Lincoln Electric SVM188-A User Manual

For use with machine code numbers: Above Code 10580

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Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

SVM188-A

October, 2008

DC-600

DC-600

View Safety Info View Safety Info View Safety Info View Safety Info

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING can be hazardous. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur­chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

____________________________________________________

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi-

tion
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety
guards
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

1.c. Do not add the fuel near an open flame weld­ing

arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

and in good repair.Keep hands, hair, clothing and tools

to perform required maintenance. Remove

1.f. Do not put your hands near the engine fan. Do
not

attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
tur

ning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii ii

SAFETY

ELECTRIC SHOCK can kill.

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.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

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.

3.g. Never dip the electrode in water for cooling.

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.

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.

ARC RAYS can burn.

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.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

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.

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
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.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

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.

vapors

to

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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

iii iii

SAFETY

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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.

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.

6.c. When not welding, make certain no par t of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

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.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

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.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

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.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

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.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

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.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.

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Jan ‘07

iv iv

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

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 met­allique 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 defonc­tionnement.

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.

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.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

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.

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.

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.

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 rayon­nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

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.

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, pan­talons sans revers, et chaussures montantes.

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.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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.

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 debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

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Mar ‘93

v v

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 com­plete 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 equip­ment.

Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems 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;

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h) the time of day that welding or other activities are to be carried out.

L10093 3-1-96H

vi vi

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 recommenda­tions. 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 equip­ment 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 con­nection 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.

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_________________________

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

I I

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

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Page

Safety ...........................................................................i-iv

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-349

DC-600

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

TABLE OF CONTENTS - INSTALLATION SECTION

Limit on Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

FusesandWireSizes ..............................................................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

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DC-600

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS – DC-600

INPUT - THREE PHASE ONLY

Standard

Volatge

230/460/60

230/460/575/60

460/60
575/60

220/380/440/50/60

380/500/50/60

440/50/60

200/400/50/60

415/50/60

Duty Cycle

100% Duty Cycle

60% Duty Cycle
50% Duty Cycle

100% Duty

108/54/43

116/67/58

RATED OUTPUT

Input Current at Rated Output

60% Duty Cycle

Cycle

122/61

108/54

54
43

67/51

58

128/64

61

Amps

600
680
750

122/61/49

61
49

128/74/64

74/56

64

140/70

68

50% Duty Cycle

134/67

134/67/54

67
54

138/80/69

80/61

69

152/76

73

Volts at Rated Amperes

44
44
44

Output Range

70A/13V-780A/44V (CV)
90A/24V-780A/44V (CC)

INPUT

VO LTAGE /

FREQUENCY

230
460
575
200
220
380
400
415
440
500

OUTPUT

Maximum Open Circuit Voltage

72V for 60 HZ models

69V for 50/60 HZ models

See the OPERATION section

RECOMMENDED INPUT WIRE AND FUSE SIZES

HERTZ

60
60

60
50/60
50/60
50/60
50/60
50/60
50/60
50/60

INPUT AMPERE

RATING ON

NAMEPLATE

108

54

43
128
116

67

64

61

58

51

TYPE 75°C

COPPER WIRE

IN CONDUIT

AWG(IEC-MM2)SIZES

30°C (86°F) Ambient

2(34)
6(14)

8 (8.4)

1(43)
2(34)
6(14)
6(14)
6(14)
6(14)

8 (8.4)

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG(IEC-MM2)SIZES

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)

Auxiliary

for Auxiliary Power

information by model

Power

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

175 Amp

90 Amp

70 Amp
175 Amp
175 Amp
100 Amp
100 Amp
100 Amp

90 Amp

80 Amp

1

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PHYSICAL DIMENSIONS

HEIGHT

30.75 in
781 mm

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.

WIDTH

22.25 in
567 mm

DC-600

DEPTH

39.0 in

988 mm

WEIGHT

522 lbs.

237 kg.

A-3 A-3

SAFETY PRECAUTIONS

INSTALLATION

STACKING

Read entire Installation Section before installing
the DC-600.

ELECTRIC SHOCK CAN KILL.

WARNING

• Only qualified personnel should
install this machine.

• Turn the input power OFF at the
disconnect switch or fuse box
before
working on the equipment.

