SVM188-A
October, 2008
DC-600
For use with machine code numbers: Above Code 10580
Safety Depends on You
5
6
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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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
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9
1
10
DC-600
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.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 observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
3.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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. 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.
In addition to the normal safety precautions, if welding
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding 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.d. 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 welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling.
welding
procedure
and
application
involved.
Worker exposure level should be checked upon installation
and periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.h. 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.
5.c. Do not weld 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 prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. 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.
5.f. Also see item 1.b.
Aug ‘06
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
7.a. Use only compressed gas cylinders
containing 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 condition.
Remember
that
welding
sparks
and
hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. 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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding 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 out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding 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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘07
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SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
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
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar ‘93
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SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com-
plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093
3-1-96H
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vi
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SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093
3-1-96H
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I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-349
DC-600
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A-1
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Limit on Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Fuses and Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Input Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Electrode, Work and #21 Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Auxiliary Power and Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
DC-600
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – DC-600
INPUT - THREE PHASE ONLY
Input Current at Rated Output
Standard
Volatge
50% Duty Cycle
100% Duty
Cycle
60% Duty Cycle
134/67
134/67/54
67
122/61
122/61/49
61
230/460/60
230/460/575/60
460/60
108/54
108/54/43
54
54
49
575/60
138/80/69
80/61
69
152/76
73
43
128/74/64
74/56
64
140/70
68
220/380/440/50/60
380/500/50/60
440/50/60
200/400/50/60
415/50/60
116/67/58
67/51
58
128/64
61
RATED OUTPUT
Duty Cycle
Amps
600
Volts at Rated Amperes
100% Duty Cycle
60% Duty Cycle
50% Duty Cycle
44
44
44
680
750
OUTPUT
Output Range
70A/13V-780A/44V (CV)
Maximum Open Circuit Voltage
72V for 60 HZ models
Auxiliary Power
See the OPERATION section
90A/24V-780A/44V (CC)
69V for 50/60 HZ models
for Auxiliary Power
information by model
RECOMMENDED INPUT WIRE AND FUSE SIZES
TYPE 75°C
TYPE 75°C
TYPE 75°C
(SUPER LAG)
OR BREAKER
INPUT
VOLTAGE /
FREQUENCY
HERTZ
INPUT AMPERE
RATING ON
NAMEPLATE
COPPER WIRE GROUND WIRE
IN CONDUIT
IN CONDUIT
2
2
1
AWG(IEC-MM ) SIZES AWG(IEC-MM ) SIZES
30°C (86°F) Ambient
SIZE (AMPS)
230
460
575
200
220
380
400
415
440
500
60
60
60
50/60
50/60
50/60
50/60
50/60
50/60
50/60
108
54
43
128
116
67
64
61
58
51
2 (34)
6 (14)
8 (8.4)
1 (43)
2 (34)
6 (14)
6 (14)
6 (14)
6 (14)
8 (8.4)
6 (14)
8 (8.4)
8 (8.4)
6 (14)
6 (14)
8 (8.4)
8 (8.4)
8 (8.4)
8 (8.4)
8 (8.4)
175 Amp
90 Amp
70 Amp
175 Amp
175 Amp
100 Amp
100 Amp
100 Amp
90 Amp
80 Amp
PHYSICAL DIMENSIONS
HEIGHT
30.75 in
781 mm
WIDTH
22.25 in
567 mm
DEPTH
39.0 in
988 mm
WEIGHT
522 lbs.
237 kg.
1
Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
DC-600
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A-3
A-3
INSTALLATION
STACKING
SAFETY PRECAUTIONS
Three DC-600 machines can be stacked.
Read entire Installation Section before installing
the DC-600.
DO NOT stack more than three machines in one
grouping.
ELECTRIC SHOCK CAN KILL.
WARNING
DO NOT stack the DC-600 on another type of
machine.
Follow these guidelines when stacking:
• Only qualified personnel should
install this machine.
1. Select a firm, level surface capable of sup-
porting the total weight of up to three
machines (1570 pounds/712 kilograms).
• Turn the input power OFF at the
disconnect switch or fuse box
before
2. Set the bottom machine in place.
working on the equipment.
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.
• Do not touch electrically hot parts.
• Always connect the IDEALARC
DC-600 grounding terminal to a good electrical
earth ground.
4. Repeat process for third machine.
• Set the DC-600 Power ON/OFF PUSH BUTTON to
the OFF position when connecting power cord to
input power.
NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
Figure A.1.
__________________
SELECT PROPER LOCATION
STACKING HOLE
STACKING PINS
Place the welder where clean cooling air can freely cir-
culate in through the front louvers and out through the
rear louvers. Dirt, dust or any foreign material that can
be drawn into the welder should be kept at a minimum.
Failure to observe these precautions can result in
excessive operating temperatures and nuisance shut-
downs.
LIMIT ON STACKING
WARNING
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when
lifting.
• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
FIGURE A.1 - Stacking DC-600 machines
TILTING
FALLING
• Do not lift machine if lift bail is
damaged.
EQUIPMENT can
cause injury.
• Do not operate machine while
suspended from lift bail.
The DC-600 must be placed on a stable, level surface
so it will not topple over.
• Do not stack more than three high.
• Do not stack the DC-600 on top of any other machine.
------------------------------------------------------------------------
DC-600
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A-4
A-4
INSTALLATION
INPUT POWER SUPPLYCONNECTIONS
ELECTRICAL INPUT CONNECTIONS
A qualified electrician should connect the input power
supply leads.
Before installing the machine check that the input sup-
ply voltage, phase, and frequency are the same as the
voltage, phase, and frequency as specified on the
welder Rating Plate located on the Case Back
Assembly. 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.
1. Follow all national and local electrical codes.
2. Use a three-phase line.
3. Remove Input Access Door at upper rear of
machine.
4. Follow Input Supply Connection Diagram located
on the inside of the door.
INPUT SUPPLY
CABLE ENTRY
INPUT
CONTACTOR (CR1)
5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
terminals in the Input Box Assembly by passing
them thru the three aligned .50” diameter holes in
the baffle and tighten them in the terminal connec-
tors. Be sure to close the baffle by inserting the tab
into the slot in the baffle. See Figure A.3.
OPENING
RECONNECT
PANEL ASSEMBLY
FIGURE A.2 - Rear Panel
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or ther-
mal/magnetic circuit breakers.
INPUT
CONTACTOR (CR1)
DO NOT use fuses or circuit breakers with a lower amp
rating than recommended.This can result in “nuisance”
tripping caused by inrush current even when machine
is not being used for welding at high output currents.
INPUT POWER SUPPLY
CABLE WITH BUSHING
OR BOX CONNECTOR
PANEL ASSEMBLY
RECONNECT
Use input and grounding wire sizes that meet local
electrical codes or see the Technical Specifications
page in this manual.
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 he 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.
FIGURE A.3 - Input Power Supply
Connections
DC-600
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A-5
A-5
INSTALLATION
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 connection diagrams for the following codes are
listed below.
RECONNECT PROCEDURE
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 Dual Voltage except 380/500-460/575, see
Figure A.4. (M15009)
CAUTION
Failure to follow these instructions can cause
immediate failure of components within the
machine.
(S17894)
When powering welder from a generator be sure to
turn off welder first, before generator is shut down,
i-n-o-rd-e-r -to-p-re-v-en-t-d-am--ag-e-t-o-th-e-w-e-ld-er------
6. For Voltages 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.
LINK
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINALWITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.
CRI
W
V
L3
L2
L1
LINES
INPUT
CONTACTOR
U
4. CONNECT TERMINALMARKED
TO GROUND PER LOCALAND NATIONAL ELECTRIC CODES.
H1
GND
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.
H3
H2
PILOT
TRANSF.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
CRI
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINALWITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
W
L3
L2
L1
LINES
INPUT
V
CTOR
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.
U
4. CONNECT TERMINALMARKED
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
TO GROUND PER LOCALAND NATIONAL ELECTRIC CODES.
H1
GND
H2
H3
PILOT
TRANSF.
FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines
DC-600
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A-6
A-6
INSTALLATION
CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROLTRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.
CRI
W
L3
L2
L1
LINES
V
CONTACTOR
INPUT
U
4. CONNECT TERMINALMARKED
TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H3
H2
H1
GND
5. 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.
H4
H3
PILOT
TRANSF.
LINKS
CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.
CRI
W
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROLTRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINALMARKED
5. 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.
L3
L2
L1
LINES
INPUT
V
CONTACTOR
U
H4
H2
H1
TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND
PILOT
TRANSF.
LINKS
CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.
CRI
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROLTRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
W
L3
L2
L1
LINES
INPUT
V
CONTACTOR
U
H4
H3
4. CONNECT TERMINALMARKED
TO GROUND PER LOCALAND NATIONAL ELECTRIC CODES.
H1
GND
H2
5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
PILOT
TRANSF.
LINKS
FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines
CONNECTION FOR 500/575 VOLTAGES
H3
CONNECTION FOR 380/460 VOLTAGES
H2
CRI
CRI
W
L3
L2
W
V
L3
L2
L1
LINES
INPUT
LINES
INPUT
V
CONTACTOR
CONTACTOR
U
L1
U
H1
H2
GND
GND
H1
H3
LINK
LINK
TAPE
TAPE
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
4. CONNECT TERMINALMARKED
TO GROUND PER NATIONAL ELECTRIC CODES.
4. CONNECT TERMINALMARKED
TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN
ALLHEX NUTS
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALLHEX NUTS
FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines
DC-600
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A-7
A-7
INSTALLATION
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
CRI
W
L3
L2
L1
2. CONNECT TERMINALMARKED
TO GROUND PER NATIONAL ELECTRIC CODES.
LINES
INPUT
V
3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
CONTACTOR
U
GND
FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines
FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines
DC-600
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A-8
A-8
INSTALLATION
OUTPUT CONNECTIONS
See Table A.1 for recommended DC-600 cable sizes for combined lengths of electrode and work cables.
TABLE A.1
DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable
at 100% Duty Cycle
ELECTRODE, WORK AND #21 LEAD
Cable Length
Lengths up to 150 ft. (46m)
150 ft.(46m) to 200 ft (61m)
200 ft.(61m) to 250 ft.(76m)
CONNECTIONS
Parallel Cables
Cable Size
1/0 (53mm2)
2/0 (67mm2)
3/0 (85mm2)
2
2
2
A. Connect Electrode and Work Leads to
Output Terminals.
1. Set the ON/OFF toggle switch 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 strain 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.
FIGURE A.9 - Output Terminals.
5. Connect electrode lead to the desired terminal
(positive/negative).
B. Connect #21 Work Sense Lead to Proper
Terminal
6. Tighten the output terminal nut with a wrench.
There are two work sense lead connection points (+21
and -21) on terminal strip (T.S.2) located behind the
hinged access panel on the right side of the case front.
See 14 Pin MS Type Receptacle section or Terminal
Strip Section for connection procedure.
7. Connect the work lead to the other output
terminal following steps 4-6.
DC-600
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A-9
A-9
INSTALLATION
AUXILIARY POWER AND
CONTROL CONNECTIONS
PIN
LEAD NO.
FUNCTION
A
32
GND
2
115 VAC
Located at the left side of the front of the welder behind
a hinged cover is a 115VAC duplex receptacle for aux-
iliary power (60 Hertz Models only). On the right side of
the case front is a 14 Pin MS type receptacle for con-
nection of auxiliary equipment such as wire feeders.
Also, terminal strips with 115VAC and connections for
auxiliary equipment are located behind the hinged
access panel on the right side of the case front. (see
Auxiliary Power Table for details)
B
C
D
E
F
Chassis Connection
Trigger Circuit
Trigger Circuit
Output Control
Output Control
Output Control
4
77
76
75
G
H
I
21
41
Work Sense Connection2
42 VAC
J
K
L
M
N
31
42
---
---
---
115 VAC1.
42 VAC
---
---
---
AUXILIARY POWER TABLE
Voltage and Circuit Breaker Ratings at Auxiliary Power
Connections for Various Models
Auxiliary
60 Hz
50/60 Hz
Power
Models
Models
TERMINAL STRIPS
Connections
At Duplex
Receptacle
115V 15A
115V 15A
115V 15A
42V 10A
No Duplex
115V 15A
115V 15A
42V 10A
Terminal strips are available behind the cover on the
case front to connect wire feeder control cables that do
not have a 14 Pin MS-type connector. These terminals
supply the connections as shown in the following
Terminal Strip charts. NOTE:There are two work sense
lead connection points on the terminal strip. Connect
both the work sense lead #21 from the 14 pin connec-
tor and #21 lead of the control cable to “-21” when
welding positive polarity or to “+21” when welding neg-
ative polarity.
Terminal strip
terminals 31 & 32
MS-Receptacle
pins A & J
MS-Receptacle
pins I & K
115VAC DUPLEX RECEPTACLE (60 HERTZ
MODELS ONLY)
The 115VAC duplex receptacle is protected by a circuit
breaker located on the nameplate. The receptacle is a
NEMA 5-15R.
TERMINAL STRIP 1 (T.S.1)
Lead No.
Function
14 PIN MS TYPE RECEPTACLE
75
76
77
Output Control
Output Control
Output Control
(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
Refer to the figure A.10 for the available circuits in the
14 pin receptacle.
TERMINAL STRIP 2 (T.S.2)
Lead No.
Function
42 VAC is available at receptacle pins I and K.
A 10 amp circuit breaker protects this circuit.
+21
-21
41
4
2
31
32
Work Connection (Electrode Negative)
Work Connection (Electrode Positive)2
42 VAC
115 VAC is available at receptacle pins A and J (All
Models). A 15 amp circuit breaker protects this circuit.
Note that the 42 VAC and 115 VAC circuits are electri-
cally isolated from each other.
Trigger Circuit
Trigger Circuit
115 VAC1
FIGURE A.10 FRONT VIEW OF 14-PIN
CONNECTOR RECEPTACLE
K = 4 2
115 VAC1
1.
2.
115VAC circuit is on all models.
J = 3 1
A = 3 2
As shipped from the factory Lead #21 from the 14 Pin connector is
connected to “-21” on the terminal strip (T.S.2).
This is the configuration for positive welding. If welding negative
polarity, connect lead #21 to the “+21” connection point on the ter-
minal strip (T.S.2).
I = 4 1
B = G N D
L
N
C = 2
D = 4
E = 7 7
H = 2 1
G = 7 5
F = 7 6
M
DC-600
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A-10
A-10
NOTES
DC-600
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Meaning of Graphical Symbols on Case Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Meaning of Graphical Symbols on Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Meaning of Graphical Symbol for Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5, B-6
Overload, Overcurrent and Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Remote Control of Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Welding Procedure Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Semi-Automatic and Automatic Wire Feeding with a DC-600 and Wire Feeders . . . . . . . . . . . . . . . . . . . .B-7
LN-8 Semi-Automatic Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
LN-7 & LN-9 Semi-Automatic Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
DC-600
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B-2
B-2
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
• Do not use AC welder if your cloth-
ing, gloves or work area is damp or if
working on, under or inside work-
piece.
Use the following equipment:
-Semiautomatic DC constant voltage
(wire) welder.
-DC manual (stick) welder.
-AC welder with reduced voltage con-
trol.
• Do not operate with panels removed.
• Disconnect input power before ser-
vicing.
-------------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF &
OTHERS.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc,
or both,to keep fumes and gases
from your breathing zone and gener-
al area.
WELDING, CUTTING and GOUG-
ING SPARKS can cause fire or
explosion.
• Do not weld near flammable material.
• Do not weld, cut or gouge on contain-
ers which have held flammable mater-
ial.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
DC-600
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B-3
B-3
OPERATION
GENERAL DESCRIPTION
DESIGN FEATURES AND
ADVANTAGES
The DC-600 is an SCR controlled three phase welding
and cutting power source. It uses a single range poten-
tiometer to control:
•
Excellent arc characteristics for optimum constant
voltage submerged arc and Innershield welding
performance.
