximum.
When electrical strikeouts exceed 1 3/4Ó (44.4mm) an a. For the best starting performance, the NA-3
NA-3 Start Board may be required to improve arc strik- Open Circuit V oltage Control and V oltage
ing. Control setting should be the same. Set the
Inch Speed Control for the slowest inch speed
When the NA-3 Start Board is used to improve arc possible.
striking, use the following procedures:
b. To adjust the Open Circuit V oltage Control to
1. Set start time at 0. get the best starting performance, make
repeated starts observing the NA-3 voltmeter .
2. Set NA-3 start current and start voltage at mid-
range. When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
3. Set the NA-3 output current and voltage to the overshooting the desired arc voltage, the Open
proper settings for the welding procedure to be Circuit Voltage Control is set properly .
used.
If the voltmeter pointer overshoots the desired volt-
4. Turn the Start Board Timer to maximum. age and then returns back to the desired voltage,
the Open Circuit V oltage Control is set too high.
5. Set Start Board current and voltage control. This can result in a bad start where the wire tends
to "Blast of f."
a. Set the Start Board current control to 1 1/2 dial
numbers below that set on the NA-3 current If the voltmeter pointer hesitates before coming up
control. to the desired voltage, the Open Circuit V oltage
Control is set too low . This can cause the elec-
b. Set the Start Board voltage control equal with trode to stub.
the NA-3 voltage control setting.
c. Set NA-3 Start Board current and voltage as
NOTE: These Start Board current and voltage set- close to the welding procedure current and
tings result in a start up current that is lower than voltage as possible.
the NA-3 current setting and approximately equal
with the NA-3 voltage setting for the desired weld- NOTE: The Start Board current and voltage
ing procedure. should be as close as possible to the welding pro-
cedure current and voltage, while still getting satis-
factory starts.
IDEALARC DC-600
OPERATION B-9
5. Set the IDEALARC DC-600 WELDING MODE LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
SWITCH to the position that matches the welding FEEDERS OR OTHER CONSTANT WIRE
process being used. FEEDERS
a. For submerged arc welding, set WELDING To use the LN-7, LN-9, or other constant wire feed
MODE SWITCH TO CV SUBMERGED ARC speed semi-automatic wire feeders with IDEALARC
position. DC-600
b. For all open arc welding processes set WELD- 1. Set the IDEALARC DC-600 WELDING MODE
ING MODE SWITCH TO CV INNERSHIELD SWITCH to either CV Innershield mode or CV
position. Submerged Arc mode depending on the welding
process being used.
IDEALARC DC-600
TABLE OF CONTENTS Section C-1
- ACCESSORIES SECTION -
IDEALARC DC-600
C-2 ACCESSORIES
}
¥ LN-7
¥ LN-8 Semi-Automatic Wire Feeders or Air/Carbon Arc" position, only those
¥ LN-9 terminals are energized. The wire feeder nozzle or
gun and electrode are not electrically "hot" when in this
mode.
¥
¥
NA-3
NA-5 }Automatic Wire Feeders Follow these steps to install the MUL TI-PROCESS
SWITCH:
MULTI-PROCESS SWITCH 1. Confirm that the IDEALARC DC-600 ON/OFF
PUSH BUTTON is in the OFF position.
The MULTI-PROCESS SWITCH gives you the ability
to: 2. Disconnect main AC input power to the IDE-
¥ Switch between "stick welding or air/carbon arc ALARC DC-600.
cutting" and using a semi-automatic or automatic
wire feeder . 3. Open the terminal strip access door located on the
Case Front Assembly.
¥ Change the polarity of a semi-automatic or auto-
matic wire feeder without changing any electrical 4. Remove the two front, middle screws that secure
cable connections. the two side panels of the machine. See Figure
C.2.
See Figure C.1
REMOVE SCREWS
TO MOUNT
MULTI-PROCESS
SWITCH
POSITIVE
STICK OR
NEGATIVE AIR
CARBON
ARC
POSITIVE
STICK OR
NEGATIVE AIR
CARBON
Ð + ARC
WIRE STICK OR
FEEDER AIR/CARBON
CABLES ARC CABLES Ð +
IDEALARC DC-600
ACCESSORIES C-3
5. Attach the MUL TI-PROCESS SWITCH bracket 8. Connect the control leads from the MUL TI-
across the front of the machine with the flange PROCESS SWITCH to terminals #2 and #4 on the
down. Use the long, self-tapping screws and lock IDEALARC DC-600's terminal strip.
washers provided. The bracket should be on the
outside of the side panel. See Figure C.3. 9. Position the MUL TI-PROCESS SWITCH flush with
the front of the machine about 2" lower than the
NOTE: If the machine does not have any holes in bracket. Slide the switch straight up to the brack-
the front of the machine, use the switch template et.
and drill two .153" diameter holes.
10. Check that the bottom of the switch is hooked
6. Position the MUL TI-PROCESS SWITCH at the behind the top of the bottom louver .
front of the machine. See Figure C.3.
11. Connect the right cable from the MUL TI-
MULTI- PROCESS SWITCH (facing the front of the
PROCESS SELF TAPPING machine) to the IDEALARC DC-600 positive (+)
SWITCH SCREWS output terminal. See Figure C.4.
BRACKET CONTROL (DRILL .153"
LEADS HOLE IF
NEEDED) TERMINAL
STRIP
21 4 2 31 32 75 76 77 80 81
CONTROL
LEADS
ELECTRODE ELECTRODE
CABLE CABLE
WORK +
WIRE STICK AIR/CARBON
MULTI- FEEDER ARC WELDING
EQUIPMENT
PROCESS ELECTRODES
CABLE
IDEALARC DC-600
C-4 ACCESSORIES
13. Connect the wire feeder electrode and work NOTE: The instructions above are for connecting
cables. See Figure C.4. the stick polarity positive. To change the polarity ,
turn the IDEALARC DC-600 OFF, and reverse the
a. Insert the wire feeder electrode and work cables.
cables through the strain relief loop on the left
side of the IDEALARC DC-600 (facing the front NOTE: When it is not necessary to have separate
of the machine). ground cables for stick and semi-automatic or
automatic welding, connect a jumper from the
b. Connect the wire feeder electrode and work MULTI-PROCESS SWITCH "Work" terminal to the
cables to the electrode and work MULTI-PROCESS SWITCH "negative" terminal.
terminals on the left side of the MUL TI- See Figure C.4.
PROCESS SWITCH.
To operate the MUL TI-PROCESS SWITCH, refer to
NOTE: When using Dual Process Kits K317 or the operating instructions on the switch nameplate.
K318, connect the electrode and work cables to
these terminals instead of the power source output
terminals. See connection diagrams for details. UNDERCARRIAGE (K817, K817R,
14. Connect wire feeder control cable to the terminal
K842)
strip of the IDEALARC DC-600.