• Do not touch electrically hot parts.

• Always connect the IDEALARC
DC-600 grounding terminal to a good electrical
earth ground.

• Set the DC-600 Power ON/OFF PUSH BUTTON to
the OFF position when connecting power cord to
input power.

__________________

Three DC-600 machines can be stacked.

DO NOT stack more than three machines in one
grouping.

DO NOT stack the DC-600 on another type of
machine.

Follow these guidelines when stacking:

1. Select a firm, level surface capable of sup­porting the total weight of up to three
machines (1570 pounds/712 kilograms).

2. Set the bottom machine in place.

3. Stack the second machine on top of it by
aligning the two holes in the base rails of the
second machine with the two pins on top front
of the bottom machine.

4. Repeat process for third machine.

NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
Figure A.1.

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SELECT PROPER LOCATION

Place the welder where clean cooling air can freely cir­culate 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 shut­downs.

LIMIT ON STACKING

WARNING

• Lift only with equipment of ade­quate 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.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

• Do not stack more than three high.

• Do not stack the DC-600 on top of any other machine.

------------------------------------------------------------------------

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STACKING HOLE

STACKING PINS

FIGURE A.1 - Stacking DC-600 machines

TILTING

The DC-600 must be placed on a stable, level surface
so it will not topple over.

DC-600

A-4 A-4

ELECTRICAL INPUT CONNECTIONS

Before installing the machine check that the input sup­ply 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.

INPUT SUPPLY

CABLE ENTRY

OPENING

CONTACTOR (CR1)

INPUT

RECONNECT

PANEL ASSEMBLY

INSTALLATION

INPUT POWER SUPPLYCONNECTIONS

A qualified electrician should connect the input power
supply leads.

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.

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 connec­tors. Be sure to close the baffle by inserting the tab
into the slot in the baffle. See Figure A.3.

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 ther­mal/magnetic circuit breakers.

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.

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 the input contactor.
Access to the Input Box Assembly is at the upper rear
of the machine. See your local and national electrical
codes for proper grounding methods.

INPUT

CONTACTOR (CR1)

INPUT POWER SUPPLY
CABLE WITH BUSHING

OR BOX CONNECTOR

RECONNECT

PANEL ASSEMBLY

FIGURE A.3 - Input Power Supply
Connections

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DC-600

A-5 A-5

INSTALLATION

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 con­nected for the proper voltage.

CAUTION

Failure to follow these instructions can cause
immediate failure of components within the
machine.

When powering welder from a generator be sure to
turn off welder first, before generator is shut down,
in order to prevent damage to the welder

------------------------------

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.

1. For Dual Voltage except 380/500-460/575, see
Figure A.4. (M15009)

2. For 220/380/460, see Figure A.5. (M15010)

3. For 380/500-460/575, see Figure A.6. (M15011)

4. For 460 and 440 Single Voltage, see Figure A.7.
(S17894)

5. For 230/460/575, see Figure A.8. (M15666)

6. For Voltages not listed, see the Input Connection
Diagram pasted on the inside of the Case
Back Input Access Door.

LINK

LINES
INPUT

LINK

LINES
INPUT

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

L3
L2
L1

GND

H3

W

V

CONTACTOR

U

H1

PILOT

TRANSF.

CRI

H2

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX

2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH 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.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
REMAINING HEX NUTS IN PLACE.

CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

L3
L2
L1

GND

H2

W

V

CTOR

U

H1

TRANSF.

CRI

PILOT

H3

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX

2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.

FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines

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DC-600

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 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

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. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

LINES
INPUT

LINKS

L3
L2
L1

GND

H4

W

V

CONTACTOR

U

H1

CRI

PILOT

TRANSF.

H3

H2

CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.

CRI

LINES
INPUT

LINKS

L3
L2
L1

GND

H3

W

V

CONTACTOR

U

H1

PILOT

TRANSF.

H4

H2

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 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

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.

CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.

LINES
INPUT

LINKS

L3
L2
L1

GND

H2

W

V

CONTACTOR

U

H1

CRI

PILOT

TRANSF.

H4

H3

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 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines

CONNECTION FOR 380/460 VOLTAGES

H2

LINES
INPUT

GND

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.

4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.