•
Submerged Arc Semi-Automatic or Automatic
Welding
•
•
•
•
•
A control circuit designed to provide good starting
for a large variety of processes and procedures.
Output Control Potentiometer that provides easy
single range continuous control.
Output Control Switch that provides simple switch-
ing from local to remote control.
Output Terminals Switch to energize output termi-
nals either local or remote.
White neon pilot light to confirm that the Input
Contactor is energized.
•
•
•
Open Arc Semi-Automatic or Automatic Welding
Stick Welding
Air/Carbon Arc Cutting (Carbon Rod Sizes up to
3/8” Diameter)
The DC-600 has a three-position Welding Mode Switch
to enable the user to operate in one of three modes:
•
•
DC Ammeter and Voltmeter
42VAC 10 Amp auxiliary power available for the
wire feeder, circuit breaker protected.
Single MS-type (14 pin) connector for wire feeder.
115VAC 15 Amp auxiliary power available for the
wire feeder, circuit breaker protected.
115VAC 15 Amp duplex plug receptacle available
on 60 Hertz models, circuit breaker protected.
Multi-functional terminal strip for easy connection
of wire feeding control cables.
Recessed output terminals to avoid any person or
object from accidentally coming into contact with
the output terminals and labeled " + " and " - " for
easy identification.
Thermostatically protected power source.
Electronic protection circuit to protect power
source against overloads.
Input line voltage compensation to provide an
essentially constant output.
SCR electronically controlled welder output pro-
vides extra long life, especially for highly repetitive
welding applications.
•
•
•
Constant Current (CC) Stick (also used for AAC)
Constant Voltage (CV) Submerged Arc
Constant Voltage (CV) Innershield (also used for
FCAW/GMAW)
•
•
Three models are available:
•
•
•
•
Domestic
-
all 60 Hertz models except
230/460/575V.
Canadian-230/460/575V 60 Hertz models
Export-50/60 Hertz models
•
•
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
•
•
Solid state 2 and 4 circuit for extra long life.
Two circuit solid state control system provides
maximum performance and circuit protection.
Low profile case provides maximum use of space.
Convenient access to all controls.
The DC-600 is designed for GMAW (MIG), FCAW, and
submerged arc (SAW) within the capacity of the
machine. It can also be used for stick welding (SMAW)
and for air carbon arc (AAC) cutting with carbon rods
up to 3/8" diameter.
•
•
•
Output lead strain relief loops to prevent terminal
and cable damage.
The DC-600 is provided with a three position mode
switch that selects CV Innershield, CV Submerged Arc,
or CC Stick.
•
•
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.
The DC-600 can be easily connected to wire feeding
equipment, including:
•
Semi-automatic wire feeders LN-7, LN-7 GMA, LN-
742, LN-8, LN-9, LN-9 GMA, LN- 10, LN-15 LN-
23P, LN-25, and DH-10.
•
•
Automatic wire feeders NA-3, NA-5, and NA-5R.
Tractors LT-56 and LT-7
DC-600
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B-4
B-4
OPERATION
WELDING CAPABILITY
The DC-600 has the following Output and Duty Cycle
based on operation for a 10 minute period:
600 Amps, 44 Volts at 100%
680 Amps, 44 Volts at 60%
750 Amps, 44 Volts at 50%
MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT
Input POWER ON/OFF Switch
LOCAL/REMOTE Switch
SYMBOL
SYMBOL
MEANING
MEANING
Control Of Output Voltage and
Current is Via DC-600's Control Dial
ON
Remote Control of Output Voltage
and Current
OFF
MODE Switch
INPUT POWER
CC STICK: Shielded Metal Arc
Welding (SMAW), this switch
position is also used for Air
Carbon Arc Cutting (AAC)
Pilot Light
CV SUBMERGED ARC:
Constant Voltage Submerged
Arc Welding (SAW)
Input power on when light is illuminated
(except for abnormal conditions).
Always indicates POWER ON/OFF
switch is in ON position.
CV INNERSHIELD: Flux Cored
Arc Welding (FCAW), this switch
position is also used for Gas
Metal Arc Welding (GMAW).
OUTPUT CONTROL
Output Terminal Connections
OUTPUT VOLTAGE
AND CURRENT
Positive Output Terminal
Clockwise Increase of Output
Voltage and Current
Negative Output Terminal
WARNING Identification
TERMINALS ON/REMOTE Switch
OUTPUT TERMINALS
Warning Identification
ENERGIZED
Circuit Breaker
Circuit Breaker (two breakers: 15A
for 115V circuit and 10A for 42V
circuit)
Remote Control of Output Terminals
(Energized or Non-Energized)
DC-600
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B-5
B-5
OPERATION
MEANING OF GRAPHICAL MEANING OF GRAPHICAL
SYMBOLS ON RATING PLATE SYMBOL FOR GROUND CON-
(LOCATED ON CASE BACK)
NECTION
Designates welder complies with
National Electrical Manufacturers
Association requirements EW 1
Class I with 100% duty cycle at
600Amps output.
Signifies the equipment connection
point for the protective earth ground
NEMA EW 1 (100%)
CONTROLS AND SETTINGS
All operator controls and adjustments are located on
the Case Front Assembly of the DC-600. See Figure
B.1 for the location of each control.
Three Phase Input Power
3 Phase transformer with recti-
fied DC output
3
8
6
9
4
5
Line Connection
1
5
6
4
7
3
7
8
2
Gas Metal Arc Welding (GMAW)
Flux Cored Arc Welding (FCAW)
9
1
10
DC-600
2
11
10
Shielded Metal Arc Welding (SMAW)
Submerged Arc Welding (SAW)
12
13
FIGURE B.1 - CONTROL PANEL KEYS
1. Input POWER ON/OFF Switch
This toggle switch turns the machine on or off.
Putting the switch in the ON “ ” position ener-
Designates welder complies with
both Underwriters Laboratories (UL)
standards and Canadian Standards
Association (CSA) standards. (60
Hertz Models)
R
gizes the machine’s input contactor applying input
power to the machine. Switching the switch to the
NRTL/C
OFF “
tactor.
” position de-energizes the input con-
2. POWER Light
When the POWER switch is in the ON position the
machine’s white POWER light will illuminate. If the
input contactor de-energizes the machine in an
abnormal situation the pilot light will still illuminate.
In this situation it may be necessary to reset the
machine by switching the POWER switch to the
OFF and then to the ON position. (See Overload,
Overcurrent, and Fault Protection Section)
DC-600
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B-6
B-6
OPERATION
3. OUTPUT CONTROL
11.Terminal Strip Cover Panel
This control provides continuous control of the
machine’s output voltage and current from minimum
to maximum (typical full pot range between 15 to 44
volts and 90 to 750 amps) as it is rotated clock-wise.
Voltage or current control is determined by setting
of Mode Switch (CV or CC).
Rotate this panel to gain access to the circuits made
available at the two terminal strips (T.S.1 and T.S.2).
These terminal strips contains the same circuits as
the 14 pin MS-receptacle. There is a box connector
adjacent to this cover for routing leads to the termi-
nal strips.
4. OUTPUT TERMINALS ON/REMOTE Switch
12.Negative Output Terminal
When this switch is in the REMOTE “
” posi-
This output terminal is for connecting a welding
cable. To change welding polarity and for proper
welding cable size refer to Electrode and Work
Cables in the Installation Section.
tion, the DC-600’s output terminals will be electri-
cally “cold” until a remote device such as a wire
feeder closes the #2 and #4 circuit in the MS-recep-
tacle or terminal strip (T.S.2). When this switch is in
the ON “
” position the machine’s output termi-
13.Positive Output Terminal
nals will be electrically energized all the time.
This output terminal is for connecting a welding
cable. To change welding polarity and for proper
welding cable size refer to Electrode and Work
Cables in the Installation Section.
5. LOCAL/REMOTE Switch
When this switch is set to the LOCAL “ “ position,
control of the output voltage and current is via the
OUTPUT CONTROL on the DC-600’s control panel.
AUXILIARY POWER IN MS-RECEPTACLE
When this switch is set to the REMOTE
“
”
position, control is through a remote source such as
a wire feeder via the #75, #76, and #77 leads in the
MS-receptacle or terminal strip (T.S.1).
42 volt AC auxiliary power, as required for some wire
feeders, is available through the wire feeder MS-recep-
tacle. A 10 amp circuit breaker protects the 42 volt cir-
cuit from overloads.
6. Mode Switch
This switch allows for selecting the welding process
to be used:
CC STICK-for SMAW and AAC
CV SUBMERGED ARC- for SAW
CV INNERSHIELD- for FCAW and GMAW
DC-600 machines can also supply 115 volt AC auxil-
iary power through the wire feeder receptacle. A 15
amp circuit breaker protects the 115 volt circuit from
overloads.
OVERLOAD, OVERCURRENT, AND
FAULT PROTECTION
7. 115VAC Duplex Receptacle (60 Hertz Models)
This receptacle provides up to 15 amps of 115 VAC
auxiliary power.
This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and high ambi-
ent temperatures. When the welder is subjected to an
overload or loss of cooling, a thermostat will open. The
input contactor will open and remain open until the
machine cools; the white POWER light stays illuminat-
ed. No welding is possible during this cool down peri-
od. The machine will reset automatically when the ther-
mostat cools.
8. 115VAC 15 Amp Circuit Breaker
This breaker protects the 115 VAC auxiliary circuits
located in the duplex receptacle, terminal strip
(T.S.2) and MS-receptacle.
9. 42VAC 10 Amp Circuit Breaker
This breaker protects the 42VAC auxiliary circuits
located in the terminal strip (T.S.2) and MS-recep-
tacle.
The power source is also protected against overcur-
rents in the SCR bridge assembly through an electron-
ic protection circuit. This circuit senses currents over
780 amps on the power source and opens the input
contactor should the overcurrent remain for a predeter-
mined time (the white POWER light stays illuminated).
The predetermined time varies with the amount of
overcurrent; the greater the overcurrent, the shorter
the time. The input contactor will remain open until the
power source is manually started by resetting the
POWER ON/OFF toggle switch.
10.14 Pin MS-Receptacle
This connector provides easy connection for a wire
feeder control cable. It provides connections for
auxiliary power, output switching, remote output
control, wire feeder voltmeter sense lead and
ground. Refer to 14 Pin MS Type Receptacle in the
Installation Section for information about the circuits
made available at this receptacle.
DC-600
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B-7
B-7
OPERATION
The power source circuitry is protected from faults on
leads 75, 76, or 77. If any of these leads are connect-
ed to either the positive or negative output leads, the
DC-600 will either shut down completely (input contac-
tor opens and white POWER light stays illuminated), or
will operate at minimum output thus preventing any
damage to the DC-600. If DC-600 shuts down, it must
be manually started by resetting the POWER ON/OFF
toggle switch.
REMOTE CONTROL OF MACHINE
OPERATION
The toggle switch on the control panel labeled “Remote
- Panel” gives the operator the option of controlling the
machine output from a remote location. If in the
Remote position a wire feeder with remote control
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 informa-
tion.
OPERATING STEPS
The following procedures are for using the DC-600 in
the local control mode of operation. For remote control
of the machine, see the Remote Control of Machine
Operation section.
WELDING PROCEDURE
RECOMMENDATIONS
Select Welding Mode Switch position based on type of
welding to be done.
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 precau-
tions before starting work. It is important that you fol-
low these operating steps each time you use the
machine.
1. Innershield Welding (FCAW)/MIG (GMAW)
Welding: Use the CV INNERSHIELD mode.
2. Submerged Arc Welding (SAW): Use the CV SUB-
MERGED ARC mode. If 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.
1. Turn on the main AC power supply to the machine.
2. Connect the #21 work lead to either + or - on ter-
minal strip (T.S.2).
3. Air/Carbon Arc Cutting (AAC) / Stick Welding
(SMAW) / High Current, Large Puddle Submerged
Arc Welding (SAW): Use the CC STICK mode.
When the DC-600 is used for Air/Carbon Arc cut-
ting, the OUTPUT 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 currents as high as 750 amps with
excellent arc control. The welder protection circuit
protects the machine from extremely high short cir-
cuiting pulses.
3. Set the Welding Mode switch to welding process
being used:
•
•
•
CC STICK (for SMAW and AAC)
CV SUBMERGED ARC (for SAW)
CV INNERSHIELD (for FCAW and GMAW)
4. Turn the POWER ON/OFF Toggle Switch to the
“ON” position
•
•
The white pilot light glows.
The fan starts.
SEMI-AUTOMATIC AND AUTOMATIC
WIRE FEEDING WITH THE DC-600
AND WIRE FEEDERS
5. Set OUTPUT CONTROL Potentiometer to desired
voltage or current.
When using the DC-600 with semi-automatic or auto-
matic wire feeding equipment and for stick welding or
air/carbon arc cutting, it is recommended that the
optional MULTI-PROCESS 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.
6. Set the OUTPUT TERMINALS switch to either
“ON” ( output terminals energized) or “REMOTE”
(output terminals energized when #2 and #4
closed by remote device such as wire feeder)
7. Make the weld.
DC-600
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B-8
B-8
OPERATION
NA-3 AUTOMATIC WIRE FEEDER
4. Connect the electrode cables to terminal polarity to
be used.
1. Set the DC-600 LOCAL/REMOTE Switch to
REMOTE. Set the OUTPUT TERMINALS 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 CC mode position.
Some earlier models are capable of cold starting
only in the CC mode position. Cold starting
enables you to inch the wire down to the work,
automatically stop, and automatically energize the
flux hopper valve.
5. Connect the #21 work lead (on T.S.2) to the
same polarity as the work cable connection.
6. Set the DC-600 LOCAL/REMOTE Switch to
REMOTE.
7. Set the DC-600 OUTPUT TERMINALS switch to
REMOTE.
2. Connect the NA-3 Control Cable to the 14 pin
Amphenol of the DC-600.
8. Set the DC-600 WELDING MODE SWITCH to the
position that matches the welding process being
used.
3. Connect the #21 work lead (on T.S.2) to the
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22978) for remote connection (recommend-
ed) of the #21 lead.
• For submerged arc welding, set WELDING MODE
SWITCH to CV SUBMERGED ARC position.
• For all open arc welding processes set WELDING
MODE SWITCH to CV INNERSHIELD position.
4. Connect the electrode cables to terminal polarity to
be used.
GOOD ARC STRIKING GUIDELINES FOR THE DC-
600 IN THE CV INNERSHIELD, CV SUBMERGED
ARC MODES
5. Set the DC-600 welding mode switch for the
desired process: CV SUBMERGED ARC, CV
INNERSHIELD mode or CC STICK mode.
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.
6. Set the NA-3 mode Switch Position to either CV or
CC to match the DC-600 mode selected in step 2.
7. Refer to the NA-3 operators manual for instructions
on how to use the NA-3 in conjunction with the DC-
600.
1. Cut the electrode to a sharp point.
2. Set the NA-3 Open Circuit Voltage Control (NA-5
STRIKE VOLTS Control) to the same dial setting
as the Arc Voltage Control. For the NA-3, If this is
a new welding procedure, a good starting point is to
set the Open Circuit Voltage Control to # 6.
8
Follow the following guidelines for good arc striking
detailed below for each welding mode.
DC-600 POWER SOURCE SETTING WHEN
CONNECTED TO NA-5 WIRE FEEDER
NOTE: The open circuit voltage of the
DC-600 varies from approximately 16 volts to 56
volts in the CV INNERSHIELD or CV
SUBMERGED ARC modes. The open circuit volt-
age is constant in the CC STICK mode.
When using the DC-600 with the NA-5 wire feeder, set
the controls on the DC-600 as follows for the best per-
formance:
1. Turn OFF main AC input power supply to the DC-
600.
2. Connect the NA-5 Control Cable to the 14 pin
Amphenol of the DC-600.
3. Connect the #21 work lead (on T.S.2) to the
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22979) for remote connection (recommend-
ed) of the #21 lead.
DC-600
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B-9
B-9
OPERATION
3. Run a test weld. Set proper current, voltage, and
travel speed.