The IDEALARC DC-600 is designed for use with the
NOTE: Connect the control cable ground lead to Lincoln K817, K817R, or K842 Undercarriage.
the frame terminal marked ( ). Complete installation instructions are included with the
undercarriage. When any of the undercarriages are
NOTE: See the connection diagram for the wire installed, the IDEALARC DC-600 lift bail is no longer
feeder being used for connection instructions. functional. Do not attempt to lift the machine with the
undercarriage attached. The undercarriage is
15. Connect stick or air/carbon arc electrode and work designed for moving the machine by hand only .
cable. See Figure C.4. Mechanized towing can lead to injury and/or damage
to the IDEALARC DC-600.
IDEALARC DC-600
ACCESSORIES C-5
FEEDER CONTROL TO
AUTOMATIC
CONTROL
BOX
77
1. Set the ON/OFF PUSH BUTTON to OFF. 76
75
5. Connect the wire feeder grounding wire to the 5. Extend wire feeder control cable lead # 21 so it can
chassis ground screw marked with the symbol ( ). be connected directly to the work piece.
NOTE: The IDEALARC DC-600 Auxiliary Power a. Make a bolted connection using AWG #14 or
Circuit supplies 1 15-volt AC power to the wire feed- larger insulated wire. Tape the bolted connec-
ing equipment. The circuit has a 1000 volt ampere tion with insulating tape.
rating. An 8-amp slow blow fuse on the machineÕ s
b. An S-16586- X remote voltage sensing work
control panel protects the auxiliary power supply
lead is available for this purpose.
from excessive overloads.
c. Keep the # 21 lead electrically separate from
the work cable circuit and connection.
CONNECTING THE NA-3 IDEALARC DC-600
d. Tape the # 21 lead to work cable for ease of
1. Disconnect main AC input power to the IDEALARC use.
DC-600.
NOTE: The connection diagram shown in Figure C.5
2. Set IDEALARC DC-600 ON/OFF PUSH BUTTON shows the electrode connected for positive polarity . To
to OFF. change polarity:
3. Connect the wire feeder control cable leads to the a. Set the IDEALARC DC-600 ON/OFF PUSH
IDEALARC DC-600 terminal strip as shown in BUTTON to OFF
Figure C.5.
b. Move the electrode cable to the Negative (-)
4. Connect the wire feeder control cable ground lead output terminal
to the frame terminal marked ( ).
c. Move the work cable to the Positive (+) output
NOTE: The IDEALARC DC-600 must be properly terminal.
grounded.
d. Set the IDEALARC DC-600 CONTROL CIR-
CUIT POLARITY SWITCH to NEGATIVE.
IDEALARC DC-600
C-6 ACCESSORIES
CONNECTING THE NA-5 TO THE 5. Extend wire feeder control cable lead # 21 so it can
IDEALARC DC-600 be connected directly to the work piece.
NOTE: For optimum performance use the NA-5 with a. Make a bolted connection using AWG #14 or
IDEALARC DC-600 codes 8288 and above. larger insulated wire. Tape the bolted connec-
tion with insulating tape.
1. Disconnect main AC input power to the IDEALARC
DC-600. b. An S-16586- X remote voltage sensing work
lead is available for this purpose.
2. Set the IDEALARC DC-600 ON/OFF PUSH
BUTTON to OFF. c. Keep the # 21 lead electrically separate from
the work cable circuit and connection.
3. Connect the wire feeder control cable leads to the
IDEALARC DC-600 terminal strip as shown in d. Tape the # 21 lead to work cable for ease of
Figure C.6. use.
TO INPUT
CABLE a. Connect red jumper on V oltage Control Board
to pin "S."
C
B
A b. Connect white jumper on V oltage Control
21 4 2 31 32 75 76 77 80 81 32
Board to pin "B."
31
2
4 NOTE: The connection diagram shown in Figure C.6
21 shows the electrode connected for positive polarity . To
GND
Ð + change polarity:
NEGATIVE POSITIVE
ELECTRODE
CABLE TO WIRE
a. Set the IDEALARC DC-600 ON/OFF PUSH
TO WORK FEEDER
BUTTON to OFF.
IDEALARC DC-600
ACCESSORIES C-7
IDEALARC DC-600
C-8 ACCESSORIES
IDEALARC DC-600
TABLE OF CONTENTS SectionD-1
- MAINTENANCE SECTION -
IDEALARC DC-600
D-2 MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
CAN KILL.
Only qualified personnel should
perform this maintenance.
__________________
IDEALARC DC-600
MAINTENANCE D-3
Perform Periodically:
• Control board.
• Firing board.
• Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
IDEALARC DC-600
D-4 MAINTENANCE
IDEALARC DC-600
TABLE OF CONTENTS Section E-1
- THEORY OF OPERATION SECTION -
OUTPUT
CONTROL
MAIN
TRANSFORMER
F
E
PILOT E
D
RELAY B
R A
E C POSITIVE
C K TERMINAL
O
N
N F
E SHUNT E
C E PILOT
T D
RELAY
B
A
CONTACTOR C
K
TERMINAL SCR BRIDGE
STRIP 1 LATCHING
1 RESISTOR
REMOTE 5
TO CONTROL V
CONTROL A
C
BOARD NEGATIVE
CHOKE
TERMINAL
FAN
8/98
IDEALARC DC-600
E-2 THEORY OF OPERATION
FIGURE E.2 Input Line Voltage, Contactor and Main Transformer
OUTPUT
CONTROL
MAIN
TRANSFORMER
F
E
PILOT E
D
RELAY B
R A
E C POSITIVE
C K TERMINAL
O
N
N F
E SHUNT E
C E PILOT
T D
RELAY
B
A
CONTACTOR C
K
TERMINAL SCR BRIDGE
STRIP 1 LATCHING
1 RESISTOR
REMOTE 5
TO CONTROL V
CONTROL A
C
BOARD NEGATIVE
CHOKE
TERMINAL
FAN
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
8/98
IDEALARC DC-600
THEORY OF OPERATION E-3
OUTPUT
CONTROL
MAIN
TRANSFORMER
F
E
PILOT E
D
RELAY B
R A
E C POSITIVE
C K TERMINAL
O
N
N F
E SHUNT E
C E PILOT
T D
RELAY
B
A
CONTACTOR C
K
TERMINAL SCR BRIDGE
STRIP 1 LATCHING
1 RESISTOR
REMOTE 5
TO CONTROL V
CONTROL A
C
BOARD NEGATIVE
CHOKE
TERMINAL
FAN
OUTPUT, RECTIFICATION,
CONTROL AND FEEDBACK
The neutrals of the Main Transformer secondary wind- energy to the gates of the power SCRs. When this
ings are connected together and the six starts are con- energy is applied, at the correct time, the SCR will turn
nected to the six SCR assemblies to form a six phase "ON". The amount of "ON" time versus "OFF" time
output. This six phase AC output from the Main determines the output of the machine. See SCR
Transformer secondary is rectified and controlled Operation.
through the SCR bridge. Output current and voltage is
sensed at the shunt and output terminals. This feed- The Pilot Relay signals the Firing Board circuit to sup-
back information is processed in the control board. ply gate pulses to the SCR Bridge. Closing of the Pilot
The control board compares the commands of the Relay ( a "dry" closure of leads #2 and #4) also brings
Mode switch and the Output Control Potentiometer (or the Latching Resistor into the machine output circuit.