5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN
ALL HEX NUTS

L3
L2
L1

H1

H3

W

V

CONTACTOR

U

CRI

TAPE

LINK

CONNECTION FOR 500/575 VOLTAGES

H3

GND

L3
L2
L1

H1

LINES
INPUT

H2

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 TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.

5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS

CRI

W

V

CONTACTOR

U

TAPE

LINK

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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

2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.

3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.

LINES
INPUT

L3
L2
L1

GND

W

V

CONTACTOR

U

CRI

FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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 SizeParallel CablesCable Length

2

Lengths up to 150 ft. (46m)

CONNECTIONS

1/0 (53mm

2

2

2/0 (67mm

3/0 (85mm

)2

2

)150 ft.(46m) to 200 ft (61m)

2

)200 ft.(61m) to 250 ft.(76m)

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.

5. Connect electrode lead to the desired terminal
(positive/negative).

6. Tighten the output terminal nut with a wrench.

7. Connect the work lead to the other output
terminal following steps 4-6.

FIGURE A.9 - Output Terminals.

B. Connect #21 Work Sense Lead to Proper

Terminal

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.

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DC-600

A-9 A-9

AUXILIARY POWER AND

INSTALLATION

PIN LEAD NO. FUNCTION

CONTROL CONNECTIONS

A 32 115 VAC

Located at the left side of the front of the welder behind
a hinged cover is a 115VAC duplex receptacle for aux­iliary power (60 Hertz Models only). On the right side of
the case front is a 14 Pin MS type receptacle for con­nection 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)

AUXILIARY POWER TABLE

Voltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various Models

Auxiliary 60 Hz 50/60 Hz

Power Models Models

Connections

At Duplex 115V 15A No Duplex

Receptacle

Terminal strip 115V 15A 115V 15A

terminals31&32

MS-Receptacle 115V 15A 115V 15A

pinsA&J

MS-Receptacle 42V 10A 42V 10A

pinsI&K

115VAC DUPLEX RECEPTACLE (60 HERTZ
MODELS ONLY)

B GND Chassis Connection
C 2 Trigger Circuit
D 4 Trigger Circuit
E 77 Output Control
F 76 Output Control
G 75 Output Control

H 21 Work Sense Connection
I41 42VAC

J 31 115 VAC

1.

K42 42VAC
L --- --­M --- --­N --- ---

TERMINAL STRIPS

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 connec­tor and #21 lead of the control cable to “-21” when
welding positive polarity or to “+21” when welding neg­ative polarity.

2

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

The 115VAC duplex receptacle is protected by a circuit
breaker located on the nameplate. The receptacle is a
NEMA 5-15R.

14 PIN MS TYPE RECEPTACLE

(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.

42 VAC is available at receptacle pins I and K.
A 10 amp circuit breaker protects this circuit.

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 electri­cally isolated from each other.

FIGURE A.10 FRONT VIEW OF 14-PIN
CONNECTOR RECEPTACLE

K=42

A=32

B=GND

LN

C=2

D=4

E=77

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

J=31

I=41

H=21

G=75

F=76

M

1.

2.

DC-600

TERMINAL STRIP 1 (T.S.1)

Lead No. Function

75 Output Control
76 Output Control
77 Output Control

TERMINAL STRIP 2 (T.S.2)

Lead No. Function

+21

-21
41 42 VAC

4 Trigger Circuit

2 Trigger Circuit
31 115 VAC
32 115 VAC

115VAC circuit is on all models.

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 ter­minal strip (T.S.2).

Work Connection (Electrode Negative)

Work Connection (Electrode Positive)

1

1

2

A-10 A-10

NOTES

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DC-600

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

GeneralDescription ...............................................................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

TABLE OF CONTENTS - OPERATION SECTION

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5, B-6

Auxiliary Power in MS - Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Overload, Overcurrent and Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

OperatingSteps ..................................................................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

NA-3 Automatic Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

NA-5 Automatic Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

LN-8 Semi-Automatic Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

LN-7 & LN-9 Semi-Automatic Wire Feeders .............................................B-9

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DC-600

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 cloth­ing, gloves or work area is damp or if
working on, under or inside work­piece.
Use the following equipment:

-Semiautomatic DC constant voltage

(wire) welder.

-DC manual (stick) welder.

-AC welder with reduced voltage con­trol.