2. Connect the LN-8 or LN-9 Control Cable to the 14
pin Amphenol of the DC-600.
• 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.
3. Connect the #21 work lead (on T.S.2) to the
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22977) for remote connection (recommend-
ed) of the #21 lead.
• To adjust the Open Circuit Voltage Control to get
the best starting performance, make repeated
starts observing the NA-3 voltmeter.
4. Connect the electrode cables to terminal polarity to
be used.
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.
2. Set
the
IDEALARC
DC-600
OUTPUT
CONTROL SWITCH to the REMOTE position.
3. Set the LN-8 Welding Mode Switch to the CV or
VV position. The LN-8 Welding Mode Switch is
located on the variable voltage (CC) board.
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."
4. Refer to the LN-8 Operator’s Manual for instruc-
tions on how to use the LN-8 in the CC (VV) mode.
LN-7 AND OTHER CONSTANT WIRE
FEEDERS
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 electrode
to stub.
To use the LN-7 or other constant wire feed speed
semi-automatic wire feeders with IDEALARC DC-600
4. Start and make the weld.
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.
• Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes positive
contact with the work piece.
• Hot "On the Fly" starts. For hot starts, travel should
begin before the wire contacts the work piece.
2. Connect the Wire Feeder Control Cable to the 14
pin Amphenol of the DC-600.
ARC STRIKING WITH DC-600 AND THE NA-3 OR
NA-5 START BOARD
3. Connect the #21 work lead (on T.S.2) to the
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22978) for remote connection (recommend-
ed) of the #21 lead.
When electrical stickout exceeds 1 3/4” (44.4mm) the
optional Start Board (K221 for the NA-3 and K334 for
the NA-5) may be required to improve arc striking.
4. Connect the electrode cables to terminal polarity to
be used.
See the NA-3 or NA-5 Operator’s Manual for detailed
instructions on setting the Start Circuit controls.
5. Set
the
IDEALARC
DC-600
OUTPUT
LN-8 OR LN-9 SEMI-AUTOMATIC WIRE
FEEDER
CONTROL SWITCH per the Connection Diagram
for the feeder being used
To use the LN-8 or LN-9 Semi-Automatic Wire Feeder
with the IDEALARC DC-600
NOTE: Older Lincoln control cables that do not have an
Amphenol connector on the Power Source end
can be connected to the T.S.1 & T.S.2 terminal
strips behind the DC-600 nameplate. See the
Installation section of this manual and the
appropriate Connection Diagram.
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.
DC-600
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B-10
B-10
NOTES
DC-600
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C-2
C-2
ACCESSORIES
Undercarriages (K817P, K842)
WIRE FEEDERS AND TRACTORS
For easy moving of the machine, optional undercar-
riages are available with polyolefin wheels (K817P) or
a platform undercarriage (K842) with mountings for
two gas cylinders at rear of welder.
The DC-600 can be used to power any of the following
Lincoln Wire Feeders and Tractors:
Semi-Automatic Wire Feeders:
DH-10
LN-7
LN-7 GMA
LN-742
LN-8
LN-9
Paralleling Kit (K1611-1)
LN-9 GMA
LN-23P
LN-25
Permits paralleling of two DC-600's for welding cur-
rents of up to 1200 amps, 100% duty cycle.
LN-10
Automatic Wire Feeders:
Tig Module (K930-2)
NA-3
NA-5
NA-5R
LT-56
Portable high frequency generator for AC/DC TIG
welding.
Tractors:
LT-7
FACTORY OR FIELD
OPTIONS
INSTALLED
FIELD INSTALLED OPTIONS
Multi-Process Switch (K804-1)
Remote Output Control (K775 or K857 with
K864 Adapter)
The MULTI-PROCESS SWITCH gives you the ability
to:
•
Switch between "stick welding or air/carbon arc cut-
ting" and using a semi-automatic or automatic wire
feeder.
An optional “remote out control” is available. The K775
is the same remote control that is used on other
Lincoln power sources. The K775 consist of a control
box with 28 feet (8.5mm) of four conductor cable. This
connects to terminals 75,76, and 77 on the terminal
strip (T.S.1) and the case grounding screw so marked
•
Change the polarity of a semi-automatic or auto-
matic wire feeder without changing any electrical
cable connections.
with the symbol “
” on the machine. These termi-
nals are located behind the hinged cover on the case
front. This control will give the same control as the out-
put control on the machine.
See Figure C.1
The K857 is similar to the K775, except the K857 has
a 6-pin MS-style connector. The K857 requires a K864
adapter cable which connects to the 14-pin connector
on the case front.
+
STICK OR
AIR
Remote Control Adapter Cable (K864)
-
CARBON
ARC
C A B L E R E C E P T A C L E ( 6 S O C K E T )
T O : K 8 5 7 R E M O T E C O N T R O L
S T R A I G H T P L U G ( 1 4 P I N )
T O P O W E R S O U R C E
C A B L E R E C E P T A C L E ( 1 4 S O C K E T )
T O : L N - 7 W I R E F E E D E R S
+
–
A "V" cable 12" (.30 m) long to connect a K857 Remote
Control (6-pin connector) with an LN-7 wire-feeder (14-
pin connector) and the machine (14-pin connector). If
a remote control is used alone the wire-feeder connec-
tion is then not used.
STICK OR
WIRE
AIR/CARBON
ARC CABLES
FEEDER
CABLES
FIGURE C.1 - MULTI-PROCESS SWITCH
DC-600
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C-3
C-3
ACCESSORIES
The MULTI-PROCESS SWITCH has two sets of output
terminals. You connect the wire feeder unit cables to
the set of terminals on the left side of the box and the
stick or air/carbon arc cables to the set of terminals on
the right side (facing the front of the machine) as
ed against accidental contact by hinged covers.
TERMINAL
STRIP COVER
BOX
CONNECTOR
21+
21- 41
4
2
31 32
75 76 77
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.
CONTROL
LEADS
NEGATIVE (–)
OUTPUT
STUD
POSITIVE (+)
OUTPUT
STUD
+
–
Follow these steps to install the MULTI-PROCESS
SWITCH:
ELECTRODE
CABLE
ELECTRODE
CABLE
WORK
+
STICK AIR/CARBON
ARC WELDING
EQUIPMENT
WIRE
FEEDER
1. Confirm that the DC-600 POWER ON/OFF switch
is in the OFF position.
ELECTRODES
WORK
CABLE
WORK
CABLE
2. Disconnect main AC input power to the DC-600.
JUMPER (IF NEEDED
SEE INSTRUCTIONS)
3. Open the terminal strip hinged cover located on
the Case Front Assembly.
FIGURE C.2 - MULTI-PROCESS SWITCH
CABLE CONNECTIONS.
4. The MULTI-PROCESS SWITCH is mounted to the
case front with four 1/4” self-tapping screws. The
screw holes are 13.8” apart side to side and 4.5”
apart top to bottom, Run one of the 1/4” screws
part way in and out of the screw holes to open
them up. Make sure that the two sleeved control
leads do not get pinched when hanging the switch;
route them out the side to the right of the switch.
Support the switch in position and start the four
screws, then tighten them.
8. Connect the left cable from the MULTI-PROCESS
SWITCH (facing the front of the machine) to the
DC-600 negative (-) output terminal. See Figure
C.2.
9. Connect the wire feeder electrode and work
cables. See Figure C.2.
• Insert the wire feeder electrode and work cables
through the strain relief loop on the left side of the
DC-600 (facing the front of the machine).
5. Route the MULTI-PROCESS SWITCH control
leads through the strain-relief box connectors and
into the terminal strip. Connect wire feeder control
cable as specified in specific connection diagram
and make other terminal strip connections as
specified on the connection diagram for the Lincoln
wire feeder being used.
• Connect the wire feeder electrode and work cables
to the electrode and work terminals on the left side
of the MULTI-PROCESS SWITCH.
10. Connect wire feeder control cable and make other
terminal strip connections as specified on the con-
nection diagram for the Lincoln wire feeder being
used.
6. Connect the control leads from the MULTI-
PROCESS SWITCH to terminals #2 and #4 on the
DC-600's terminal strip.
11. Set the DC-600 OUTPUT TERMINALS switch to
REMOTE.
7. Connect the right cable from the MULTI-
PROCESS SWITCH (facing the front of the
machine) to the DC-600 positive (+) output termi-
nal. See Figure C.2.
DC-600
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C-4
C-4
ACCESSORIES
12. Connect stick or air/carbon arc electrode and work
CONNECTIONS FOR SEMI-AUTO-
MATIC OR AUTOMATIC WIRE FEED-
ER CONTROL
• Insert the electrode and work cables through the
strain relief loop on the right side (facing the front
of the machine) of the DC-600.
1. Set the DC-600 ON/OFF switch to OFF.
2. Set the DC-600 LOCAL/REMOTE switch to
REMOTE.
• Connect the electrode cable to the "Positive" ter-
minal on the right side of the MULTI-PROCESS
SWITCH.
3. Set the DC-600 OUTPUT TERMINALS switch to
REMOTE.
• Connect the work cable to the "Negative" terminal
on the right side of the MULTI-PROCESS
SWITCH.
4. Set the DC-600 MODE switch to the welding
process being used.
NOTE: The instructions above are for connecting
the stick polarity positive. To change the polarity,
turn the DC-600 OFF, and reverse the cables.
5. Refer to the proper connection diagram in the DIA-
GRAMS section for more information.
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.
To operate the MULTI-PROCESS SWITCH, refer to the
operating instructions on the switch nameplate.
DC-600
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
ELECTRIC SHOCK CAN KILL.
Only qualified personnel should
perform this maintenance.
Turn the input power OFF at the dis-
connect switch or fuse box before
working on this equipment.
Do not touch electrically hot parts.
ROUTINE AND PERIODIC
MAINTENANCE
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts.
Perform the following daily:
1. Check that no combustible materials 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.
•
•
•
•
•
•
Main transformer and choke.
Electrode and work cable connections.
SCR rectifier bridge and heat sink fins.
Control board.
Firing board.
Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
DC-600
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Circuit and Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Protective Devices and Shutdown Circuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
FIGURE E.1 BLOCK LOGIC DIAGRAM
POWER
SWITCH
CONTROL
TRANSFORMER
115VAC
TERMINAL
STRIP 1
•
OUTPUT
CONTROL
SWITCH
Pilot
Light
w
FAULT PROTECTION
OUTPUT
CONTROL
CR2
•
OUTPUT
32VAC
32VAC
32VAC
CONTROL SIGNAL
FIRING
BOARD
Secondary
Thermostat
S
G
A
T
Primary
Theromstat
I
14-pin
Fan
G
N
A
L
115VAC
Amphenol Receptacle
Motor
E
CONTROL
T
E
115VAC
S
BOARD
MODE
T
R
I
•
R
M
I
SWITCH
OUTPUT
P
N
A
TERMINAL
SWITCH
1CR Coil
2
L
F
42VAC
115VAC
E
E
D
B
A
C
K
MAIN
TRANSFORMER
R
E
C
POSITIVE
TERMINAL
O
N
N
E
C
T
SHUNT
F
E
E
D
B
A
C
LATCHING
RESISTOR
CONTACTOR
CR1
SCR BRIDGE
CHOKE
NEGATIVE
TERMINAL
K
DC-600
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 - INPUT AND TRANSFORMER
POWER
SWITCH
CONTROL
TRANSFORMER
115VAC
TERMINAL
STRIP
1
•
OUTPUT
CONTROL
SWITCH
Pilot
Light
w
FAULT PROTECTION
OUTPUT
CR2
•
CONTROL
OUTPUT
32VAC
32VAC
32VAC
CONTROL SIGNAL
FIRING
BOARD
Secondary
Thermostat
S
G
A
T
Primary
Theromstat
I
14-pin
Fan
G
N
A
L
115VAC
Amphenol Receptacle
Motor
E
CONTROL
T
E
115VAC
S
BOARD
MODE
T
R
I
•
R
M
I
SWITCH
OUTPUT
P
N
A
TERMINAL
SWITCH
1CR Coil
2
L
F
42VAC
115VAC
E
E
D
B
A
C
K
MAIN
TRANSFORMER
R
E
C
POSITIVE
TERMINAL
O
N
N
E
SHUNT
F
E
E
D
B
A
C
K
C
T
LATCHING
RESISTOR
CONTACTOR
CR1
SCR BRIDGE
CHOKE
NEGATIVE
TERMINAL
GENERAL DESCRIPTION
A reconnect panel allows the user to configure the
machine for the desired input voltage. This three-
phase AC input is applied to the primary of the main
transformer. The transformer changes the high voltage,
low current input power to a lower voltage, higher 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 SCR
rectifier assembly.
The DC-600 is a three-phase, SCR controlled DC
power source. It is capable of either constant current
or constant voltage output. It is rated at 600 amps,
100% duty cycle with outstanding arc characteristics
for multiple welding processes.
INPUT CIRCUIT AND MAIN TRANS-
FORMER
In addition, the main transformer also has five isolated
secondary windings. There are three 32 VAC windings,
which provide power and “timing” to the firing board.
The 115 VAC winding powers the fan motor and pro-
vides the user with up to 20 amps of 115 VAC auxiliary
power at the receptacle or 14-pin MS type connector.
The 42 VAC winding provides 10 amps of power to the
14 pin MS type connector to power a wire feeder.
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.
The secondary of the control transformer supplies 115
VAC power to the control board and to the input con-
tactor through the fault protection relay.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
DC-600
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E-3
E-3
THEORY OF OPERATION
FIGURE E.2 - FIRING BOARD,CONTROL BOARD AND RECTIFICATION
POWER
SWITCH
CONTROL
TRANSFORMER
115VAC
TERMINAL
STRIP
1
•
OUTPUT
CONTROL
SWITCH
Pilot
Light
w
FAULT PROTECTION
OUTPUT
CR2
•
CONTROL
OUTPUT
32VAC
32VAC
32VAC
CONTROL SIGNAL
FIRING
BOARD
Secondary
Thermostat
S
G
A
T
Primary
Theromstat
I
14-pin
Fan
G
N
A
L
115VAC
Amphenol Receptacle
Motor
E
CONTROL
T
E
115VAC
S
BOARD
MODE
T
R
I
•
R
M
I
SWITCH
OUTPUT
P
N
A
TERMINAL
SWITCH
1CR Coil
2
L
F
42VAC
115VAC
E
E
D
B
A
C
K
MAIN
TRANSFORMER
R
E
C
POSITIVE
TERMINAL
O
N
N
E
SHUNT
F
E
E
D
B
A
C
K
C
T
LATCHING
RESISTOR
CONTACTOR
CR1
SCR BRIDGE
CHOKE
NEGATIVE
TERMINAL
FIRING CIRCUIT, CONTROL CIR-
CUIT AND RECTIFICATION
CONTROL BOARD
RECTIFICATION
The control board receives current feedback informa-
tion from the shunt and voltage feedback information
from the choke and welding output terminals. This
feedback information is processed on the control
board. The control board compares the commands of
the mode switch, the output control potentiometer (or
remote control device) and the arc force control with
the feedback information and sends the appropriate
output control signal to the firing board. In the event of
a “fault condition,” the control board de-activates the
fault relay (CR2). See Protective Devices and Shut
Down Circuits.
The “neutrals” of the welding secondary windings in the
main transformer are connected together, and the six
starts are connected to the six Silicon Controlled
Rectifier (SCR) assemblies to form a six-phase output.
This six-phase AC output from the main transformer
secondary is rectified and controlled by the SCR
bridge.
FIRING BOARD
The firing board is powered by the three-phase 32vac
transformer windings. Each phase provides two firing
pulses, one for each of the two SCRs controlled by that
phase. When a gate firing enable*(trigger) signal is
received, the firing circuit supplies the proper amount
of energy to the gates of the power SCRs. When this
gate firing signal 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. At the same time the latching resistor is
connected across the machine’s output circuit. The
latching resistor provides a pre-load for the SCR bridge
so the SCR’s will stay activated providing open circuit
voltage (OCV).