Remote Control) with the feedback information and The Latching Resistor provides a pre-load for the SCR
sends the appropriate signal to the Firing Board. Bridge.
The Firing Board is a three phase circuit. Each phase A Choke is connected between the neutral connection
provides two firing pulses, one for each of the two of the Main Transformer secondaries and the negative
Silicon Controlled Rectifiers (SCR) controlled by that output terminal. This large inductor stores energy and
phase. The firing circuit supplies the proper amount of provides filtering for the output of the DC-600.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
8/98
IDEALARC DC-600
E-4 THEORY OF OPERATION
FIGURE E.4 Protection Devices and Circuits (Contactor Hold-In)
OUTPUT
CONTROL
MAIN
TRANSFORMER
F
E
PILOT E
D
RELAY B
R A
E C POSITIVE
C K TERMINAL
O
N
N F
E SHUNT E
C E PILOT
T D
B RELAY
A
CONTACTOR C
K
TERMINAL SCR BRIDGE
STRIP 1 LATCHING
1 RESISTOR
REMOTE 5
TO CONTROL V
CONTROL A
C
BOARD NEGATIVE
CHOKE
FAN
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
8/98
IDEALARC DC-600
THEORY OF OPERATION E-5
INPUT
CATHODE
OUTPUT
ANODE GATE NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
GATE
SCR OPERATION
A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the
device used to control rather large currents to a load. gate. This gate pulse must be more positive than the
An SCR acts very much like a switch. When a gate sig- cathode voltage. Since there is a standard PN junction
nal is applied to the SCR it is turned ON and there is between gate and cathode, the voltage between these
current flow from anode to cathode. In the ON state the terminals must be slightly greater than 0.6V. Once the
SCR acts like a closed switch. When the SCR is turned SCR has fired it is not necessary to continue the flow
OFF there is no current flow from anode to cathode of gate current. As long as current continues to flow
thus the device acts like an open switch. As the name from anode to cathode the SCR will remain on. When
suggests, the SCR is a rectifier, so it passes current the anode to cathode current drops below a minimum
only during positive half cycles of the AC supply. The value, called holding current, the SCR will shut off.
positive half cycle is the portion of the sine wave in This normally occurs as the AC supply voltage passes
which the anode of the SCR is more positive than the through zero into the negative portion of the sine wave.
cathode. If the SCR is turned on early in the positive half cycle,
the conduction time is longer resulting in greater SCR
When an AC supply voltage is applied to the SCR, the output. If the gate firing occurs later in the cycle the
device spends a certain portion of the AC cycle time in conduction time is less resulting in lower SCR output.
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 the Gate.
IDEALARC DC-600
TABLE OF CONTENTS SECTION F-1
- TROUBLESHOOTING & REPAIR SECTION -
Troubleshooting & Repair Section ................................................................Section F
Safety Precautions .................................................................................................F-2
How to Use Troubleshooting Guide .......................................................................F-2
PC Board Troubleshooting Procedures .................................................................F-3
Troubleshooting Guide ................................................................................F-4 - F-12
Test Procedures
Control Transformer V oltage Test .......................................................F-13 - F-14
Main Transformer V oltage Test ...........................................................F-16 - F-20
Firing Board Test .................................................................................F-21 - F-27
Control Board Test ..............................................................................F-28 - F-32
Static SCR Test ...................................................................................F-33 - F-36
Active SCR Test ..................................................................................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 .......................................................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 Removal.........................................................................F-49
Removal of Individual SCR Heat Sinks ......................................F-50 - F-53
Removal of Lift Bail Assembly ............................................................F-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
IDEALARC DC-600
F-2 TROUBLESHOOTING & REPAIR
______________________________
This Troubleshooting Guide is provided to Step 3. PERFORM COMPONENT TESTS.
help you locate and repair possible machine The last column labeled “Recommended
malfunctions. Simply follow the three-step Course of Action” lists the most likely com-
procedure listed below. ponents that may have failed in your
machine. It also specifies the appropriate
Step 1. LOCATE PROBLEM (SYMPTOM). test procedure to verify that the subject com-
Look under the column labeled “PROBLEM ponent is either good or bad. If there are a
(SYMPTOMS)”. This column describes pos- number of possible components, check the
sible symptoms that the machine may exhib- components in the order listed to eliminate
it. Find the listing that best describes the one possibility at a time until you locate the
symptom that the machine is exhibiting. cause of your problem.
Symptoms are grouped into several main
categories: output problems and welding All of the referenced test procedures
problems. referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Step 2. PERFORM EXTERNAL TESTS. Refer to the Troubleshooting and Repair
The second column labeled “POSSIBLE Table of Contents to locate each specific
AREAS OF MISADJUSTMENT(S)” lists the Test Procedure. All of the specified test
obvious external possibilities that may con- points, components, terminal strips, etc. can
tribute to the machine symptom. Perform be found on the referenced electrical wiring
these tests/checks in the order listed. In diagrams and schematics. Refer to the
general, these tests can be conducted with- Electrical Diagrams Section Table of
out removing the case wrap-around cover. 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.
______________________________
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-3
CAUTION: Sometimes machine failures - If you return a P.C. Board to The Lincoln
appear to be due to PC board failures. These Electric Company for credit, it must be in the
problems can sometimes be traced to poor static-shielding bag. This will prevent further
electrical connections. To avoid problems when damage and allow proper failure analysis.
troubleshooting and replacing PC boards,
please use the following procedure: 4. Test the machine to determine if the failure
symptom has been corrected by the
1. Determine to the best of your technical abili- replacement PC board.
ty that the PC board is the most likely com-
ponent causing the failure symptom. NOTE: It is desirable to have a spare (known
good) PC board available for PC board trou-
2. Check for loose connections at the PC board bleshooting.
to assure that the PC board is properly con-
nected. NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
3. If the problem persists, replace the suspect temperature.
PC board using standard practices to avoid
static electrical damage and electrical shock. 5. Remove the replacement PC board and sub-
Read the warning inside the static resistant stitute it with the original PC board to
bag and perform the following procedures: recreate the original problem.