• Do not operate with panels removed.

• Disconnect input power before ser­vicing.

-------------------------------------------------------------

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 gener­al area.

WELDING, CUTTING and GOUG­ING SPARKS can cause fire or
explosion.

• Do not weld near flammable material.

• Do not weld, cut or gouge on contain­ers 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.

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DC-600

B-3 B-3

OPERATION

GENERAL DESCRIPTION

The DC-600 is an SCR controlled three phase welding
and cutting power source. It uses a single range poten­tiometer to control:

• Submerged Arc Semi-Automatic or Automatic
Welding

• 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:

• 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 dis­connecting the wire feeder equipment control, elec­trode,and work leads.

RECOMMENDED PROCESSES AND
EQUIPMENT

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.

The DC-600 is provided with a three position mode
switch that selects CV Innershield, CV Submerged Arc,
or CC Stick.

The DC-600 can be easily connected to wire feeding
equipment, including:

• Semi-automatic wire feeders LN-7, LN-7 GMA, LN­742, LN-8, LN-9, LN-9 GMA, LN- 10, LN-15 LN­23P, LN-25, and DH-10.

• Automatic wire feeders NA-3, NA-5, and NA-5R.

• Tractors LT-56 and LT-7

DESIGN FEATURES AND
ADVANTAGES

• Excellent arc characteristics for optimum constant
voltage submerged arc and Innershield welding
performance.

• 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 switch­ing from local to remote control.

• Output Terminals Switch to energize output termi­nals either local or remote.

• White neon pilot light to confirm that the Input
Contactor is energized.

• 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 pro­vides extra long life, especially for highly repetitive
welding applications.

• 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.

• Output lead strain relief loops to prevent terminal
and cable damage.

• Easily removed case side, even when stacked.

• Outdoor operation because enclosure is designed
with air intake louvers that keep dripping water
from entering the unit. Transformer, SCR bridge,
and choke have special corrosion resistant paint
for added protection.

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DC-600

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

SYMBOL

MEANING

INPUT POWER

Pilot Light

Input power on when light is illuminated

(except for abnormal conditions).

Always indicates POWER ON/OFF

switch is in ON position.

OUTPUT CONTROL

ON

OFF

LOCAL/REMOTE Switch

SYMBOL

Control Of Output Voltage and

Current is Via DC-600's Control Dial

Remote Control of Output Voltage

MODE Switch

CC STICK: Shielded Metal Arc

Welding (SMAW), this switch

position is also used for Air

Carbon Arc Cutting (AAC)

CV SUBMERGED ARC:

Constant Voltage Submerged

Arc Welding (SAW)

CV INNERSHIELD: Flux Cored

Arc Welding (FCAW), this switch

position is also used for Gas
Metal Arc Welding (GMAW).

MEANING

and Current

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OUTPUT VOLTAGE

Clockwise Increase of Output

TERMINALS ON/REMOTE Switch

OUTPUT TERMINALS

Remote Control of Output Terminals

(Energized or Non-Energized)

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AND CURRENT

Voltage and Current

ENERGIZED

Output Terminal Connections

Positive Output Terminal

Negative Output Terminal

WARNING Identification

Warning Identification

Circuit Breaker

Circuit Breaker (two breakers: 15A

for 115V circuit and 10A for 42V

circuit)

DC-600

B-5 B-5

OPERATION

MEANING OF GRAPHICAL
SYMBOLS ON RATING PLATE
(LOCATED ON CASE BACK)

Designates welder complies with
National Electrical Manufacturers

NEMA EW 1 (100%)

Association requirements EW 1
Class I with 100% duty cycle at
600Amps output.

Three Phase Input Power

3 Phase transformer with recti­fied DC output

Line Connection

Gas Metal Arc Welding (GMAW)

MEANING OF GRAPHICAL
SYMBOL FOR GROUND CON­NECTION

Signifies the equipment connection
point for the protective earth ground

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.

7

5

3

6

8

5

6

4

7

3

8

2

9

1

10

DC-600

49

1

2

NRTL/C

Flux Cored Arc Welding (FCAW)

Shielded Metal Arc Welding (SMAW)

Submerged Arc Welding (SAW)

Designates welder complies with

R

both Underwriters Laboratories (UL)
standards and Canadian Standards
Association (CSA) standards. (60
Hertz Models)

11

10

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 ener­gizes the machine’s input contactor applying input
power to the machine. Switching the switch to the
OFF “ ” position de-energizes the input con­tactor.