An output choke is connected between the neutral con-
nection of the main transformer secondaries and the
negative output terminal. This large inductor stores
energy, and provides current filtering for the welding
output of the DC-600.
*Triggering is accomplished by a connection of lead
#2 & #4 by way of the Output Terminal Switch or by a
remote signal from a wire feeder. The 2 to 4 closure
is indicated by LED10 on the firing Board and LED 6
on the Control Board.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
DC-600
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E-4
E-4
THEORY OF OPERATION
FIGURE E.2 - GENERAL DISCRIPTION
POWER
SWITCH
CONTROL
TRANSFORMER
115VAC
TERMINAL
STRIP
1
•
OUTPUT
CONTROL
SWITCH
Pilot
Light
w
FAULT PROTECTION
OUTPUT
CR2
•
CONTROL
OUTPUT
32VAC
32VAC
32VAC
CONTROL SIGNAL
FIRING
BOARD
Secondary
Thermostat
S
G
A
T
Primary
Theromstat
I
14-pin
Fan
G
N
A
L
115VAC
Amphenol Receptacle
Motor
E
CONTROL
T
E
115VAC
S
BOARD
MODE
T
R
I
•
R
M
I
SWITCH
OUTPUT
P
N
A
TERMINAL
SWITCH
1CR Coil
2
L
F
42VAC
115VAC
E
E
D
B
A
C
K
MAIN
TRANSFORMER
R
E
C
POSITIVE
TERMINAL
O
N
N
E
SHUNT
F
E
E
D
B
A
C
K
C
T
LATCHING
RESISTOR
CONTACTOR
CR1
SCR BRIDGE
CHOKE
NEGATIVE
TERMINAL
PROTECTIVE DEVICES AND
SHUTDOWN CIRCUITS
THERMAL PROTECTION
REMOTE CONTROL FAULT PROTECTION
The power source circuitry is protected from faults on
the control circuit leads (#75, 76, or 77). If any of these
leads become common with either of the output leads,
the DC-600 will either shut down completely (control
lead fault to Negative Output), or will remain at mini-
mum output (control lead fault to Positive Output) thus
preventing any damage to the DC-600. If DC-600 shuts
down, (input contactor opens and white POWER light
stays illuminated) it must be manually started by reset-
ting the POWER ON/OFF toggle switch.
This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and high ambi-
ent temperatures. When the welder is subjected to an
overload or loss of cooling, a thermostat will open. The
input contactor will open and remain open until the
machine cools; the white POWER light stays illuminat-
ed. No welding is possible during this cool down peri-
od. The machine will reset automatically when the ther-
mostat cools.
OVER CURRENT PROTECTION
The power source is also protected against overcur-
rents in the SCR bridge assembly through an electron-
ic protection circuit. This circuit senses currents over
780 amps on the power source and opens the input
contactor should the overcurrent remain for a predeter-
mined time (the white POWER light stays illuminated).
The predetermined time varies with the amount of
overcurrent; the greater the overcurrent, the shorter
the time. The input contactor will remain open until the
power source is manually started by resetting the
POWER ON/OFF toggle switch.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
DC-600
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E-5
E-5
THEORY OF OPERATION
FIGURE E.2 - SCR OPERATION
SCR OPERATION
A silicon controlled rectifier (SCR) is a three-terminal
device used to control rather large currents to a load.
An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cath-
ode 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.
An SCR acts very much like
a
switch.
When a gate signal 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 the Gate.
DC-600
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E-6
E-6
NOTES
DC-600
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures
PC Board Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Internal Trigger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Firing Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Control Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19
Main Transformer Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21
Control Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-25
Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-27
SCR Bridge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-29
Removal and Replacement
Contactor Cleaning/ Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
SCR Bridge Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41
Main Transformer and Choke Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45
Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
DC-600
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F-2
F-2
TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
This Troubleshooting Guide is provided to
help you locate and repair possible machine
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
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.
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 the following
categories: output problems, function prob-
lems, wire feeding problems, and welding
problems.
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.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
DC-600
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when 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
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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:
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.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- Remove your body’s static
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
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
Workstations
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
DC-600
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The Machine is dead - The Input
contactor does not operate.
1. The ON/OFF Switch (S1) may
be faulty
1. Check for blown or missing
fuses in input lines.
2. The Control Transformer (T2)
may be faulty. Perform the
Control Transformer Test.
2. Check the three phase input line
voltage at the machine. The
input voltage must match the
rating plate and reconnect
panel.
3. The primary or secondary ther-
mostats may be open. Check or
replace. Also check the associ-
ated wiring. See the Wiring
Diagram.
4. The pilot relay (CR2) may be
faulty. Check or replace.
5. The input contactor coil may be
open.
6. The Control Board may be
faulty. Perform the Control
Input contactor (CR1) chatters.
1. The pilot relay (CR2) may have
bad contacts. Check or replace
relay.
1. The input line voltage may be
low. Check all three phases.
2. Make sure input line voltage
matches machine rating and the
reconnect panel is connected
correctly for the line voltage
2. Check for loose or faulty wiring
between pilot relay (CR2) and
input contactor (CR1) coil con-
nections.See Wiring Diagram.
3. The input contactor (CR1) may
be faulty.-Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
DC-600
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Input contactor pulls in when
ON/OFF Switch is closed but imme-
diately drops out.
1. If contactor (CR1) functions
correctly with the cables
removed there may be a fault in
the control cables or the wire
feeder. See Protective Devices
1. Make sure input line voltage
matches machine rating and the
reconnect panel is connected
correctly for the line voltage.
Remove all weld cables and
external wires attached to termi-
nal strip and the 14pin MS con-
nector and make sure the
Output Terminals Switch is in
the REMOTE position.
2. Check internal remote control
circuit (leads 75, 76 and 77)
including the Output Terminals
Switch (S3) and the Output
Control (R1) for grounds or
shorts. See the Wiring
2. If the problem persists after per-
forming step 1 the problem is in
the DC600.
4. The Control Board may be
Machine shuts off (input contactor
drops out) when the welder output
terminals are made electrically
"hot".
1. Remove all welding cables and
control cables from the DC 600.
If the machine does NOT shut
off and normal open circuit volt-
age is present at the welder out-
put terminals the problem is
external to the DC600. Either
the remote leads #75, #76 or
#77 are grounded to the nega-
tive output circuit or there is a
short on the welding output ter-
minals.
1. Check for grounds and or shorts
in the #75, #76, #77 circuit. See
(Output Terminals Switch ON).
2. Check for grounds and shorts in
the welder output terminals and
associated leads. See the
3. Check the output shunt and
associated leads.
See the
2. If the machine still shuts off
when all control and welding
cables are removed then the
problem is internal to the
DC600.
4. Perform the Control Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
DC-600
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine input contactor operates
but machine has no weld output with
the Output terminal Switch ON. Fan
runs and pilot light glows.
1. If both LEDs are OFF,try an
alternate method of triggering.
If LEDs come ON and machine
weld output is restored check
the Weld Terminal Switch (S2)
and the associated wiring. If not,
see the Internal Trigger Circuit
there is still no output go to Step
2.
1. Check LED 10 on the Firing
Board and LED 6 on the Control
Board. Both Should be ON.
NOTE: Alternate Trigger methods.
• Operate Wire Feeder trigger.
• Place a jumper across 2 & 4 on
the terminal strip T.S.2. or
across pins C & D in 14 pin con-
nector.
2. Check all of the LEDs on both
PC Boards for proper operation.
2. The Firing Board or Control
Board may be defective. See the
The machine does not have maxi-
mum weld output.
1. Check all three phase input 1. Check the Output Control
lines at the DC600. Make
sure input voltages match
machine rating and recon-
nect panel.
Potentiometer (R1) and
associated wiring for loose or
faulty connections.
wiring diagram.
See
3. Perform the Control Board
2. Put LOCAL/REMOTE Switch
(SW3) in "LOCAL" position.
If problem is solved then
check remote control unit or
wire feeder.
1. Remove any external leads 1. Check for an internal short
The weld output terminals are
always electrically "hot".
hooked to #2 and #4 on the ter-
minal strip. If the problem dis-
appears the fault is in the control
cable or wire feeder.
between leads #2 and #4. See
wiring diagram.
present (over 3VDC.) after per-
lem is within the DC600.
6. The SCR Snubber(s) may be
"leaky". 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 before you proceed.
Call 1-888-935-3877.
DC-600
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine has maximum weld output
and no control.
1. Check the LOCAL/REMOTE
Switch (SW3) and associated
wiring.
1. If remote control is being used
set LOCALl/REMOTE SWITCH
(SW3) to ‘LOCAL’ position and
try to control weld output using
the Output Control
2. Check feedback leads #222
(negative output terminal),
#215, and #210 (output shunt)
for loose or faulty connections.
Potentiometer (R1) at the
DC600. If the problem is solved
check the remote control unit
(or wire feeder) and associated
control cable.
3. Check the #75 lead for continu-
ity (zero ohms) from the Output
Control Potentiometer (R1) to
the control board connector
J1,Pin2. See Wiring Diagram.
4. Possible defective Control
Board or Firing Board. See the
1. If a remote control unit is NOT 1. Check the Output Control
Machine has minimum output and
no control.
connected to the DC-600, the
LOCAL/REMOTE Switch must
be in the "LOCAL" position.
Potentiometer (R1) and associ-
ated wiring.
2. Check the LOCAL/REMOTE
Switch (SW3), the Weld Mode
Switch (SW4) and associated
wiring.
2. If a remote control cable is con-
nected, the control leads may
be "shorted" to the positive weld
output.
3. Perform the Control Board
3. Make certain the three phase
input voltage is correct and
the reconnect panel.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
DC-600
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Poor arc starting when the DC600 is
in the CV Sub-Arc or CV Innershield
Modes.
1. Make sure the proper welding
procedures are being used.
(wire feed speed, arc voltage
and wire size)
1. Check the connections from the
shunt to the Control Board
(leads 210 and 215). When weld
current is present there should
be a millivolt signal at the board
(6.25mv/100 amps).
2. Check weld cables for loose or
faulty connections.
4. The Control Board may be
faulty.
Poor arc characteristics in all 1. Check for the correct input volt- 1. Check the Mode Switch (SW4)
processes.
ages on the three phase input
lines at the DC600.
and the associated wiring for
loose or faulty connections. See
the Wiring Diagram.
2. Make sure the proper welding
procedures are being used (wire 2. Check the voltage at the shunt
feed speed, arc voltage and wire
size).
(leads 210 and 215). When weld
current is present there should
be a millivolt signal at the board
(6.25mv/100 amps). If not cor-
rect, the shunt may be defective
3. Check the welding cables for
loose or faulty connections.
5. The Control Board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
DC-600
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F-9
F-9
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This is a quick reference guide to explain the function of the LEDs (Light Emitting Diodes)
on the PC Boards. If one (or more) of the LEDs is not performing correctly, see the test for
the individual boards
MATERIALS NEEDED
Misc Hand Tools
Wiring Diagram or Machine Schematic
TEST CONDITIONS
POWER SWITCH
ON
MODE SWITCH
CV INNERSHIELD
LOCAL/REMOTE Switch
OUTPUT TERMINAL SWITCH
LOCAL
ON
DC-600
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F-10
F-10
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING GUIDE (continued)
FIGURE F.1 – FIRING BOARD LEDs
J5
(205) 8
16 (204)
15 (203)
14
LED9 LED7
LED8
(206) 7
(207) 6
(208) 5
13 (231)
12 (215)
11
4
3
2
1
10
9
LED5
LED6
LED1
LED3
J6
LED10
J7
LED4
LED2
J8
J4
FIRING BOARD
G3742-[ ]
FIRING BOARD
1. With DC-600 set for the Test Conditions all ten
4. LEDs 1 thru 6 indicate that gate signals are being
sent to the SCRs in the Main Rectifier. These
LEDs will vary in brightness as the Output Control
is changed.
LEDs on the Firing Board should be lit.
2. LEDs 7, 8 & 9 indicate that the three 34vac sup-
plies from the Main Transformer are present on the
Firing Board. They should all be ON whenever the
Power Switch is ON.
• It is important that all six LEDs are the same bril-
liance as each other.
If none are lit, check the voltage at lead 231
OK, Replace the Firing Board.
If LEDs are not the same brilliance, see the
SCR Bridge Test and check the connections
to J-4. If OK, replace the Firing Board.
• If any are not ON check the voltages at P5
LED that Check AC voltage between pins specified,
was off it should be approximately 34VAC .
7
8
9
P5 pins 15 & 16 (wires 203,204)
P5 pins 7 & 8 (wires 205,206)
P5 pins 5 & 6 (wires 207,208)
• If voltage is present and the LED is OFF, replace
the Firing Board
3. LED 10 indicates that the machine is “triggered”
(Output Terminal Switch ON).
• Alternate Trigger Methods:
Operate Wire Feeder trigger.
Place a jumper across 2 & 4 on T.S.2.
Jumper between pins C & D of 14 pin connector.
• If LED 10 does not come ON, check wiring.
Perform the Internal Trigger Circuit Test.
DC-600
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F-11
F-11
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING GUIDE (continued)
FIGURE F.2 – CONTROL BOARD LEDs
1
2 (256)
(291) 8
J2
(290) 7
(255) 6
5 (231)
J3
1 (210)
LED3
LED1
(222)12
1
LED5
LED4
LED2
J1
LED6
G3409-1
DC600 CONTROL
CONTROL BOARD
5. LED 4 indicates an overload or “fault” condition and
is normally OFF. If it comes ON, the input contactor
(CR-1) will open and the machine will shut down.
The Power Switch must be turned OFF and back
1. With the DC-600 set for the Test Conditions, all
the LEDs except LED 4 should be lit.
2. LED 1 indicates the 120vac input to the Control
Board and should be ON whenever the Power
Switch is ON. If not check for voltage at leads 255
& 256 (J2- pin 6 & pin 3). If there is no voltage,
check the wiring from the input power circuit. See
the Wiring Diagram.
6. LED 5 indicates a DC control signal to the Firing
Board is present at lead 231 (J2-pin5). LED 5 will
vary in brilliance as the Control Potentiometer is
changed getting dimmer as output is increased
(opposite of LED 2)
3. LED 2 indicates presence of Arc Voltage feedback
to the Control Board and should be ON. LED 2
increases in brilliance as the arc voltage increases.
If not ON check the voltage at leads 210+ (J3-pin1)
to lead 222- (J1-pin12).
NOTE: LED 5 will be very dim or OFF in CC (Stick)
Mode until a load is applied (arc struck).
7. LED 6 indicates a signal from the Firing Board that
a ‘trigger’ has been applied. LED 6 should be ON
whenever there is a closure of the 2 & 4 circuit. See
Firing Board information regarding LED 10.
4. LED 3 indicates that power is being applied to the
Fault Protection relay (CR-2) and should be ON
whenever the Power Switch is ON. Under a “fault”
condition, LED 3 will go OFF and LED 4 will turn
ON. See Protective Devices and Shutdown
DC-600
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F-12
F-12
NOTES
DC-600
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F-13
F-13
TROUBLESHOOTING AND REPAIR
INTERNAL TRIGGER CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help to determine if the wiring and connections are correct from the 14 Pin
MS connector and the Terminal Strip to the Firing Board. It will aalso determine the pres-
ence of the 42vac trigger supply voltage.
MATERIALS NEEDED
Multi-meter
Misc. Hand Tools
Wiring Diagram or Machine Schematic
DC-600
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F-14
F-14
TROUBLESHOOTING AND REPAIR
INTERNAL TRIGGER CIRCUIT TEST (continued)
FIGURE F.3 – FIRING BOARD
J5
(205) 8
16 (204)
LED9 LED7
LED8
(206) 7
15 (203)
14
(207) 6
(208) 5
13 (231)
12 (215)
11
4
3
2
1
10
9
LED5
LED6
LED1
LED3
J6
LED10
J7
LED4
LED2
J8
J4
FIRING BOARD
G3742-[ ]
PROCEDURE
4. With a Voltmeter, check for 42vac at TS-2, termi-
wiring per the Simlpified Trigger Diagram (Figure
WARNING
ELECTRIC SHOCK
can kill.