P.C. Board can be dam- a. If the original problem does not reappear
aged by static electricity. by substituting the original board, then
the PC board was not the problem.
- Remove your body’s sta- Continue to look for bad connections in
tic charge before opening the control wiring harness, junction
the static-shielding bag. blocks, and terminal strips.
ATTENTION Wear an anti-static wrist
Static-Sensitive strap. For safety, use a 1 b. If the original problem is recreated by the
Devices Meg ohm resistive cord substitution of the original board, then
Handle only at connected to a grounded the PC board was the problem. Reinstall
Static-Safe part of the equipment the replacement PC board and test the
Workstations frame. machine.
Reusable - If you don’t have a wrist 6. Always indicate that this procedure was
Container strap, touch an unpainted, followed when warranty reports are to be
Do Not Destroy grounded, part of the submitted.
equipment frame. Keep touching the frame to
prevent static build-up. Be sure not to touch any NOTE: Following this procedure and writing on
electrically live parts at the same time. the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROB-
- Tools which come in contact with the P.C. LEM,” will help avoid denial of legitimate PC
Board must be either conductive, anti-static or board warranty claims.
static-dissipative.
IDEALARC DC-600
F-4 TROUBLESHOOTING & REPAIR
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical Contact the Lincoln Electric Service
Damage is Evident Dept. (216) 383-2531 or 1-800-833-
9353 (WELD)
The Machine is dead- The Input 1. Check for blown or missing 1. The ON/OFF PUSHBUTTON
contactor does not operate. fuses in input lines. (S1) may be faulty - Check for
proper operation. See wiring
2. Check the three- phase input diagram.
line voltage at the machine.
The input voltage must match 2. The Control Transformer (T2)
the rating plate and reconnect may be faulty. Perform the
panel. Control Transformer Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln
Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-5
Input contactor pulls in when start 1. Make sure input line voltage 1. The CR1 interlock may be
button is pressed but immediately matches machine rating and faulty. Replace if necessary.
drops out when start button is the reconnect panel is connect-
released. ed correctly for the line voltage. 2. The ON/OFF PUSHBUTTON
may be faulty. Check or
2. Remove all external wires replace.
attached to terminal strip. ( 2, 4,
31, 32 75,76,77). If contactor 3. Check internal remote control
(CR1) functions correctly there circuit ( leads 75, 76 and 77)
may be a "ground" or negative and switch SW3 for grounds
intrusion on the remote control or shorts.
leads (75, 76, or 77). There
may also be a "short" at the 4. The control board may be
welder output terminals. 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.
IDEALARC DC-600
F-6 TROUBLESHOOTING & REPAIR
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine input contactor operates 1. Install a jumper from #2 to #4 1. Check operation of output pilot
but machine has no weld on machine terminal strip. If relay(CR4). There should be
output.Fan runs and pilot light machine weld output is restored 115VAC present at leads #31
glows. the problem is in the wire feed- and #4 at (CR4) when #2 and
er or control cable. #4 are jumpered together at
the terminal strip.
2. If remote control is not being a. If the correct voltage is
used make certain the OUT- present and the relay
PUT CONTROL SWITCH does not activate, the
(SW3) is in the "OUTPUT CON- relay may be faulty.-
TROL AT DC 600" position. Replace.
b. If the 115VAC is missing,
3. Check 8AMP fuse in the front check the associated
panel.Replace if blown. wiring for loose or faulty
connections. See wiring
4. Check for loose or faulty weld diagram.
cable connections.
2. Check the OUTPUT CON-
TROL POTENTIOMETER
(R1) and associated circuitry
for loose or faulty connections.
See wiring diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln
Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-7
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
F-8 TROUBLESHOOTING & REPAIR
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine has minimum output and 1. If a remote control unit is NOT 1. Check the OUTPUT CON-
no control. connected to the terminal strip TROL POTENTIOMETER
#75, #76, and #77 terminals, (R1) and associated wiring.
the OUTPUT CONTROL
SWITCH must be in the "OUT- 2. Check the OUTPUT CON-
PUT CONTROL AT DC600" TROL SWITCH (SW3), the
position. WELDING MODE SWITCH
(SW4) and associated wiring.
2. If a remote control cable is con-
nected to terminals #75, #76 3. Perform the Control Board
and #77 the leads may be test.
"shorted" to the positive weld
output. 4. Perform the Firing Board test.
The machine does not have maxi- 1. Check all Three-Phase input 1. Check the OUTPUT CON-
mum weld output.
lines at the DC600. Make TROL POTENTIOMETER
sure input voltages match (R1) and associated wiring
machine rating and recon- for loose or faulty connec-
nect panel. tions. See wiring diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln
Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-9
The DC600 will NOT shut off when 1. Contact your local Lincoln 1. The input contactor(CR1)
the Stop button is pushed.
Authorized Field Service contacts may be stuck
Facility. closed. Check and replace
if necessary.
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.
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.
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
F-12 TROUBLESHOOTING & REPAIR
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Poor arc characteristics in all 1. Check for the correct input volt- 1. Check the WELDING MODE
processes. ages on the three- phase input SWITCH (SW4) and the asso-
lines at the DC600. ciated wiring for loose or faulty
connections. See wiring dia-
2. Make sure the proper welding gram.
procedures are being
used.(wire feed speed, arc volt- 2. Check the CR3 reed switch.
age and wire size). The voltage from lead #215 to
lead #220 should be 8VDC
3. Check the welding cables for when the DC600 is in an idle
loose or faulty connections. 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.
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
TROUBLESHOOTING & REPAIR F-13
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
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 TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
TEST PROCEDURE
1. Disconnect main AC input power to 5. Locate Control Transformer leads
the machine. X1 and X2.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-15
6. Test for 115 VAC between leads X1 b. Connect the other end of the
and X2. alligator clip to one of the meter
probes. Be sure that neither
NOTE: If the main AC input supply the alligator clip nor the meter
voltage varies, the Control probe touches any metal sur-
Transformer voltage will vary by the faces.
same percentage.
c. Connect the other meter probe
a. Connect one end of an insulat- to the X2 connection at the
ed alligator clip to the X1 con- secondary winding thermostat.
nection at the Input Contactor See Figure F.2.
(CR1) interlock. See Figure
F.2. d. Apply current Input Power to
DC-600.
CONTROL INPUT
TRANSFORMER CONTACTOR (CR1)
X1
METER INSULATED
PROBE ALLIGATOR CLIP CABLE
LEFT SIDE OF
LIFT BAIL ASSEMBLY CASE BACK
7. Read meter for 115 VAC. 8. If 115 VAC is not present between
leads X1 and X2, test for correct
a. If 115 VAC is present, the main AC input power to the Control
Control Transformer is func- Transformer primary windings (H1,
tioning properly. H2, H3, etc.) See Wiring Diagram.