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)

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DC-600

B-6 B-6

OPERATION

3. OUTPUT CONTROL

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).

4. OUTPUT TERMINALS ON/REMOTE Switch

When this switch is in the REMOTE “ ” posi­tion, the DC-600’s output terminals will be electri­cally “cold” until a remote device such as a wire
feeder closes the #2 and #4 circuit in the MS-recep­tacle or terminal strip (T.S.2). When this switch is in
the ON “ ” position the machine’s output termi­nals will be electrically energized all the time.

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.
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).

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

11.Terminal Strip Cover Panel

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 termi­nal strips.

12.Negative Output Terminal

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.

13.Positive Output Terminal

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.

AUXILIARY POWER IN MS-RECEPTACLE

42 volt AC auxiliary power, as required for some wire
feeders, is available through the wire feeder MS-recep­tacle. A 10 amp circuit breaker protects the 42 volt cir­cuit from overloads.

DC-600 machines can also supply 115 volt AC auxil­iary power through the wire feeder receptacle. A 15
amp circuit breaker protects the 115 volt circuit from
overloads.

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7. 115VAC Duplex Receptacle (60 Hertz Models)

This receptacle provides up to 15 amps of 115 VAC
auxiliary power.

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-recep­tacle.

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.

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OVERLOAD, OVERCURRENT, AND
FAULT PROTECTION

This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and high ambi­ent 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 illuminat­ed. No welding is possible during this cool down peri­od. The machine will reset automatically when the ther­mostat cools.

The power source is also protected against overcur­rents in the SCR bridge assembly through an electron­ic protection circuit. This circuit senses currents over
780 amps on the power source and opens the input
contactor should the overcurrent remain for a predeter­mined 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.

DC-600

B-7 B-7

The power source circuitry is protected from faults on
leads 75, 76, or 77. If any of these leads are connect­ed to either the positive or negative output leads, the
DC-600 will either shut down completely (input contac­tor 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.

OPERATING STEPS

OPERATION

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 informa­tion.

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.

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 precau­tions before starting work. It is important that you fol­low these operating steps each time you use the
machine.

1. Turn on the main AC power supply to the machine.

2. Connect the #21 work lead to either + or - on ter­minal strip (T.S.2).

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.

WELDING PROCEDURE
RECOMMENDATIONS

Select Welding Mode Switch position based on type of
welding to be done.

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.

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 cut­ting, 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 cir­cuiting pulses.

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• The fan starts.

5. Set OUTPUT CONTROL Potentiometer to desired
voltage or current.

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.

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SEMI-AUTOMATIC AND AUTOMATIC
WIRE FEEDING WITH THE DC-600
AND WIRE FEEDERS

When using the DC-600 with semi-automatic or auto­matic 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.

DC-600

B-8 B-8

OPERATION

NA-3 AUTOMATIC WIRE FEEDER

4. Connect the electrode cables to terminal polarity to

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.

be used.

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.

Connect the #21 work lead (on T.S.2) to the

3.

same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22978) for remote connection (recommend­ed) of the #21 lead.

4. Connect the electrode cables to terminal polarity to
be used.

5. Set the DC-600 welding mode switch for the
desired process: CV SUBMERGED ARC, CV
INNERSHIELD mode or CC STICK mode.

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.

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

When using the DC-600 with the NA-5 wire feeder, set
the controls on the DC-600 as follows for the best per­formance:

8. Set the DC-600 WELDING MODE SWITCH to the
position that matches the welding process being
used.

• 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.

GOOD ARC STRIKING GUIDELINES FOR THE DC­600 IN THE CV INNERSHIELD, CV SUBMERGED
ARC MODES

Following are some basic arc striking techniques that
apply to all wire feed processes. Using these proce­dures should provide trouble-free starting. \These pro­cedures apply to single, solid wires and Innershield
wires.

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
set the Open Circuit Voltage Control to # 6.

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 volt­age is constant in the CC STICK mode.

point is to

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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.

Connect the #21 work lead (on T.S.2) to the

3.

same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22979) for remote connection (recommend-

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ed) of the #21 lead.