600.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
6. Check for continuity (zero ohms) from lead #42A to
lead #2 at the 14-pin receptacle pin “C”. Also check
continuity to the Output Terminal Switch. See the
Simplified Trigger Diagram. If a resistance of any
value is indicated, check the associated wires and
plugs.
1. With the correct input power applied to the DC-600
and the trigger circuit not activated, LEDs 7, 8 &9
on the firing board should be lit. When the trigger is
activated, all of the LEDs should come ON. See
7. Check for continuity (zero ohms) from pin “D” (lead
#4) at the 14-pin receptacle to the output terminal
switch and also to plug J5-pin 9 at the firing board.
See the Simplified Trigger Diagram and Figures
2. If LED 10 and LEDS 1 thru 6 light when the trigger
circuit is activated, the wiring and circuitry to the fir-
ing board is good. If there is no output at the studs,
8. Check for continuity (zero ohms) from lead #41 (14
Pin Connector Pin I) to plug J5-pin 1 at the firing
board. See the Simplified Trigger Diagram and
Figure F.1.
3. If LED 10 does not light when the trigger circuit is
activated check the 10 amp Circuit Breaker. See
DC-600
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F-15
F-15
TROUBLESHOOTING AND REPAIR
INTERNAL TRIGGER CIRCUIT TEST (continued)
FIGURE F.4 - TERMINAL STRIPS AND AMPHENOL
10 AMP
CIRCUIT
BREAKER
OUTPUT
TERMINALS
SWITCH
5
6
4
7
3
8
2
9
1
10
DC-600
K = 4 2
J = 3 1
I = 4 1
A = 3 2
B = G N D
TS 2
TS 1
L
N
14 PIN
CONNECTOR
C = 2
H = 2 1
D = 4
E = 7 7
21+ 21- 41
4
2
31 32
G = 7 5
75 76 77
F = 7 6
M
FIGURE F.5 - SIMPLIFIED TRIGGER DIAGRAM
10AMP
CIRCUIT
BREAKER
To 42A at Main
Transformer
42
FIRING BOARD
TERMINAL
STRIP TS 2
11J5
291
TO
CONTROL
BOARD
14-PIN
2
RECEPTACLE
4J5
OUTPUT
2
2
4
C
2
TERMINAL
SWITCH
LED10
K
42
41
10J5
290
4
4
4
LATCHING
D
9J5
1J5
RESISTOR
ENABLE
I
41
41
FIRING
CIRCUIT
ENABLE
To 41 at Main
Transformer
DC-600
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F-16
F-16
NOTES
DC-600
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F-17
F-17
TROUBLESHOOTING AND REPAIR
FIRING BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will help to determine if the Firing Board is receiving the correct signals.
The LEDs (Light Emitting Diodes) will help to determine if the Firing Board is generating
SCR gate signals.
MATERIALS NEEDED
Misc. Hand Tools
Multimeter
Wiring Diagram or Machine Schematic
DC-600
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F-18
F-18
TROUBLESHOOTING AND REPAIR
FIRING BOARD TEST (continued)
FIGURE F.6 FIRING BOARD
J5
(205) 8
16 (204)
15 (203)
14
LED9 LED7
LED8
(206) 7
(207) 6
(208) 5
13 (231)
12 (215)
11
4
3
2
1
10
9
LED5
LED6
LED1
LED3
J6
LED10
J7
LED4
LED2
J8
J4
FIRING BOARD
G3742-[ ]
7. Trigger the DC-600 using the Output Terninal
Switch and see that LEDs 1 thru 6 and LED 10
come on.
PROCEDURE
WARNING
NOTE: LEDs 1 thru 6 should alwaysl be the same bril-
liance as each other. The brilliance will vary as
the Output Control is changed.
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
9. If LEDs 7,8 &9 are ON and any of LEDs 1 thru 6
are not ON, turn the machine OFF , disconnect J4
and re- energize the machine. All six LEDs should
be ON very bright. If not Replace the Firing Board.
1. Disconnect the AC input power to the DC-600
machine.
2. Locate the firing board on the left side of the con-
trol box.
10. If LEDs 7,8 &9 are ON and any of LEDs 1 thru 6
are not the same briliance as the others, Perform
Board.
3. Perform a visual inspection on the firing board to
see if there are any loose or faulty connections or
physical damage.
4. Connect the correct AC input power to the DC-600.
5. Turn the power switch (SW1) to the ON position.
11. If LEDs 1 thru 6 do not change as the output con-
trol is varied:
6. LEDs 7, 8 and 9 should be lit and equally bright.
See Figure F.4 to locate the LEDs. The three LEDs
should be of equal intensity. If not correvt, see the
• Check the Output Control Potentiometer.
• Make sure that the Local/Remote Switch is in
Local and functioning properly.
the Firing Board
DC-600
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F-19
F-19
TROUBLESHOOTING AND REPAIR
CONTROL BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will help to determine if the Control Board is functioning properly. The
LEDs (Light Emitting Diodes) will help to determine if the Control Board is receiving the
correct signals and sending the proper signal to the Firing Board.
MATERIALS NEEDED
Misc. Hand Tools
Multimeter
Wiring Diagram or Machine Schematic
DC-600
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F-20
F-20
TROUBLESHOOTING AND REPAIR
CONTROL BOARD TEST (continued)
FIGURE F.7 CONTROL BOARD
1
2 (256)
(291) 8
J2
(290) 7
(255) 6
5 (231)
J3
1 (210)
LED3
LED1
(222)12
1
LED5
LED4
LED2
J1
LED6
G3409-1
DC600 CONTROL
PROCEDURE
4. If the machine stays ON and all LEDs are correct,
the problem is external to the machine. If LED4 still
comes ON:
WARNING
• Check the Output Studs and associated wiring for
a ‘shorted’ or ‘grounded’ condition.
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
• Check for grounds in the control circuit (Output
Control, Local/Remote Switch & TS1).
• Control Board may be defective.
NOTE: LED 4 should be OFF except in a “shutdown“
condition. If ON and machine is still function-
ing, replace the Control Board.
1. Turn the POWER Switch ON. LEDs 1 and 3 should
turn ON.
5. LED 5 indicates a signal to the Firing Board and
should vary in brilliance as the Output Control is
adjusted. If LED 5 is not ON or does not change:
2. If LED 1 does not come ON, but the Power Light
is ON, check for 120vac at J2 (pin 6 and pin 2).
See the Wiring Diagram.
• Make certain that LED 6 is ON. The Output
Terminal Switch the Local/Remote Switch must
be in “LOCAL” position and the Mode Switch in
CV. If switches are set properly and functional, the
Control Board may be defective.
• If the Power Light is not ON, perform the Control
Transformer Voltage Test and check the Power
Switch and associated wiring.
3. If LED 3 does not come ON but LED4 is ON, the
DC-600 has shut down due to over-current or a
fault in the control leads (75,76 & 77).
6. LED 6 indicates a signal from the Firing Board that
the DC-600 is “triggered”. If not ON, perform the
• Disconnect any control cables, welding leads or
jumpers from the terminal strips (TS1& TS2).
DC-600
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F-21
F-21
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltages are being applied to the primary windings
of the main transformer and that the voltages from secondary windings, the auxiliary wind-
ings and the phase angle windings are correct.
MATERIALS NEEDED
Misc. Hand Tools
Multimeter
Wiring Diagram or Machine Schematic
DC-600
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F-22
F-22
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER VOLTAGE TEST (continued)
FIGURE F.8 - INPUT CONTACTOR AND RECONNECT PANEL
L3 T3
L2 T2
L1 T1
PROCEDURE
6. Make sure the input contactor (CR1) energizes.
1. Disconnect the main input power from the DC-600.
7. Test with an AC voltmeter for the proper main AC
input voltages applied to the line side of the input
contactor (CR1). See Figure F.8 .
2. Inspect the input contactor, reconnect panel and
primary leads to the main transformer for loose or
faulty connections. See Figure F.8.
a. L1 to L2
b. L2 to L3
c. L1 to L3
3. Confirm that the reconnect panel is configured cor-
rectly for the three-phase AC input power supplied
to the DC-600. See the connection diagram locat-
ed on the inside of the input box assembly.
• If the voltages are not correct at the line side of
the input contactor, check the input fuses and
leads.
4. Connect the correct AC three-phase input power to
the DC-600.
8. Test with an AC voltmeter for the proper AC input
voltages at the output side of the input contactor
(CR1). See Figure F.8.
WARNING
a. T1 to T2
b. T2 to T3
c. T1 to T3
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
• If the correct voltages are not present, perform
5. Turn the power switch (SW1) to the ON position.
DC-600
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F-23
F-23
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER VOLTAGE TEST (continued)
FIGURE F.9 – TRANSFORMER SECONDARIES
SECONDARY LEADS
COMMON BUSS
(6 PLACES)
PROCEDURE
NOTE: All of the secondary voltages will vary if the
input line voltages vary. If any one or more of the volt-
age checks are incorrect, check for loose or faulty con-
connections are OK, the main transformer may be
faulty.
9. Test with an AC voltmeter for approximately 55 VAC
from each of the six main transformer secondary
leads to the common bus connected to the output
choke. See Figure F.9.
FIGURE F.10 – AUXILIARY VOLTAGES
5
6
4
7
3
8
2
9
RECEPTACLE
1
10
DC-600
TS 2
21+ 21- 41
4
2
31 32
PROCEDURE
12. Test for 42 VAC between leads #41 and #2 on the
terminal strip. See Figure F.10. If the correct volt-
age is not present, make sure the 10 amp circuit
breaker is not tripped or faulty. Also check the
wiring between the main transformer, the terminal
10. Test for 120 VAC between leads #31 and #32 on
terminal strip TS-2. See Figure F.10. 120 VAC
should also be present at the receptacle. If the cor-
rect voltage is not present, make sure the 20 amp
circuit breaker is not tripped or faulty. Also check
the wiring between the main transformer, the termi-
nal strip, the circuit breaker and the receptacle. See
the Wiring Diagram.
DC-600
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F-24
F-24
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER VOLTAGE TEST (continued)
FIGURE F.11 – FIRING BOARD
J5
(205) 8
16 (204)
15 (203)
14
LED9 LED7
LED8
(206) 7
(207) 6
(208) 5
13 (231)
12 (215)
11
4
3
2
1
10
9
LED5
LED6
LED1
LED3
J6
LED10
J7
LED4
LED2
J8
J4
FIRING BOARD
G3742-[ ]
PROCEDURE
WARNING
Plug J5 pin-15 (lead #203) to pin-16 (lead #204)
Plug J5 pin-8 (lead #205) to pin-7 (lead #206)
Plug J5 pin-6 (lead #207) to pin-5 (lead #208)
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
18. If the correct primary voltages are applied to the
main transformer and any of the secondary volt-
ages are missing or not correct, the transformer
may be faulty.
13. Remove the input power to the DC-600. Remove
the screws from the control box cover and careful-
ly lower the cover and locate plug J5 on the Firing
Board. See Figure F.11.
NOTE: Always check the wiring between the trans-
former windings and the test points before replac-
ing the transformer.
14. Turn on the DC-600 and check for approximately
32 VAC at the following pins of plug J5. These are
the phase angle winding voltages. See Figure
F.11.
DC-600
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F-25
F-25
TROUBLESHOOTING AND REPAIR
CONTROL TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of the
control transformer and also if the correct voltage is being supplied by the secondary wind-
ing.
MATERIALS NEEDED
Misc. Hand Tools
Multimeter
Wiring Diagram or Machine Schematic
DC-600
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F-26
F-26
TROUBLESHOOTING AND REPAIR
CONTROL TRANSFORMER TEST (continued)
FIGURE F.12 - CONTROL TRANSFORMER
Control
Transformer
Secondary
Thermostat
H2, H3 or H4 (see Input Diagram)
Power
Switch
L3 T3
L2 T2
L1 T1
H1
PROCEDURE
3. Measure the voltage from X1 to X2. It should be
approximately 120VAC.
1. With the Input Power OFF, remove the case top,
right side panel and the input access door. The
Control Transformer is located on the back of the
Input Box. See Figure F.12.
4. If this reading is incorrect check the connections on
the Primary and Secondary lads. If OK, the trans-
former may be defective.
• The Primary Leads (black)are routed through the
Input Box and two of them (depending on input
voltage) are connected to L1 and L3 of the Input
Contactor. Any unused leads are to be insulated
and taped.
NOTE: Common causes of control transformer failure
are;
• Improper connection of the Primary leads.
• A defective (shorted) Input Contactor coil.
IMPORTANT
• The Secondary leads (red) are connected to the
Power Switch (X1) and the Secondary
Thermostat (X2).
Before installing a new transformer perform the
2. Connect the Input Power and make certain that
rated voltage is present at L1 and L3.
Carefully read and follow the Input Connection
instructions located on the Input Access Door
when installing the new transformer. If you do not
have those instructions, call The Lincoln Electric
Co. (1-888-935-3877) with the Code Number of the
DC-600 and the instructions can be faxed or e-
mailed to you.
NOTE: The DC-600 does not need be to turned ON.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
DC-600
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F-27
F-27
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in determining if the Input Contactor is defective.
MATERIALS NEEDED
Misc. Hand Tools
Multimeter
External 120VAC Supply
Wiring Diagram or Machine Schematic
DC-600
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F-28
F-28
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST (continued)
FIGURE F.13 – INPUT CONTACTOR
CR 1 Contactor
272
Coil Terminals
Apply External
120vac Here
L3 T3
L2 T2
L1 T1
271
Cover Plate Screws
PROCEDURE
VOLTAGE TEST
CONTACT TEST
1. Disconnect the input power and remove leads 271
and 272 from the CR1 coil terminals. See Figure
F.13.
1. Disconnect the input power and remove the Input
Access Panel from the rear of the machine
2. Remove the contactor cover plate, blow out any
dust or dirt with low pressure air.
2. Connect an AC voltmeter to the two coil terminals
of the Contactor See Figure F.13.
3. Examine the contacts for signs of arcing, sticking or
pitting. If any of these conditions exist, the
Contactor should be replaced.
3. Apply the 3 phase power to the DC-600 and turn
the Power Switch ON.
WARNING
4. With the cover back in place, apply an external
120VAC supply to the coil terminals and make sure
the Contactor activates and is not ‘noisy’. A noisy
contactor should be cleaned or replaced.
ELECTRIC SHOCK can kill.
NOTE: A noisy or shorted contactor can damage the
Control Transformer.
• Do not touch electrically hot parts.
5. With an ohmmeter, check across each set of con-
tacts for continuity (0 ⏐ ’s). See Figure F.13.
L1 t0 T1
4. If the meter shows 120vac and the Contactor does
not operate, it is defective.
L2 to T2
L3 to T3
5. If the 120VAC is not present at the coil:
If there is any resistance, replace the contactor.
• Check the Power Switch, Thermostats and asso-
ciated wiring. See the Wiring Diagram.
6. Remove the 120VAC supply and re-check the con-
tacts for an open condition. If any resistance is
measured, replace the contactor.
• Also check the Control Board LEDs to be certain
that the machine is not in a “shut down” condition.
• Check the CR 2 relay for proper operation.
DC-600
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F-29
F-29
TROUBLESHOOTING AND REPAIR
SCR BRIDGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in testing of the SCRs in the output rectifier assem-
bly by providing both a static and an active test for the devices.
MATERIALS NEEDED
Misc. Hand tools
Analog Multimeter
SCR Tester (Described in this procedure)
DC-600
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F-30
F-30
TROUBLESHOOTING AND REPAIR
SCR BRIDGE TEST(continued)
FIGURE F.14 – SCR BRIDGE ASSEMBLY
ANODE
CATHODE
REMOVE
INSULATING
PAINT
PROCEDURE
STATIC TEST
5. Using the analog ohmmeter:
1. Disconnect the input power from the DC-600.
• Measure the resistance from each Anode to the
Cathode plate with the Positive meter lead on the
Anodes. The resistance should be very high or
‘open’.