IDEALARC DC-600
F-16 TROUBLESHOOTING & REPAIR
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
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).
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-17
L3 T3
L2 T2
L1 T1
TEST PROCEDURE
1. Set ON/OFF PUSHBUTTON to 4. Connect main AC input power to
OFF the machine.
IDEALARC DC-600
F-18 TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-19
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. If 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.
31
32A
203
204
205
206
207
208
IDEALARC DC-600
F-20 TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST
PIN 4 PIN 9
(LEAD #204) (LEAD #207)
PIN 3 PIN 8
(LEAD #206) (LEAD #208)
PIN 2 PIN 7
(LEAD #203) J5 (LEAD #205)
From To
Expected VAC
Plug Pin Lead Plug Pin Lead
FIGURE F.6 - Phase Angle Windings Test Points and Firing Board
Location.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-21
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
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).
IDEALARC DC-600
F-22 TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
2. Locate the Firing Board on the left 5. Set the ON/OFF PUSHBUTTON to
side of Control Box facing the ON.
machine.
6. Locate LEDs 7, 8, and 9 on the
3. Perform a visual inspection of the Firing Board. See Figure F.7.
Firing Board to see if there are any Each LED should be ON and be
loose or faulty connections. equally bright. Use Table F.1 to
check the operation of each LED.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-23
IDEALARC DC-600
F-24 TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
IF THEN
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-25
7. Locate the terminal strip directly NOTE: This jumper connection ini-
below the Control Box. tiates machine output.
IDEALARC DC-600
F-26 TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-27
14. Test for approximately 5.8 VDC 15. Test Output Pilot Control Relay
between leads #231 and # 215 on (CR4) for proper operation by
the Firing Board in VV (CC) mode. removing and replacing repeatedly
the jumper wire from terminal # 2.
a. Keep the meter probes insert- This should cause the relay con-
ed into the Plug lead cavities tacts to open and close. The con-
for leads #231 and #215. tacts can be seen closing and
opening through the clear plastic
b. Keep the jumper connected at relay case or can be heard opening
terminals #2 and #4 at the ter- and closing.
minal strip.
a. If the Output Control Relay
c. Set the WELDING MODE (CR4) does not close when
SWITCH (SW4) to the VV (CC) energized, check for loose or
position. faulty wiring.
d. Rotate the OUTPUT CON- 16. Remove the jumper from terminals
TROL POTENTIOMETER #2 and #4 on the terminal strip.
clockwise and counter-clock-
wise. The DC voltage between 17. Replace the Firing Board if the
leads #231 and #215 should be above voltage and control relay
constant at approximately 5.8 tests were passed. It may be
VDC. This voltage should not faulty.
vary when the pot is turned.
IDEALARC DC-600
F-28 TROUBLESHOOTING & REPAIR
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
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).
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-29
IDEALARC DC-600
F-30 TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
TEST PROCEDURES
If LED 1 Does Not Glow When If 115 VAC is present AND LED
ON/OFF PUSH BUTTON is Set to ON 1 does not glow, the Control
Board may be faulty. Replace.
1. Test for 115 VAC between leads
#255 and #256 at Plug J2 on the If 115 VAC is not present,
Control Board.
• 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
c 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 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
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-31
IDEALARC DC-600
F-32 TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
NOTE: If previous tests do not reveal Machine is operating under load (or ter-
the problem then the Control Board minals #2 and #4 are jumpered togeth-
may be faulty. Replace. er on the terminal strip).
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-33
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 Static SCR Test is used to quickly determine if an SCR is shorted or "leaky." See the
Waveform Section in this manual for normal 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 & REPAIR
STATIC SCR TEST
TEST PROCEDURE
1. Disconnect main AC input power to 2. Disconnect all Molex Plugs from
the machine. the Firing Board and Control
Board. See Figure F.12.
FIGURE F.12 - Firing Board and Control Board Molex Plug Locations.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-35
IDEALARC DC-600
F-36 TROUBLESHOOTING & REPAIR
STATIC SCR TEST
8/98
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-37
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-600 wiring diagrams (See Electrical Diagrams Section of this Manual).
IDEALARC DC-600
F-38 TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
TEST PROCEDURE
1. Disconnect main AC input power to 2. Disconnect all Molex Plugs from
the machine. the Firing Board and Control
Board. See Figure F.15.
FIGURE F.15 - Firing Board and Control Board Molex Plug Locations.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-39
IDEALARC DC-600
F-40 TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
7. Read meter for zero voltage. a. If the voltage is zero, the SCR
is functioning.
a. If the voltage reading is higher
than zero, the SCR is shorted. b. If the voltage is higher than
zero, the SCR is shorted.
8. Close or keep closed switch SW-1
14. Perform the Active Test Procedure
9. Close switch SW-2 for 2 seconds outlined in Steps 5-13 for SCRs
and release and read meter. 2-6.
a. If the voltage is 3 - 6 volts while 15. Replace all SCR assemblies that
the switch is closed and after do not pass the above tests.
the switch is open, the SCR is
functioning. 16. Replace all Molex Plugs onto the
Firing Board and Control Board.
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.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-41
CH1
0 volts
50 volts 2ms
IDEALARC DC-600
F-42 TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
MAXIMUM OUTPUT SETTING - NO LOAD
CH1
0 volts
50 volts 2ms
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-43
LINE
0 volts
20 volts 2ms
IDEALARC DC-600
F-44 TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
CONSTANT VOLTAGE INNERSHIELD MODE
CH 1
0 volts
20 volts 2ms
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-45
CH1
0 volts
2 volts 5ms
IDEALARC DC-600
F-46 TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
ONE OUTPUT SCR NOT FUNCTIONING
CH 1
0 volts
20 volts 2ms
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-47
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
IDEALARC DC-600
F-48 TROUBLESHOOTING & REPAIR
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT
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 & #272).
pressure air stream. See wiring diagram.
5. Inspect the contacts for signs of 7. Disconnect the leads from the Input
excessive wear, pitting, or contacts Contactor interlock (leads #211 &
fused (stuck) to together. #212). See wiring diagram.
X1
CASE BACK
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-49
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
IDEALARC DC-600
F-50 TROUBLESHOOTING & REPAIR
SCR / SCR OUTPUT BRIDGE REMOVAL
A. REMOVAL OF INDIVIDUAL SCR HEAT SINK
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-51
5. Remove the four thru bolts and 6. Install the replacement SCR Heat
associated nuts and washers hold. Sink in reverse order of removal.
ing the SCR heat sink to the bridge
tie bars. a. Apply a thin layer of Lincoln
E1868 (Dow Corning 340) heat
a. The main mounting bolts that sink compound to all bolted
mount the SCR bridge assem- electrical connections on the
bly to the frame rail may have aluminum heat sinks.
to be loosened to slide the
SCR Heat Sink out from under
the buss jumper strap.