DC-600

B-9 B-9

3. Run a test weld. Set proper current, voltage, and
travel speed.

OPERATION

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.

• To adjust the Open Circuit Voltage Control to get
the best starting performance, make repeated
starts observing the NA-3 voltmeter.

When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
overshooting the desired arc voltage, the Open
Circuit Voltage Control is set properly.

If the voltmeter pointer overshoots the desired volt­age and then returns back to the desired voltage,
the Open Circuit Voltage Control is set too high.
This can result in a bad start where the wire tends
to "Blast off."

If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit Voltage
Control is set too low.This can cause the electrode
to stub.

4. Start and make the weld.

• Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes positive
contact with the work piece.

Connect the #21 work lead (on T.S.2) to the

3.

same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22977) for remote connection (recommend­ed) of the #21 lead.

4. Connect the electrode cables to terminal polarity to
be used.

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.

4. Refer to the LN-8 Operator’s Manual for instruc­tions on how to use the LN-8 in the CC (VV) mode.

LN-7 AND OTHER CONSTANT WIRE
FEEDERS

To use the LN-7 or other constant wire feed speed
semi-automatic wire feeders with IDEALARC DC-600

1. Set the IDEALARC DC-600 WELDING MODE
SWITCH to either CV Innershield mode or CV
Submerged Arc mode depending on the welding
process being used.

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• Hot "On the Fly" starts. For hot starts, travel should
begin before the wire contacts the work piece.

ARC STRIKING WITH DC-600 AND THE NA-3 OR
NA-5 START BOARD

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.

See the NA-3 or NA-5 Operator’s Manual for detailed
instructions on setting the Start Circuit controls.

LN-8 OR LN-9 SEMI-AUTOMATIC WIRE
FEEDER

To use the LN-8 or LN-9 Semi-Automatic Wire Feeder
with the IDEALARC DC-600

1. Set the IDEALARC DC-600 WELDING MODE
SWITCH to either CV Innershield mode or CV
Submerged Arc mode depending on the welding
process being used.

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2. Connect the Wire Feeder Control Cable to the 14
pin Amphenol of the DC-600.

Connect the #21 work lead (on T.S.2) to the

3.

same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22978) for remote connection (recommend­ed) of the #21 lead.

4. Connect the electrode cables to terminal polarity to
be used.

5. Set the IDEALARC DC-600 OUTPUT
CONTROL SWITCH per the Connection Diagram
for the feeder being used

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.

DC-600

B-10 B-10

NOTES

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DC-600

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Factory Installed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3/C-4

TABLE OF CONTENTS - ACCESSORIES SECTION

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DC-600

C-2 C-2

T

WIRE FEEDERS AND TRACTORS

ACCESSORIES

Undercarriages (K817P, K842)

The DC-600 can be used to power any of the following
Lincoln Wire Feeders and Tractors:

Semi-Automatic Wire Feeders:

DH-10 LN-9
LN-7 LN-9 GMA
LN-7 GMA LN-23P
LN-742 LN-25
LN-8 LN-10

Automatic Wire Feeders:

NA-3 NA-5R
NA-5

Tractors:

LT-7 LT-56

FIELD INSTALLED OPTIONS

Remote Output Control (K775 or K857 with
K864 Adapter)

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
with the symbol “ ” on the machine. These termi­nals are located behind the hinged cover on the case
front. This control will give the same control as the out­put control on the machine.

For easy moving of the machine, optional undercar­riages are available with polyolefin wheels (K817P) or
a platform undercarriage (K842) with mountings for
two gas cylinders at rear of welder.

Paralleling Kit (K1611-1)

Permits paralleling of two DC-600's for welding cur­rents of up to 1200 amps, 100% duty cycle.

Tig Module (K930-2)

Portable high frequency generator for AC/DC TIG
welding.

FACTORY OR FIELD INSTALLED
OPTIONS

Multi-Process Switch (K804-1)

The MULTI-PROCESS SWITCH gives you the ability
to:

• Switch between "stick welding or air/carbon arc cut­ting" and using a semi-automatic or automatic wire
feeder.

• Change the polarity of a semi-automatic or auto­matic wire feeder without changing any electrical
cable connections.

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.