2. Remove the top and side panels and drop the
nameplate to access the PC Boards.
• Reverse the meter leads and measure all the
same points. The readings should be very high or
‘open’, and typically, will all be similar.
3. Unplug the Molex connectors from both the Control
Board and the Firing Board.
6. If any of the test points shows a low resistance, dis-
connect the Snubber Board from that SCR. If the
reading is still low, the SCR is defective.
4. Scratch off some of the insulating paint from each
of the six heat sinks (anodes) and the base plate
(cathode). See Figure F.14.
7. Continue to the Active Test.
The Active test will require constructing a test cir-
cuit or use of a commercial SCR Tester. See
DC-600
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F-31
F-31
TROUBLESHOOTING AND REPAIR
SCR BRIDGE TEST(continued)
FIGURE F.15 – ACTIVE SCR TEST
PROCEDURE
6. Close switch SW-2 for 2 seconds and release and
read the meter.
ACTIVE TEST
a. If the voltage is 3-6 volts while the switch is
closed and after the switch is open, the SCR is
functioning.
1. With the circuit shown in Figure F.17. One 6-volt
lantern battery can be used. Set the voltmeter
scale low, at approximately 0-5 volts or 0-10 volts.
b. If the voltage is 3-6 volts only when the switch
is closed or there is no voltage when the switch
is closed, the SCR is defective.
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.
NOTE: A low battery can affect the results of the test.
Repeat the battery test procedure in Step 1 if
needed.
7. Open switch SW-1.
a. Connect Tester lead (A) to the anode.
b. Connect Tester lead (C) to the cathode.
c. Connect Tester lead (G) to the gate.
a. Connect Tester lead (A) to the cathode.
b. Connect Tester lead (C) to the anode.
c. Disconnect Test lead (G) from the gate.
3. Close switch SW-1.
NOTE: Switch SW-2 should be open.
9. Close switch SW-1.
4. Check the meter for zero voltage.
a. If the voltage reading is higher than zero, the
SCR is shorted.
10. Read the meter for zero voltage.
a. If the voltage is zero, the SCR is functioning.
b. If the voltage is higher than zero, the SCR is
shorted.
b. If the reading is zero volts, continue to Step 6.
11. Repeat steps 2 through 10 for each SCR.
DC-600
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F-32
F-32
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT CURRENT MODE – NO LOAD
0 volts
50V
2ms
This is the typical DC open circuit
voltage waveform generated from a
properly operating machine. Note
that each vertical division represents
50 volts and that each horizontal divi-
sion represents 2 milliseconds in
time.
Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega-
tive high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
DC-600
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F-33
F-33
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
MAXIMUM OUTPUT SETTING – NO LOAD
0 volts
50V
2ms
This is the typical DC open circuit
voltage waveform generated from a
properly operating machine. Note
that each vertical division represents
50 volts and that each horizontal divi-
sion represents 2 milliseconds in
time.
Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega-
tive high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
DC-600
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F-34
F-34
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
MINIMUM OUTPUT SETTING – NO LOAD
0 volts
20V
2ms
This is the typical DC open circuit
voltage waveform generated from a
properly operating machine. Note
that each vertical division represents
20 volts and that each horizontal divi-
sion represents 2 milliseconds in
time.
Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega-
tive high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
DC-600
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F-35
F-35
TROUBLESHOOTING AND REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
CONSTANT VOLTAGE INNERSHIELD MODE
0 volts
20V
2ms
This is the typical DC open circuit
voltage waveform generated from a
properly operating machine. Note
that each vertical division represents
20 volts and that each horizontal divi-
sion represents 2 milliseconds in
time. The machine was loaded with a
resistance grid bank. The grid bank
meters read 650 amps at 44 VDC.
Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega-
tive high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
DC-600
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F-36
F-36
TROUBLESHOOTING AND REPAIR
TYPICAL SCR GATE VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
MAXIMUM OUTPUT SETTING – NO LOAD
0 volts
2 V
5ms
This is the typical DC open circuit
voltage waveform. The machine was
in an open circuit condition (no load)
and operating properly. Note that
each vertical division represents 2
volts and that each horizontal division
represents 5 milliseconds in time.
Note: Scope probes connected at
SCR gate and cathode: (+) probe to
gate, (-) probe to cathode.
SCOPE SETTINGS
Volts/Div.......................2V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
DC-600
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F-37
F-37
TROUBLESHOOTING AND REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
ONE OUTPUT SCR NOT FUNCTIONING
0 volts
20V
2ms
This is NOT the typical DC open cir-
cuit voltage waveform. One output
SCR is not functioning. Note the
“gap” in the waveform. One SCR
gate is disconnected to simulate an
open or non-functioning output SCR.
Each vertical division represents 20
volts and each horizontal division rep-
resents 2 milliseconds in time.
Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega-
tive high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
DC-600
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F-38
F-38
NOTES
DC-600
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F-39
F-39
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The following procedure will aid the technician in inspecting, cleaning, and replacing the
input contactor.
MATERIALS NEEDED
Misc. Hand Tools
Low Pressure Air Supply
Wiring Diagram
DC-600
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F-40
F-40
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR CLEANING/REPLACEMENT PROCEDURE (continued)
FIGURE F.16 – CONTACTOR
CR 1 Contactor
272
Coil Terminals
Apply External
120vac Here
L3 T3
L2 T2
L1 T1
271
Cover Plate Screws
CLEANING PROCEDURE
CONTACTOR REPLACEMENT
PROCEDURE
1. Remove the main input supply power to the
machine.
1. Disconnect main input supply power to the
machine.
2. Locate and get access to the input contactor (CR1)
2. Locate and get access to the input contactor (CR1)
3. Remove the input contactor cover plate using a
phillips head screwdriver.
3. Disconnect the main input supply power leads L1,
L2, and L3 to the input contactor.
WARNING
Remove the control transformer primary leads H1,
H2 or H3 (dependent on input voltage) from the L1
and L3 terminals on the input side of the contactor.
Do not apply input power to the
machine with the input contactor
cover plate removed.
4. Disconnect the output leads T1, T2, and T3 from
the input contactor.
5. Identify and label the leads connected to the input
contactor coil. See the Wiring Diagram.
4. Blow out any dirt or dust in or around the contacts
with a low pressure air stream.
6. Disconnect the leads from the input contactor coil
5. Inspect the contacts for signs of excessive wear,
pitting, or contacts fused (stuck) together.
7. Remove the three self-tapping mounting screws
using a 5/16” socket wrench.
a. If any of these conditions are present, replace
the input contactor assembly.
8. Remove the input contactor.
NOTE: Lincoln does not supply contactor parts. They
9. Insert the replacement input contactor and install it
following the procedures in reverse order.
may be available through the manufacturer.
6. Replace the input contactor cover plate.
NOTE: Be sure to reconnect all leads correctly.
DC-600
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F-41
F-41
TROUBLESHOOTING AND REPAIR
SCR RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the SCR Rectifier
Assembly.
MATERIALS NEEDED
Misc, Hand Tools
Wiring Diagram
NOTE: If the Transformer and Rectifer both need to be replaced, perform the
Transformer Removal and Replacement Procedure first to provide easier
access to the rectifier assembly
DC-600
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F-42
F-42
TROUBLESHOOTING AND REPAIR
SCR RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT PROCEDURE (cont.)
FIGURE F.17 – RECTIFIER ASSEMBLY
TO LEFT SIDE
OF CHOKE
OUTPUT
SNUBBER
A
LEFT SIDE
OF CHOKE
SECONDARY
LEAD (6 PLACES)
MOUNTING
BOLTS (4)
GATE LEAD
CONNECTOR
A
A
A
215
BUSHING
210
"A" LEAD, WHITE
OUTPUT
SHUNT
(6 PLACES)
CONNECTION
STRAP
"C" LEAD, RED
(6 PLACES)
REMOVAL PROCEDURE
5. Disconnect the #210(2) and #215(5) leads from the
Shunt, noting their positioning for proper reassem-
bly. See Figure F.17.
1. Remove the input power to the DC-600.
2. Remove the case sides and top and lower the
nameplate.
6. Unbolt the Shunt from the Connection Strap at the
Positive Output Stud. See Figure F.17.
NOTE: Before removing the Rectifier Assembly pay
particular attention to the original place-
ment and location of the electrical connec-
tions to assure proper reassembly. Tag any
leads where the Lincoln lead number is not
evident.
7. Remove the four (4) mounting bolts, noting the
placement of the insulators and hardware for prop-
er reassembly.
8. Remove the rectifier assembly from the machine.
Loosening the Choke mountings will increase the
flexibility of the bracket and make it easier to
remove the rectifier.
3. Disconect J4 from the firing PC Board and push it
and the plastic bushing through the bottom of the
control box.
NOTE: Lincoln Electric does not recommend
replacement of individual SCRs. In the event
of a failure, the entire assembly should be
replaced.
4. Disconnect the Output Snubber lead from the left
side of the Choke and remove the Output Snubber
from the left side rectifier mounting bracket. See
Figure F.17.
DC-600
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F-43
F-43
TROUBLESHOOTING AND REPAIR
SCR RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT PROCEDURE (cont.)
FIGURE F.18 – RECTIFIER REPLACEMENT
Negative Output Lead
Output Snubber Lead
5/16-18 Hex Nut
Choke Lead
Lock Washer
3/8-16 Hex Nut
Thread Forming Screw
Plain Washer
Insulator
Plain Washer
Lock Washer
Transformer
Secondary Lead
‘A’ Lead from
Snubber
Bridge Mounting
Bracket
Insulator
Insulator
Rectifer Mounting
Bracket
Heat Sink
3/8-16 x 1 Cap Screw
Plain Washers (2)
Fig. 18 ‘A’
Fig. 18 ‘B’
Fig 18 ‘C’
A
OUTPUT
SNUBBER
CONNECTION
SECONDARY
LEAD CONNECTION
(6 PLACES)
MOUNTING
BOLTS (4)
A
A
A
215
210
OUTPUT
SHUNT
CONNECTION
STRAP
REPLACEMENT PROCEDURE
4. Reconnect the transformer secondary and snubber
‘A’ leads to the assembly. See Figure F.18’B’.
NOTE: Any instructions packaged with the replace-
ment SCR Bridge assembly will supercede
these instructions.
5. Mount the Output Snubber to the left side bracket
and connect the lead to the Choke. See Figure
F.18’C’.
1. Use steel wool or Scotch-Brite to provide a bright,
clean,smooth paint-free surface for connection of
the leads. Clean the surfaces of the heat sink as
well as those of the leads. Wipe away any abrasive
material with a clean cloth.
NOTE: Torque all bolts for the following minimum
settings:
1/4” bolts
5/16” bolts
3/8” bolts
1/2” bolts
6 ft/lbs.
11 ft/lbs.
19 ft/lbs.
45 ft/lbs.
2. Apply a thin coating of joint compound (provided
with new assembly)to all of the heatsink areas
where leads will be connected.
3. Carefully mount the SCR assembly into the DC-
600 using the original hardware or the hardware
provided with the new assembly. See Figure
F.18’A’.
6. Bolt the shunt to the Positive Output Stud connec-
tion strap and connect the # 210 and #215 leads as
they were on the original assembly.
NOTE: A new rectifier assembly will have mounting
brackets with both 1/2” holes and 3/8” holes
to allow for proper mounting in all units.The
spare insulating tubes and washers are for
use in older machines.
NOTE: It is important that the current feedback
leads(twisted pair) and the meter leads are
connected across the shunt and the other
215 leads connected near the top of the
shunt assembly. See Figure F.18.
DC-600
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F-44
F-44
NOTES
DC-600
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F-45
F-45
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER AND CHOKE
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Main
Transformer and Output Choke.
MATERIALS NEEDED
Misc. Hand Tools
Crane or Hoist
Wiring Diagram
DC-600
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F-46
F-46
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER AND CHOKE
REMOVAL AND REPLACEMENT (continued)
FIGURE F.19 – TRANSFORMER REMOVAL
INPUT
ACCESS
COVER
NEGATIVE
OUTPUT LEAD
A
OUTPUT
CHOKE
AUXILIARY
LEADS
CONTROL
PANEL
SECONDARY
LEAD (6 PLACES)
FIRING BOARD
CONNECTORS
(J-4 & J-5)
A
A
A
215
210
OUTPUT
SHUNT
CONNECTION
STRAP
MOUNTING
HARDWARE
(4 PLACES)
SECONDARY
THERMOSTAT
30 Ω
RESISTOR
BAFFLES
PRIMARY
LEADS
NOTE: Cut ties and remove sleeving as necessary
to perform the following steps. Note the
positioning for reassembly.
REMOVAL PROCEDURE
1. Disconnect all input power and remove the case top,
sides, terminal strip cover and the input access cover
and drop the Control Panel.
6. Disconnect leads #271 and #272 from th e Contactor
coil and pull them through the back of the Input Box.
2. Remove the fiber baffles that are around the Choke
and Transformer and save for installation when the
new transformer is installed.
7. Disconnect the leads from the Secondary
Thermostat and separate the X2 lead from te #256
lead.
3. Disconnect the Transformer Primary leads from the
reconnect panel.
8. Pull the three leads from Step 4 and the #271 lead-
towards the Control Box.
NOTE: Pay close attention to the positioning of the
brass and steel hex nuts for reassembly.
9. Disconnect the #41, #2, and #4 leads from the
Terminal Strip and separate the “piggy-back” con-
nections.
4. Pull the leads out of the Input Box. This will require
removing some of the RTV sealant from the inside of
the box.
10. Separate the three in-line connectors between J5
of the Firing Board and J2 of the Control Board
(Leads 231, 290, & 291).
NOTE: Tag any leads where the Lincoln lead num-
bers are not evident to facilitate reassembly.
11. Unplug J5 and J4 from the Firing Board and work
them through the bottom of the Control Box. It will
be necessary to remove the grommet with the J4
connector. (A new grommet is provided with the
replacement transformer).
5. Cut off the crimp connectors from the fan leads
(#31 A) and lead #41 and #42A. Tag any leads
where the Lincoln lead number is not evident.
DC-600
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F-47
F-47
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER AND CHOKE
REMOVAL AND REPLACEMENT (continued)
FIGURE F.20 – TRANSFORMER REMOVAL
Negative Output Lead
Output Snubber Lead
5/16-18 Hex Nut
Choke Lead
Lock Washer
3/8-16 Hex Nut
Thread Forming Screw
Plain Washer
Plain Washer
Lock Washer
Transformer
Secondary Lead
Insulator
‘A’ Lead from
Snubber
Bridge Mounting
Bracket
Insulator
Insulator
Rectifer Mounting
Bracket
Heat Sink
3/8-16 x 1 Cap Screw
Plain Washers (2)
A
OUTPUT
SNUBBER
CONNECTION
SECONDARY
LEAD CONNECTION
(6 PLACES)
TIG WELDED
CHOKE
CONNECTION
RECTIFIER
MOUNTING
(4 Places)
CHOKE
MOUNTING
(4 Places)
A
A
LIFT BALE
MOUNTING
(4 Places)
17. Carefully lift the entire assembly out of the
machine and move it to a work bench or other
area where it can be safely disassembled.
REMOVAL PROCEDURE (cont.)
12. Disconnect the five (5) #215 and the two(2) #210
leads from the Shunt, noting their positions for
reassembly. .
this procedure is already done. Save the hardware
and insulators for reassembly.
NOTE: It is important that the twisted pair (feed-
back leads) and the meter leads be recon-
nected correctly to the Shunt.
19. Carefully grind the welds from the right hand
choke connection to separate the common sec-
ondary strap from the choke. Do not cut the choke
lead or reduce it’s size any more than necessary.
See Figure F.20.
13. Disconnect the four(4) #222 leads from the
Negative Output lead and the two leads from the
30 ⏐ resistor.
14. Unbolt the Output Shunt from the Connection
Strap at the Positive Output Stud and the Negative
Output Lead from the Negative Output Stud.
20. Remove the mounting hardware (4 places) that
holds the choke to the top of the transformer. Note
the hardware placement for reasembly. See Figure
F.20.