IDEALARC DC-600
F-52 TROUBLESHOOTING & REPAIR
SCR / SCR OUTPUT BRIDGE REMOVAL
B. REMOVAL OF COMPLETE BRIDGE ASSEMBLY
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-53
5. Remove the bolt that connects the 8. Lift the SCR Bridge Assembly
Shunt Assembly (heavy copper) straight up and out of the machine
lead to the SCR Bridge Assembly. being sure that no leads become
The Shunt Assembly connects the tangled or hooked on the other
positive Weld Output Terminal to machine parts.
the SCR Bridge Assembly.
a. Be sure to locate the SCR
6. Remove the small snubber lead Bridge Assembly on a stable
from the left hand (facing the front work surface capable of hold-
of the machine) rear heat sink ing the weight of the assembly.
mounting bolt using a 1/2" socket
wrench. 9. Remove individual SCR Heat Sinks
following the procedure described
7. Clear all leads from any obstruc- in A above.
tions.
10. Replace all insulating materials,
including the insulators on the
frame rail and all insulating tubes,
when installing the SCR Output
Bridge Assembly.
IDEALARC DC-600
F-54 TROUBLESHOOTING & REPAIR
LIFT BAIL REMOVAL (INCLUDING MAIN TRANSFORMER,
CHOKE, AND OUTPUT BRIDGE ASSEMBLY)
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician
or the machine operator and will invalidate your factory warranty. For your safety and to
avoid electrical shock, please observe all safety notes and precautions detailed throughout
this manual.
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).
______________________________
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-55
REMOVAL PROCEDURE
IDEALARC DC-600
F-56 TROUBLESHOOTING & REPAIR
LIFT BAIL REMOVAL (INCLUDING MAIN TRANSFORMER,
CHOKE, AND OUTPUT BRIDGE ASSEMBLY)
5. Disconnect leads #215 and #216 13. Disconnect lead #272 from Input
from Relay CR4 and lead #231 Contactor (CR1) coil.
from the splice connector.
14. Disconnect the heavy copper lead
6. Disconnect leads #211 and #212 from the negative Weld Output
from the ON/OFF PUSH BUTTON. Terminal.
7. Disconnect lead #256 from the 15. Identify, label, and disconnect the
PILOT LIGHT. Main Transformer leads from the
Reconnect Panel and the three
8. Disconnect lead #271 from relay leads that go to the Input
CR2 located in the Control Box. Contactor.
9. Remove resistor R2 from the hori- 16. Remove the four mounting nuts
zontal rail. See Figure F.21. that hold the Lift Bail Assembly to
the Base.
10. Cut and remove all cable ties and
unbundle all wires. 17. Lift the Bail Assembly carefully
straight up and out of the machine
11. Label and cut fan motor leads. using a hoist. Be sure all leads are
free to move with the assembly.
12. Separate leads #271, #211, and X2
from the harness.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-57
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
9/16" open end wrench
1/2" socket wrench
1/2" open end wrench
3/8" socket wrench
IDEALARC DC-600
F-58 TROUBLESHOOTING & REPAIR
TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY
TRANSFORMER
REMOVAL PROCEDURE
1. Remove the four screws that con- 4. Lift the Output Choke straight up
nect the top and side baffles until the through bolts are cleared
around the Output Choke using a and then move it out toward the
3/8" socket wrench. rear of the transformer.
2. Remove the two bolts and nuts 5. Remove the six transformer sec-
connecting the Output Choke leads ondary leads from the SCR Output
to the copper strap and the main Bridge Assembly using a 1/2" sock-
secondary common buss lead et wrench and a 1/2" open end
using a 9/16" socket wrench and a wrench.
9/16" open end wrench.
a. Identify and label all leads,
a. Identify and label the small including the small snubber
snubber leads. leads.
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-59
IDEALARC DC-600
F-60 TROUBLESHOOTING & REPAIR
TRANSFORMER REMOVAL FROM LIFT BAIL ASSEMBLY
COIL REMOVAL
IDEALARC DC-600
TROUBLESHOOTING & REPAIR F-61
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.
IDEALARC DC-600
F-62 TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any mechanical part
that could affect the machine’s electrical characteristics, or if any electrical components are repaired or
replaced, the machine must be retested.
IDEALARC DC-600
TABLE OF CONTENTS Section G
- ELECTRICAL DIAGRAMS -
IDEALARC DC600
G-1 ELECTRICAL DIAGRAMS
CONTROL PC BOARD (G1504-4 AND ABOVE)
IDEALARC-600
ELECTRICAL DIAGRAMS G-2
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%
R13,R62,R120 . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,475K,1%
R66 . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,56.2K,1%
R69,R100,R109 . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,681,1%
R9,R34,R56,R57,R64,R71,R96 . . .RESISTOR-MF,1/4W,6.81K,1%
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.
IDEALARC-600
G-3 ELECTRICAL DIAGRAMS
FIRING PC BOARD (G1486-5 AND ABOVE)
FIRING BOARD
G-1486
IDEALARC-600
ELECTRICAL DIAGRAMS G-4
Identification Item
C1,C2,C3,C4,C5,C6,C7, . . . . .CAPACITOR-PEMF,0.15,200V,10%
C8,C9,C10,C11,C12
SCR1,SCR2,SCR3,SCR4,SCR5, . . . . .SCR-T202,4A,400V,C106D
SCR6*
C13,C14,C15,C16,C17,C18 . . .CAPACITOR-CEMO,.022,50V,20%
C19,C20,C21,C22,C23,C24
C25,C26,C27
J5 . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,12-PIN
J4 . . . . . . . . . . . . . . . . . .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%
R55,R56,R57 . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,26.7K,1%
R64,R65,R66 . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,332K,1%
R43,R44,R45 . . . . . . . . . . . . . . . . . .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
D1,D2,D3,D4,D5,D6,D10,D11 . . . . . . . .DIODE-AXLDS,1A,1000V
D12,D13,D14,D15,D16,D17
D18,D19,D20,D21
R1,R2,R3,R4,R5,R6 . . . . . . . . .RESISTOR-WW,20W,250,5%,SQ
DZ1,DZ2,DZ3 . . . . . . . . . . .ZENER DIODE-1W,20V,5%,1N4747A
TP1,TP2,TP3 . . . . . . . . . . . . . . . . . . . .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%
R7,R8,R9 . . . . . . . . . . . . . . . . . .RESISTOR-WW,5W,1.5K,5%,SQ
J6 . . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,4-PIN
J7 . . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,8-PIN
QU1,QU2,QU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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.
IDEALARC-600
NOTES
IDEALARC-600
ELECTRICAL DIAGRAMS G-5
FIGURE G1 - Wiring Diagram for Codes 9773, 9776, 9778, 9779, 9780, 9910
3 8 0 /5 0 0 V . & 4 6 0 /5 7 5 V .
S ING L E V OL T A G E OV E R 300 V . TO TO H2
H3
S UPPLY
(S HOWN C ONNE C T E D
S UPPLY 236 R1 OUTPUT
(E XC E P T 380V .) H1 H1
FOR LOW VOLTAGE ) L INE S
L INE S
272 272 C ONTR OL
TO G R OUND P E R TO G R OUND P E R 210 237 75 215
X1 X1
NA T IONA L NA T IONA L 229
8750
15
1-17-92B
6 9 3
E L E C T R IC A L 3
E L E C T R IC A L
L3
211
L3
211 32A 76
C ODE 5 8 2 C ODE 14
2 X1 SW3
L2 L2 T2 31 N.C .
210 77
L
R E C ONNE C T 4 7 1 R E C ONNE C T 13 H1
212 1 212 START VM
P ANE L L1 P ANE L L1 S TOP + - 226 80
211 SW2
CR 1 CR 1
271 271 238
T O P R IMA R Y C O IL S T O P R IMA R Y C O IL S
222 21
H2 F1
SW1
W IR ING DIA G R A M
IDE A L A R C DC -600
SW4
380V . OR T R IP L E V OL T A G E 212 222 2
DUA L & S ING L E V OL T A G E TO H2 TO H2 81
S UPPLY
H1
S UPPLY
H1
255 232
UNDE R 300V . 32
L INE S
TO G R OUND P E R
L INE S H3
272 272
AM 224
NA T IONA L
TO G R OUND P E R
6 9 3
X1
6 3
X1 + -
9 11
NA T IONA L E L E C T R IC A L
L3 L3 X2 21 4 2 31 32 75 76 77 80 81
E L E C T R IC A L 2 211 C ODE 2 211
5 8 5 8 10
C ODE R E C ONNE C T L2 271
1
L2
1 80 280 81
4 7 P ANE L (S HOWN 4 7 12
R E C ONNE C T
L1
212
C ONNE C TE D L1
212 7 5 T.S .3
P ANE L 271
CR 1 F OR 380V .) CR 1
271 271 CR2 T.S .2
T O P R IMA R Y C O IL S T O P R IMA R Y C O IL S
B 255
A
R P IL OT 235
L IG HT 235 1 1 229
233 256 2 2 75
256
255 3 3 232
L E G E ND
P R IMA R Y 231 4 4 80
256
C 7 . 0 5 +. 0 5 MF D T HE R MO S T A T 238 5 J2 5 81
F 1 8 A MP S L O W B L O W F US E 272 233 6 6 226
273 J1
R 1 10K POT N.A. 1 S 2 3 32A 7 7 224
S SEC. LEAD
R 2 30 , 100W 1 31 8 8 215
T1 AUX.2 31 T HE R MO S T A T
13 14 15 F 9 9
T 1 MA IN P O W E R T R A NS F O R ME R F
L E ADS 4 P R I. 205 10 10 280
T 2 C O NT R O L T R A NS F O R ME R F F F
THR U 9 203 207 11
1C R INP UT C ONT A C T OR 210 1
4 5 6 J3 12
2C R F A UL T P R OT E C T ION R E L A Y T O INP UT S S S FAN 215 215 2
206 210 13 220
P ANE L 204 AUX. 1 208 MO T O R
3C R C UR R E NT A C T IV A T E D R E E D S W IT C H
32A C ONTR OL 14 222
4C R OUT P UT P IL OT R E L A Y 7 8 9
T HE R E IS NO P.C . B OAR D
S W 1 INP UT P OW E R 31
10, 11 & 12 215
S W 2 E L E C T R ODE P OL A R IT Y P R I. 4 216
C ONNE C T ION
S W3 OUTP UT C ONTR OL B
10 11 12 ON 380 OR
S W 4 W E L DING MO DE (S HO W N IN S T IC K P O S IT IO N) 4 5 6
T R IP L E V OL T A G E
NOTE S : MA C HINE S . TO OUTPUT G3 1 1 216
T O T 1 A UX. W INDING
J UMP E R 2 T O 4. O UT P UT T E R MINA L S W IL L 215
NO W B E E NE R G IZE D. P L A C E MO DE S W IT C H B 2 9 207
OUTPUT
SEC.
IN V V F OR S T IC K A ND C V (I) F OR A IR 3 10 231
OUTPUT B'
C A R B O N A R C . S E E O P E R A T ING MA NUA L 4 11
C HOK E J7
C7 C 5 12
F OR F UR T HE R INS T R UC T IONS .
GATE C' 6
N.C . C E NT E R T E R MINA L O F F US E HO L DE R . L E ADS TO N.D. 7 1 X
G1
F IR ING A' 8 J6 2 Y
N.D. W E L DING C A B L E MUS T B E O F T HE P R O P E R G3 210
C IR C UIT 3 Z
C A P A C IT Y F OR T HE C UR R E NT A ND DUT Y C Y C L E G5 F IR ING C IR C UIT
P.C . 4
O F IMME DIA T E A ND F UT UR E A P P L IC A T IO NS . SCR P.C . B OAR D
B OAR D ( +)
N.E . T HIS DIA G R A M S HOW S T HE " S T IC K " P OL A R IT Y J4 S NUB B E R S 210
" P OS IT IV E " . T O C HA NG E T HE P OL A R IT Y , T UR N A A A 215
T HE DC -600 O F F , A ND R E V E R S E T HE L E A DS A T
CR3
T HE MUL T I-P R O C E S S S W IT C H. SCR SCR SCR + - 4
2
J3 J6 J4 J7
T O S T IC K E L E C T R ODE HOL DE R OR
WOR K +
A IR -C A R B O N A R C T O R C H
SCR SCR SCR
N.D., N.F . N.D. N.E .
2 4 6
E L E C TR ODE
T O " W OR K " US E D W IT H S T IC K
J2 J5 J1
- O R A IR -C A R B O N A R C
A A A
O P T IO NA L US E R S UP P L IE D J UMP E R F O R
OUT P UT R E C T IF IE R OP T IONA L S T IC K W OR K L E A D NOT
G6 G ATE L E ADS TO T HOS E S IT UA T IONS W HE R E IT IS NOT
A S S E MB L Y MUL T I-P R O C E S S US E D W HE N J UMP E R IS
C O NNE C T O R C A V IT Y NUMB E R ING S E Q UE NC E G4 F IR ING C IR C UIT NE C E S S AR Y TO HAVE S E P AR ATE G R OUND
S W IT C H US E D.
G2 P.C . B OAR D C A B L E S F O R S T IC K A ND S E MI-A UT O MA T IC
(V IE W E D F R O M C O MP O NE NT S IDE O F B O A R D)
J4 W E L DING .