15. Attach a hoist to the lift bale with very slight ten-
sion to provide support during the following Steps.
21. Remove the 4 bolts holding the lift bale assembly
to the transformer and lift it off and remove the
choke.
16. Remove the mounting hardware (4 places) that
holds the transformer/choke assembly to the base.
Note the sequence of the washers for reassembly.
See Figure F.20
NOTE: The hole in the lift bale assembly is to
allow access to the mounting bolts with a
socket and extension.
DC-600
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F-48
F-48
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER AND CHOKE
REMOVAL AND REPLACEMENT (continued)
FIGURE F.21 – CHOKE TIG WELD
WELD
XXXXXXXXXXX
W
W
REPLACEMENT PROCEDURE
5. Connect the transformer secondary and snubber
1. Place the flat washers and the choke on top of the
transformer and the lift bale assembly over both.
proper assembly. Torque all bolts per the following:
2. Install the four thread cutting bolts that mount the
lift bale to the transformer and then replace the
choke mounting hardware that was removed in
Step 20 of the removal procedure. See Figure F.20.
1/4” bolts
5/16” bolts
3/8” bolts
1/2” bolts
6 ft/lbs.
11 ft/lbs.
19 ft/lbs.
45 ft/lbs.
NOTE: Cover the transformer assembly with
‘damp’ shop cloths before performing Step
3 to prevent weld spatter from damaging
the transformer.
6. Using the hoist, place the transformer/lift bale
assembly over the mounting bolts in the base and
replace the hardware removed in Step 21 of the
removal procedure.
3. Thouroughly clean the choke lead and the sec-
ondary lead and TIG weld along the two edges.
The welds must be at least as long as the widths of
the two pieces See Figure F.21.
7. Carefully back track through the removal procedure,
re-routing and re-connecting the leads that were
cut, removed or separated using proper electrical
techniques and insulating where required.
4. Mount the SCR Bridge assembly using the hard-
ware and insulators removed in Step 18 of the
removal procedure. See Figure F.18.
8. Replace the baffles and any sleeving, cable ties or
sealants that were removed during the disassembly
procedure.
DC-600
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F-49
F-49
TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could
affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the
machine must be retested.
INPUT IDLE AMPS AND WATTS
Input volts/Phase/Hertz
208/3/60
Maximum Idle Amps
Maximum Idle KW
11.0
10.0
6.0
5.5
5.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
230/3/60
380/3/60
416/3/60
460/3/60
550/3/60
575/3/60
4.2.
4.0
200/3/50
220/3/50
230/3/50
380/3/50
400/3/50
415/3/50
440/3/50
500/3/50
550/3/50
21.0
19.1
18.3
11.0
10.5
10.1
9.6
1.3
1.3
1.3
1.3
1.3
1.3
1.3
1.3
1.3
8.4
7.7
MAXIMUM OPEN CIRCUIT VOLTAGES
Mode
Input Hertz
Open Circuit Volts
CC Stick
60
66/70
CV MIG
60
60
60
44/47
Auxiliary Output (#31-#32)
Auxiliary Output (#41-#42)
122/128 VAC
44/48 VAC
MINIMUM ACCEPTABLE OUTPUT VOLTAGE - AT MAXIMUM OUTPUT SETTINGS
Mode
CC Stick
Control Settings
Output Control at Maximum
Arc Force Control at
Minimum
Load
815 Amps @ 44.0 Volts (Min)
CV MIG
Output Control at Maximum
815 Amps @ 44.0 Volts (Min)
5 Amps @ 120/126 VAC (Min)
5 Amps #41/45 VAC (Min)
Auxiliary Output (#31-#32)
Auxiliary Output (#41-#42)
N/A
N/A
DC-600
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F-50
F-50
NOTES
DC-600
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram (G3506) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram - 230/460/575 Volt Machines (G3506-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Schematic – Complete Machine (G3575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Schematic – Control PC Board (G3408) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Control PC Board Assembly (G3409-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Schematic – Firing PC Board (G3741) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered
and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.
DC-600
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - G3506
0 6 3 5 G
E
NGINEERING CONTROLLED
CHANGE
DETAIL:
REVISED G
RAPHI
CS FOR RECONNECT PA
NEL.
MANUFACTURER: No
S
INGLE VOLTAGE OVER 345 V.
TO
SUPPLY
INES
DUPLE
32
X
(
ON 60
H
Z. MACHINES O
N
LY)
(EXCEPT 440 & 460V.)
H3
H1
272
42
32
31
GND
L
CIRCUIT
BREAKE
TO GROUND
PER NATIONA
ELECTRICA
CODE
41
15A
OUTPUT
TE M.
R
L
A
J
31
3
2
9
8
7
6
5
R
L
I
B
T.S.2
W
ELDIN
G
MODE
32A
L3
S
WITCH
236
R1
10K 2
OUTPUT
CONTROL
K
32
31
S
WITCH S4
21
S2
2
L2
L1
(SHOWN IN CC
STI
L
H
C
N
1
4
RECONNECT
PANEL
4
75
237
CK POSITION)
W
M
R.F.
CHOKE
AS'BLY
D
G
CR1
INPU
CON ACTOR
4
42
42
2
TO PRI
MARY COILS
T
E
F
271
2
N.C.
2
4
T
75
14 PI
N
76
77
81
80
DUAL EXCEPT 380/500V AND
IN LE VOLTAGE UNDER 3 6V
4
TO
SUPPLY
INES
H2
H1
272
S
G
4
.
RECEPT.
(FRONT
LOCAL/
76
77
(SHOWN CONNECTED FOR LOW VOLTAGE)
41
REMOTE
L
41
41
226
232
215
S
WITCH
-
VIEW
)
21
222
210
S3
TO GROUND
PER NATIONA
ELECTRICA
CODE
3
2
1
9
8
7
6
5
222
210
-
+
L
VM
21
L3
H1
X1
H3
H2
L
CONTROL
TRANSFORMER
237
76
236
280
229
L2
L1
T2
4
224
RECONNECT
PANEL
238
CR1
INPU
CON ACTOR
X2
TO PRIMARY COILS
255
T
271
FA
ULT
S1
T
INPUT
PROTE
CTIO
N
R.F.
255
75
77
POWER
380/500V. & 460/575V
.
CHOKE
AS'BLY
R
ELAY
CR2
255
SWITCH
(SHOWN CONNECTED
FOR LOW VOLTAGE)
NO
T.S.1
TO
H2
H1
272
271
256
SUPPLY
NC
COM
L
INES
PILOT
LIGHT
TO GROUND
W
235
PER NATIONA
ELECTRICA
CODE
L
233
256
229
75
232
80
226
81
3
2
1
CIRCUIT
BREAKE
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
15
14
13
L
L3
10A
233
R
T1
MAI
N
T
RANSFORMER
42
L2
L1
RECONNECT
PANEL
PRIMARY
256
231
255
290
291
238
235
J2
J3
THERMOSTAT
273
272
CR1
TO PRIMARY COILS
INPU
T
271
J1
3
1
2
42A
S
32A
S
S
CON
T
ACTOR
SEC. LEAD
31
280
42V
220/380/440 VOLT
69V
N
.A.
THERMOSTAT
H2
H1
31
69V
F
15
TO
13
PRI.
14
T
WISTE
D
F
F
SUPPLY
06/02/
2005
41
TOGETHER
10
215
224
222
272
207
F
R.F.
TO GROUND
F
S
11
12
F
S
210
215
34V
1
2
34V
PER NATIONA
ELECTRICA
CODE
L
LEADS 4
THRU 9 TO
RECONNECT
PANEL
6
9
CHOKE
AS'BLY
34V
S
4
7
5
AUX. 1
8
3
2
1
6
11
10
12
9
L
FAN
MOTOR
L3
204
206
205
208
8
7
5
4
32A
CONTROL
R
.F.
RECONNECT
PANEL SHOWN
CONNECTED
FOR 380V.)
L2
L1
203
P.
C. BOARD
(
CHOKE
AS'BLY
PRI.
N
.B.
N
.B.
CR1
TO PRIMARY COILS
271
INPU
T
R2
30 OHM
214
12
11
10
CON
T
ACTOR
222
222
(-)
41
2
208
207
206
205
4
290
291
215
231
214
203
204
G1
1
2
3
4
5
6
1
2
3
4
5
SIN
GLE VOLTAGE 440V & 460V
06/
222
H3
H1
G2
G3
G4
G5
G6
100
W
02/
200
5
J4
3
2
1
L3
L2
L1
TO
SUPPLY
INES
SEC.
222
6
L
J5
7
1
2
3
4
5
6
7
8
A
B
8
9
320V
160
TO GROUND
CR1
INPU
.05
mFd
J
PER NATIONA
L
271
272
T
ELECTRICA
CODE
L
10
11
12
13
14
15
16
CON
T
ACTOR
SEC.
B'
C
C'
.05
mFd
J7
OUTPUT
CHOKE
320V
160
NOTES:
.A. LEA
C7
J
N
D
S 4 THRU 9 A
R
E
NOT PRESENT ON
460V., 380/500V. & 460/575V. MACHINES.
A'
N.D.
N.B.
T
HERE IS
ON 220/380/440 VOL
LO ATIO F T IS LEA
AY VARY. SEE IM MANUAL FOR LO
WELDIN ABLE MUST BE OF T E P
APA ITY FO CURRENT AND DUTY CYCLE
F IMMEDIATE AND UTURE APPLI ATIO S.
IS DIAGRAM SHOWS THE "STICK" POLA
"POSITIVE". TO CHANGE T E POLA ITY, URN
TH DC-600 OFF, AND REVE SE T E LEA S AT
THE M LTI-PROCESS SWITCH.
USI G A WI E FEEDER, K-317 O
CONNECTION DIAGRAM, CONNECT ELECTRODE
AND ORK LEA S TO T ESE TE MI ALS
INSTEA F T E POWER SOURCE
OUTP T TE MI ALS.
N
O 10, 11 AND 12 CONNECTIO
MACHINES.
T.S.2 TE
N
210
T
P22
N.C
.
C
N
O
H
D
O
N
R
MI
NAL STRIP
1
2
3
4
261
262
263
342
1
2
3
4
J6
CIRCUIT
AM
-
M
CATION.
210
(+)
+
G1
SCR
SNUBBERS
G5
G3
N.D
.
G
C
H
ROPE
R
A
A
A
FIRIN
G
C
O
C
R
THE
P.
C
. BOARD
210
215
F
C
N
2
SCR
3
SCR
5
J
23
SCR
1
+
-
N.E.
T
H
RITY
FOR OPTIONAL
ALLELING
4
320V
160J
PA
R
H
R
T
210
215
TP
1
KIT
E
R
H
D
O
UT
PUT
S
HUNT
U
(5 MV @800 AMPS)
0
C1
.05mF
C
C
C
N.F.
N
R
R
K-318
d
OUTPUT
600
V
W
D
H
R
N
SNUBBE
R
215
.F.
C
C
C
D
O
H
U
R
N
THESE NOTES APPLY O
MULTI-PROCESS SWITCH INSTALLED.
NLY TO DC-600 WITH
A
T
O STI
C
K ELECTROD
E
H
OLDER
OR
SCR
6
SCR
4
SCR
2
WORK
+
AIR-CARBO
N
A
RC TORCH
J6
J4
J7
J3
N
.E.
N.D.
N.D.,
N
1
1
2
1
3
6
1
5
4
8
ELECTRODE
T
O "WORK"
U
SE
D
WITH
STICK
A
A
A
G2
G6
G4
-
OR AIR-CARBO
N
A
RC
3
4
4
2
OUTP
U
T
RECTIFIER
M
J1
J5
J2
OPTIO
THOSE SIT
NECESSA
ABLES FOR STI
ELDING.
N
AL
U
SE
R
S
N
H
U
PPLIE
D
J
UMPE
R FOR
1
7
1
1
5
8
ASSE BLY
STI
SE
SED.
C
D
K WORK LEAD NOT
UATIO
S WHERE IT IS NOT
AVE SEPA ATE GROUND
K AND SEMI-AUTOMATI
U
U
W
HEN UMPE IS
J
R
OPTIONAL
LTI-PROCESS
R
Y TO
R
MU
8
6
10
8
16
14
C
W
C
C
SWITCH
CONNECT
O
R
CAVITY
COMP
NUMBERIN
G
SE
Q
UE
NCE
(VIEWE FRO
D
M
ONENT SIDE OF
BOARD)
E
ELECTRICAL SYMBOLS PER E1537
G3506PRINT
R
CLEVELAND, OHIO U.S.A.
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
CONTROL: CLEVELAND
SCA E:
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
MANUFACTURING TO
L
ERANC
E
P
ER E2056
L
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
SUBJECT:
MA ERIAL
M
ENT TYPE:
1
1
DOCUMEN
DC-600
IRING DIAGRAM
PAGE ___ OF ___
T
ON
ON
ON
2
3
PLAC
PLACE
LL ANGL
TO
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
.02 in.
(
0.5 mm)
NONE
DRAWN BY:
ENGINEER:
APPROVED:
d
di
e
tz
D
E
.
00
A
2
i
n.
GREE
GREE
(
0.
0
5
mm)
T
DOCUMEN
NUMBER:
IF PRIN
T
ED
A
E
L
S
I
S
DE
REVISION:
W
4/25/2008
@
A
1
SIZ
E
MATERI
A
L
E
"
)
TO
A
t
UNITS:
WITH PU
B
LISHED STANDARDS.
REFERENCE:
T
APPROVA
L
PROJEC
T
G3506
UF
E
CRM38710
-
DISPOSI ION:
T
DATE:
NUMBER:
INCH
DO NO
T
SCAL HIS DR
E
T
A
WING
-
Insight
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-3
G-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - 230/460/575 VOLT MACHINES - G3506-1
1 - 0 6 3 5 G
E
NGI
NEERING CONTROLLE
D
CHANGE
DETAIL:
REVISED GRAPHICS FOR CR2.
MANUFACTURER: No
230/460/575V
(SHOWN CONNECTED
FOR LOW VOLTAGE)
H4
DUPLEX RECEPTACLE TO BE WIRED AS
SHOWN FOR ALL CODES EXCEPT 10663.
DUPLE
32
X
(
ON 60
H
Z
MACHINES ONLY)
N.G.
42
32
H3
H2
H1
31
GND
TO
SUPPLY
INES
CIRCUIT
BREAKE
41
L
15A
OUTPUT
TE M.
272
R
T.S.2
A
J
GFCI RECEPTACLE FOR CODE 10663 TO
HAVE LEAD 31 CONNECTED TO THE
31
R
I
B
W
ELDIN
G
MODE
32A
TO GROUND
PER NATIONA
S
WITCH
9
3
8
236
R1
10K 2
OUTPUT
CONTROL
K
32
31
S
WITCH S4
L
21
S2
2
WHITE LINE. LEAD 32 TO BE CONNECTED
TO THE HOT LINE.
L3
6
5
ELECTRICA
L
(SHOWN IN CC
STI
L
H
C
N
CODE
4
75
237
2
4
7
CK POSITION)
L2
L1
W
R.F.
M
D
G
RECONNECT
PANEL
4
CHOKE
AS'BLY
1
2
42
42
E
F
2
N.C.
2
4
CR1
INPU
CON ACTOR
TO PRI
MARY CO
I
LS
T
271
75
14 PI
N
76
77
81
80
T
4
RECEPT.
(FRONT
LOCAL/
76
77
41
REMOTE
41
18,17,16
N.G.
15,14,13
N.G.
41
226
232
215
S
WITCH
-
VIEW
)
21
222
210
S3
222
210
-
+
VM
21
H1
X1
H3
T2
H2
CONTROL
TRANSFORMER
237
76
236
280
229
224
238
X2
255
FA
ULT
S1
INPUT
PROTE
CTIO
N
75
77
255
POWER
R.F.