E L E C T R IC A L S Y MB O L S P E R E 1537
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 G-6
8751
SINGLE VOLTAGE 440&460v 229
1-17-92B
NC SWITCH
272A 32A 76
X1 SW3
31 N.C.
L
T2 H1 210 77
X1
WIRING DIAGRAM
IN + H2 222
L3 F1
2 211 SW1
CODE
SW4
L2 212 222 2
1 _ 81
255 232
PICK 212 D1 H3 32
L1 224
UP AM
+ -
TO PRIMARY COILS 21 4 2 31 32 76 80 81
CR 1 271A X2 75 77
271 80 280 81
7 5 T.S.3
271
CR2 T.S.2
B 255
A
R PILOT 235
LIGHT 235 1 1 229
233 256 2 2 75
272 256
255 3 3 232
LEGEND
PRIMARY 231 4 4 80
256
C7 .05 +.05 MFD THERMOSTAT 238 5 J2 5 81
F1 8 AMP SLOW BLOW FUSE 233 6 6 226
273 J1
R1 10K POT N.A. 1 S 2 3 32A 7 7 224
S SEC. LEAD
R2 30 , 100W 1 31 8 8 215
T1 AUX.2 31 THERMOSTAT
13 14 15 F 9 9
T1 MAIN POWER TRANSFORMER F
LEADS 4 PRI. 205 10 10 280
T2 CONTROL TRANSFORMER F F F
THRU 9 203 207 11
1CR INPUT CONTACTOR 210 1
4 5 6 J3 12
2CR FAULT PROTECTION RELAY TO INPUT S S S FAN 215 215 2
206 210 13 220
PANEL 204 AUX. 1 208 MOTOR
3CR CURRENT ACTIVATED REED SWITCH
32A CONTROL 14 222
4CR OUTPUT PILOT RELAY 7 8 9
THERE IS NO P.C. BOARD
SW1 INPUT POWER 31
10, 11 & 12 215
SW2 ELECTRODE POLARITY PRI. 4 216
CONNECTION
SW3 OUTPUT CONTROL B
10 11 12 ON 380 OR
SW4 WELDING MODE (SHOWN IN STICK POSITION) 4 5 6
TRIPLE VOLTAGE
NOTES: MACHINES. TO OUTPUT G3 1 1 216
TO T1 AUX. WINDING
CONTROL LEADS TO ANY WIRE FEEDERS.
A 1 8 208
JUMPER 2 TO 4. OUTPUT TERMINALS WILL 215
B 2 9 207
OUTPUT
NOW BE ENERGIZED. PLACE MODE SWITCH
SEC.
IN VV FOR STICK AND CV (I) FOR AIR 3 10 231
OUTPUT B'
CARBON ARC. SEE OPERATING MANUAL 4 11
CHOKE J7
C7 C 5 12
FOR FURTHER INSTRUCTIONS.
GATE C' 6
N.C. CENTER TERMINAL OF FUSE HOLDER. LEADS TO N.D. 7 1 X
G1
FIRING A' 8 J6 2 Y
N.D. WELDING CABLE MUST BE OF THE PROPER G3 210
CIRCUIT 3 Z
CAPACITY FOR THE CURRENT AND DUTY CYCLE G5 FIRING CIRCUIT
P.C. 4
OF IMMEDIATE AND FUTURE APPLICATIONS. SCR P.C. BOARD
BOARD (+)
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY J4 SNUBBERS 210
"POSITIVE". TO CHANGE THE POLARITY, TURN A A A 215
THE DC-600 OFF, AND REVERSE THE LEADS AT
THE MULTI-PROCESS SWITCH. SCR SCR SCR
CR3
+ - 4
2
J3 J6 J4 J7
TO STICK ELECTRODE HOLDER OR
WORK +
AIR-CARBON ARC TORCH
SCR SCR SCR
N.D., N.F. N.D. N.E.
2 4 6
ELECTRODE
TO "WORK" USED WITH STICK
J2 J5 J1
- OR AIR-CARBON ARC
A A A
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 G-7
271 271A
272
272A
CR1
INPUT
L3
POWER L2
L1
GROUND
1CR 1CR 1CR
START
211 212
STOP 271
255
1 31 2 3 32A
222
H3
2CR 21
N.A. TO OUTPUT STUDS 4 5 6
210 205
120VAC 1CR 1CR R 7
203
TO 8 TO 9 207 TO
OUTPUT CHOKE
H2
21 FIRING FIRING FIRING
S2 10 11 12
H1 256 273 272 204 PCB 206 PCB 208 PCB
MAIN POWER 222
4
SECONDARY TRANSFORMER 222 "-" OUTPUT STUD
CONTROL
PRIMARY 4CR TO S2
TRANSFORMER
2
THERMOSTATS
31
31
F1 32A 120VAC
TS 2 R2
8A
1
C10 400
4CR
R13
R10
R11
R12
216 214
50mV @ 800Amps
8J1
R14
R15
R16
10J1 280
+ - + -
VV
255 215
CVI 224 256
+32V AMMETER VOLTMETER
7J1
+16V
CVS
POWER SUPPLY
S4-A -6.2V
13J1
-10V
220
2J1
75 CONTROL PCB 204
4J5
2J6
SCR1 & SCR2
GATE DRIVE
X FIRING CIRCUIT G1
6J1 2J5 75 VAC
203 1J7
226 A
A' GATE DRIVE
R1 231 8J7 G2
TO MAIN POWER
TRANSFORMER
75 FAULT DETECT.
5J2
238 3J5
206 1J6 SCR3 & SCR4
76 7J5 75 VAC Y FIRING CIRCUIT GATE DRIVE
S3 205
G3
2J7
B
77 231
1J1 B' GATE DRIVE
5J7 G4
VV 229
4J1
80 CVI 80
GENERAL INFORMATION
VOLTAGE FEEDBACK 3J6
TS 3
231 Z
8J5
208 6J7
215 VV 3J1 TO MAIN POWER C GATE DRIVE
232 9J5 75 VAC G5
CVI TRANSFORMER C'
207 5J7 SCR5 & SCR6
CVS 9J1
FIRING CIRCUIT G6
GATE DRIVE ELECTRICAL SYMBOLS PER E1537.
S4-B
222
235
CAPACITORS= MFD/VOLTS
SHUTDOWN
1J2
235
OVERLOAD DETECT.
CURRENT FEEDBACK
6J2
2CR
J3 J6 J4 J7
236
210 215
236
FIRING PCB
14J1 1J3 2J3
J2 J5 J1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
IDEALARC DC600
ELECTRICAL DIAGRAMS G-8
FIGURE G4 - Control Board Schematic for G1504-4 and above
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be
totally applicable to your machine’s specific PC board version. 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
ELECTRICAL DIAGRAMS G-9
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