R
ELAY
CR2
S
WITCH
NO
CHOKE
AS'BLY
T.S.1
271
256
255
235
NC
COM
PILOT
LIGHT
W
233
256
229
75
232
80
226
81
CIRCUIT
BREAKE
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
12
10A
233
256
R
T1
MAI
N
T
RANSFORMER
42
PRIMARY
THERMOSTAT
231
255
290
291
238
235
J2
J3
272
273
J1
17
S
18
3
16
42A
32A
S
SEC. LEAD
31
42
41
V
S
F
280
69 V
F
N.G.
THERMOSTAT
69 V
31
2
1
PRI.
T
WISTED
F
10
215
224
222
TOGETHER
207
F
F
S
F
R
.F.
210
215
1
2
34 V
34 V
34 V
6
ALL P
LEA S TO
RECONNECT
PA EL
RIMARY
4
5
S
CHOKE
AS'BLY
S
FA
MOTOR
N
D
15
13
204
206
205
208
32A
CONTROL
R
.F.
14
8
203
N
P.
C. BOARD
CHOKE
AS'BLY
7
9
PRI.
R2
30 100
214
222
222
(-)
W
41
2
208
207
206
205
4
290
291
215
231
214
203
204
G1
1
2
3
4
5
6
1
2
3
4
5
222
222
G2
G3
G4
G5
G6
J4
SEC.
6
J5
7
1
2
3
4
5
6
7
8
A
B
8
9
320V
160
.05
J
mFd
10
11
12
13
14
15
16
SEC.
B'
C
C'
.05
mFd
J7
OUTPUT
CHOKE
320V
160
C7
J
NOTES:
N.C LO
.
C
ATIO
N
O
F T
H
IS LEA
D
O
N
T.S.2 TE
R
MI
ATION.
OPE
CURRENT AND DUTY CYCLE
UTURE APPLI ATIO S.
IS DIAGRAM SHOWS THE "STICK" POLA
"POSITIVE". TO CHANGE T E POLA ITY, URN
TH DC-600 OFF, AND REVE SE T E LEA S AT
THE M LTI-PROCESS SWITCH.
SI G A WI E FEEDER, K-317 O
CONNECTION DIAGRAM, CONNECT ELECTRODE
AND ORK LEA S TO T ESE TE MI ALS
INSTEA F T E POWER SOURCE
OUTP T TE MI
N
AL ST
RIP
A'
N.D.
M
AY VARY. SEE IM MANUAL FOR LO
WELDIN ABLE MUST BE OF T E P
APA ITY FO
F IMMEDIATE AND
C
210
N.D.
G
C
H
R
R
P22
C
O
C
R
THE
1
2
3
4
261
262
263
342
1
2
3
4
J6
CIRCUIT
AM
-
F
C
N
210
(+)
+
G1
G5
SCR
SNUBBERS
G3
N.E.
T
H
RITY
A
A
A
FIRIN
G
H
R
H
T
D
P.
C
. BOARD
210
215
E
R
2
SCR
3
SCR
5
J
23
SCR
1
+
-
U
N
FOR OPTIONAL
ALLELING
4
320V
160J
PA
R
N.F.
U
R
R
K-318
210
215
TP
1
KIT
O
UTPUT SHUNT
W
D
H
R
N
C1
.05mFD
(50MV @800 AMPS)
C
C
D
O
H
N
C
U
R
ALS.
OUTPUT
600
V
N
.G. TAPE P SEPA
LEAST 600V INSULATION.
U
R
ATELY TO PROVIDE AT
SNUBBE
R
C
C
C
215
THESE NOTES APPLY O
NLY TO DC-600 WITH
A
MULTI-PROCESS SWITCH INSTALLED.
SCR
6
SCR
4
SCR
2
T
O STI
C
K ELECTROD
E
H
OLDER
OR
WORK
+
J6
J4
J7
J3
AIR-CARBO
N
A
RC TORCH
1
1
2
1
3
6
1
5
4
8
N
.E.
N.D.
N.D.,
N.F.
A
A
A
ELECTRODE
G2
G6
G4
T
O "WORK"
USE
D
WIT
H
STICK
3
4
4
-
2
OR AIR-CARBO
N
A
RC
OUTPUT
RECTIFIER
J1
J5
J2
1
7
1
1
5
8
ASSE BLY
M
OPTIO
THOSE SIT
NECESSA
ABLES FOR STI
ELDING.
N
AL
U
U
SE
ATIO
Y TO
R
S
N
H
U
PPLIE
D
J
UMPE
R FOR
STI
SE
SED.
CK WORK LEAD NOT
S WHERE IT IS NOT
AVE SEPA ATE GROUND
K AND SEMI-AUTOMATI
U
D
W
HEN UMPE IS
J
R
OPTIONAL
R
R
8
6
10
8
16
14
U
M
ULTI-PROCESS
C
C
C
CONNECT
O
R
CAVITY
COMP
N
UMBERIN
G
SE
Q
UENCE
SWITCH
W
(VIEWE FRO
D
M
ONENT SIDE OF
BOARD)
E
ELECTRICAL SYMBOLS PER E1537
G3506-1PRINT
R
CLEVELAND, OHIO U.S.A.
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
CONTROL: CLEVELAND
SCA E:
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
MANUFACTURING TO
L
ERANC
E
P
ER E2056
L
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
SUBJECT:
MA ERIAL
M
ENT TYPE:
1
1
DOCUMEN
DC-600
DIAGRAM (230/460/575)
REFERENCE:
PAGE ___ OF ___
T
ON
ON
ON
2
3
PLAC
PLACE
LL ANGL
TO
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
.02 in.
(
0.5 mm)
NONE
DRAWN BY:
ENGINEER:
APPROVED:
d
di
e
tz
D
E
.
00
A
2
i
n.
GREE
GREE
(
0.
0
5
mm)
T
DOCUMEN
NUMBER:
IF PRIN
T
ED
A
E
L
S
I
S
DE
REVISION:
W
IRING
@
A
1
SIZ
E
MATERI
A
L
E
"
)
TO
A
t
UNITS:
WITH PU
B
LISHED STANDARDS.
T
APPROVA
DA E:
L
PROJEC
T
G3506-
1
UF
3/20/2008
E
CRM36965
-
DISPOSI ION:
T
T
NUMBER:
INCH
DO NO
T
SCAL HIS DR
E
T
A
WING
G3506
Insight
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - G3575
Printed by John Howell
Printed at 10:20 on 08/15/2008 (month/day/year)
Drawing Number- G3575
Revision- 12-17-99
Status- STANDARD
This print is Current
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD - G3408-1
Printed by John Howell
Printed at 10:22 on 08/15/2008 (month/day/year)
Drawing Number- G3408-1C1
Revision- 11-30-2001E
Status- STANDARD
This print is Current
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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G-6
G-6
ELECTRICAL DIAGRAMS
CONTROL PC BOARD ASSEMBLY - G3409-1
1 9 - 4 3 0 G
E
NGI
NEERING CONTROLLED
CHANGE
DETAIL:
REVISED
C2 TH
RU
C4
IT
E
M
R
EQ'D
1
P
AR
T
NO
.
IDENTIFICATION
MANUFACTURER: No
C1
S13490-48
T11577-38K
S13490-39
T11577-26
S13490-12
T11577-32
S16668-5
47/160
C2,C3,C4
3
2
.02/600
18/15
N.C.
C5,C14
C6,C18
2
.1/100
10/25
N.D.
C7
1
C8
1
.01/200
C9,C21,C22,C23,C24,C26,C27,
11
.022/50
C28,C29,C31,C35
C12
C13
C16
C17
C19
C20
1
1
S13490-25
S13490-63
4.7/35
.47/50
1
S13490-10
2
.047/100
6/150
.022/200
1
1
1
S13490-61
S13490-4
S13490-40
2.7/5
0
C25
C30
1
1
S13490-67
S13490-19
T11577-58
S16668-3
T12199-2
2/50
1.8/2
0
C32,C33
2
.0047/3000V
00pF/10
R1
C34
1
10
1
0
R2
D1,D2,D3,D4,D7,D9,D10,D19,
D20,D21
1N4007
D5,D11,D12,D13,D14,D15,D16,
D17,D18,D22,D23,D25,
D26,D28,D29,D30,D31,D32,
D33,D34,D35,D36,D37,D38,
D40,D41,D42,D43,D44,D45,D46
D47,D48
33
T12199-1
1N4004
R113
R153
S
CR1
C22
DZ1
1
2
1
1
1
T12702-42
T12702-33
T12702-27
T12702-29
T12702-19
1N5353 ZENER DIODE
1N5347B
DZ2,DZ16
DZ4
1N4740A ZENER DIODE
1N4744A
D
Z5
Z7
D
1N4742A
D
D
Z9,
Z13,DZ14,DZ15
Z17
D
Z12
2
3
T12702-38
T12702-30
1N4751
1N5225B
D
1
1
T12702-41
S24020-12
1N5359B ZENER DIODE
J1
H
EADER, VERTI
EADER, VERTI
HEADER, VERTI
D LED
C
AL
AL
AL, GOLD
D38
LED3
LED1
R114
J2
1
1
6
S24020-10
S24020-2G
T13657-2
H
C
N.B.
D43
J3
C
{
LED1,L
E
D2,LE
D3,LE
D4,LED5,
RE
R78
C26
LED6
Q3
QU1
Q9
Q12
D44
Q1,Q2,Q4,Q8,Q10
Q3,Q5,Q6,Q11
Q9,Q12
5
4
2
T12704-36
T12704-68
T12704-69
T12707-4
T14900-1
2N4857
2N4401
2N4403
2N6027
R127
D28
C
8
Q
U1
1
R
63
R
80
R39
R1,R2
2
2
00 20W
R3
R4,R46
R5,R98,R123,R136
R6,R23,R48,R154
1
2
4
4
7
T14648-17
S19400-3320 332 1/4W
S19400-1503 150K 1/4W
270 5W
R
18
R101
N.B.
C27
R79
X1
S19400-825
2
82.5K 1/4W
C32
R89
R7,R22,R24,R29,R44,R45,
R102
S19400-1001 1K 1/4W
Q11
+
R8,R72,R78,R79,R88,R97,
8
S19400-2211 2.21K 1/4W
R42
D17
LED4
LED5
R86
R62
C25
R41
R103,R150
C
6
LED2
R13
R9,R34,R42,R56,R57,R64,R71
R96,R125,R156,R157
11
S19400-6811 6.81K 1/4W
D42
D25
C14
TP3
TP2
R10,R11,R155
R12,R61,R93,R106
R13,R62,R120
R14,R124
3
4
3
2
2
2
1
2
S24000-3300 330/.75W
S19400-4752 47.5K 1/4W
S19400-4753 475K 1/4W
D26
R65
R12
R61
R88
X3
Q8
S19400-39R2
39.2 1/4W
D22
R56
R47
D19
R15,R160
S19400-2431 2.43K 1/4W
S19400-1372 13.7K 1/4W
S19400-3011 3.01K 1/4W
Q10
R46
D16
R67
R16,R118
D9
R17
R18,R101
R66
R58
C
3
T10812-77
20K 1/2W TRIMMER
R54
D21
D20
D30
R19,R58,R65,R81,R105,R133,
R134
7
S19400-1002 10K 1/4W
D23
R50
R16
D10
DZ13
N.B.
R20,R21,R50
3
8
S19400-1003 100K 1/4W
S19400-1004 1M 1/4W
C
4
R25,R51,R67,R73,R77,R107,
R121,R137
C33
R15
R160
Q4
R
38
26
C7
R26,R38
2
T10812-68
1K 1/2W TRIMMER
+
D7
R27,R37,R41,R76,R91,R114,R115
R28,R87,R108
7
3
2
4
4
3
S19400-4751 4.75K
X2
DZ9
Q1
D11
R44
R51
Q2
S19400-4750 475 1/4W
S19400-2670 267 1/4W
S19400-1501 1.5K 1/4W
S19400-1502 15K 1/4W
C
2
R30,R104
LED6
DZ16
R154
R43
R31,R85,R99,R151
R45
D18
R36,R94,R126,R127
R39,R63,R80
R
DZ15
R7
T10812-39
50K 1/2W TRIMMER
R40,R83,R89,R139
R43,R68,R82,R90,R92
4
5
S19400-6812 68.1K 1/4W
S19400-2212 22.1K 1/4W
G3409-
1
R151
DC600 CONTRO
L
R150
R47,R110,R117
R52,R141
3
2
S19400-1301 1.3K 1/4W
S19400-2213 221K 1/4W
R53,R54,R55,R159
R66
4
1
S24000-1000 100/.75W
S19400-5622 56.2K 1/4W
R69,R100,R109
R70,R86,R140
R74
3
3
1
2
1
1
1
1
2
1
1
S19400-6810 681 1/4W
S19400-1821 1.82K 1/4W
S19400-3923 392K 1/4W
S19400-3322 33.2K 1/4W
R95,R138
R111
S19400-47R5
S19400-1000 100 1/4W
T12300-68 50 10W
S19400-3922 39.2K 1/4W
S19400-243 4.3K 1/4W
S19400-2001 2.0K 1/4W
47.5 1/4W
R112
R113
2
R135
N
OTES
N.B. DO NOT COAT WITH ENCAPS
N.C. O .30 AREA TO BE FREE OF ENCAPS
R148,R149
R152
2
2
1
U
LATION MATERIAL.
LATION MATERIAL
ES)
R153
T14648-23
20 5W
U
C
S
TP1
C
R1
1
1
S15161-19
T13640-11
8A.,400V. SCR
45J
BOTH SIDES OF BOA (TOTAL 5 PLA
ESISTOR EET MUST BE FLAT AGAINST BOA
IT TO R1 A 2 RESISTOR EET TO ANCHOR
TO BOARD.
RD
TP2,TP3
X1
2
1
T13640-18
S15128-16
S15128-4
S15128-10
1
60J
IC,LT1014,LIN.I
IC,LM224,OP-AMP
IC,431,VOLTAG REF.
N.D.
R
F
RD. APPLY
N
T. CIR.
X2,X3
X4
2
1
EM
2
ND
R
F
CAPACITO
RS
= M
FD/VOLTS
E
RESISTORS
=
OHMS
I
TEM
1
R
E
1
Q'D
P
AR
G3409-C
T
NO.
IDENTIFICATION
CONTROL P.C.
BOARD BLANK
N.D.
2
.04oz.
E2861
RTV COATING
FOR PARTS ORDERS:
SEA
L
T
RIMMERS WIT
H
A
DROP OF E4018.
AND INCLUDE T11590-90.
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
MANUFACTURING TO
L
ERANCE
P
ER
E2056
CONTROL: CLEVELAND
SCAL
E:
-
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
SUBJECT:
MA ERIAL
M
ENT TYPE:
1
1
DOCUMEN
DC 600
PAGE ___ OF ___
T
ON
ON
ON
2
3
PLAC
PLACE
LL ANGL
TO
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
.02 in.
(
0.5 mm)
DRAWN BY:
ENGINEER:
APPROVED:
fiv
or
-
y
D
E
.
00
2
i
n.
GREE
GREE
(
0.
0
5
mm)
T
DOCUMEN
NUMBER:
IF PRIN
T
ED
E
A
E
L
S
I
S
A
)
DE
REVISION:
CONT
R
11-16-2007
OL PC BOA
R
D ASSE
M
BLY
@
A
1
SIZ
MATERI
A
L
E
"
TO
A
t
UNITS:
WITH PU
B
LISHED STANDARDS.
REFERENCE:
T
APPROVA
DA E:
L
PROJEC
T
G3409-
1
UF
C
CRM39073
DISPOSI ION:
T
T
NUMBER:
INCH
DO NO
T
SCAL HIS DR
E
T
A
WING
G1504-4
Insight
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 pro-
vided for reference only. 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.
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G-7
G-7
ELECTRICAL DIAGRAMS
SCHEMATIC - FIRING PC BOARD - G3741-1
Printed by John Howell
Printed at 10:23 on 08/15/2008 (month/day/year)
Drawing Number- G3741-1B1
Revision- 11-30-2001E
Status- STANDARD
This print is Current
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Download from Www.Somanuals.com. All Manuals Search And Download.
|