+

Remote Control Adapter Cable (K864)

STRAIGHT PLUG (14 PIN)

O POWER SOURCE

A "V" cable 12" (.30 m) long to connect a K857 Remote
Control (6-pin connector) with an LN-7 wire-feeder (14­pin connector) and the machine (14-pin connector). If
a remote control is used alone the wire-feeder connec­tion is then not used.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CABLE RECEPTACLE (6 SOCKET)

TO: K857 REMOTE CONTROL

CABLE RECEPTACLE (14 SOCKET)

TO: LN-7 WIRE FEEDERS

WIRE
FEEDER
CABLES

FIGURE C.1 - MULTI-PROCESS SWITCH

DC-600

-

–

STICK OR

AIR

CARBON

ARC

+

STICK OR

AIR/CARBON

ARC CABLES

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

TERMINAL
STRIP COVER

BOX
CONNECTOR

shown in Figure C.1. The output terminals are protect­ed against accidental contact by hinged covers.

When the MULTI-PROCESS SWITCH is in the "Stick

21-21+ 41 4 2 31 32

or Air/Carbon Arc" position, only those terminals are

75 76 77

CONTROL

LEADS

energized. The wire feeder nozzle or gun and electrode
are not electrically "hot" when in this mode.

NEGATIVE (–)

OUTPUT

STUD

–

POSITIVE (+)

+

OUTPUT

STUD

Follow these steps to install the MULTI-PROCESS
SWITCH:

1. Confirm that the DC-600 POWER ON/OFF switch
is in the OFF position.

2. Disconnect main AC input power to the DC-600.

ELECTRODE

CABLE

WIRE

FEEDER

WORK

CABLE

WORK

ELECTRODES

(IF NEEDED

JUMPER
SEE INSTRUCTIONS)

+

ELECTRODE

CABLE

STICK AIR/CARBON
ARC WELDING
EQUIPMENT

WORK

CABLE

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

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.

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.

9. Connect the wire feeder electrode and work
cables. See Figure C.2.

Support the switch in position and start the four
screws, then tighten them.

• Insert the wire feeder electrode and work cables
through the strain relief loop on the left side of the

5. Route the MULTI-PROCESS SWITCH control

DC-600 (facing the front of the machine).

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

• Connect the wire feeder electrode and work cables
to the electrode and work terminals on the left side
of the MULTI-PROCESS SWITCH.

specified on the connection diagram for the Lincoln
wire feeder being used.

10. Connect wire feeder control cable and make other
terminal strip connections as specified on the con-

6. Connect the control leads from the MULTI­PROCESS SWITCH to terminals #2 and #4 on the

nection diagram for the Lincoln wire feeder being
used.

DC-600's terminal strip.

11. Set the DC-600 OUTPUT TERMINALS switch to

7. Connect the right cable from the MULTI­PROCESS SWITCH (facing the front of the
machine) to the DC-600 positive (+) output termi­nal. See Figure C.2.

REMOTE.

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DC-600

C-4 C-4

ACCESSORIES

12. Connect stick or air/carbon arc electrode and work
cable. See Figure C.2.

• 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.

• Connect the electrode cable to the "Positive" ter­minal on the right side of the MULTI-PROCESS
SWITCH.

• Connect the work cable to the "Negative" terminal
on the right side of the MULTI-PROCESS
SWITCH.

NOTE: The instructions above are for connecting
the stick polarity positive. To change the polarity,
turn the DC-600 OFF, and reverse the cables.

NOTE: When it is not necessary to have separate
ground cables for stick and semi-automatic or
automatic welding, connect a jumper from the
MULTI-PROCESS SWITCH "Work" terminal to the
MULTI-PROCESS SWITCH "negative" terminal.
See Figure C.2.

CONNECTIONS FOR SEMI-AUTO­MATIC OR AUTOMATIC WIRE FEED­ER CONTROL

1. Set the DC-600 ON/OFF switch to OFF.

2. Set the DC-600 LOCAL/REMOTE switch to
REMOTE.

3. Set the DC-600 OUTPUT TERMINALS switch to
REMOTE.

4. Set the DC-600 MODE switch to the welding
process being used.

5. Refer to the proper connection diagram in the DIA­GRAMS section for more information.

To operate the MULTI-PROCESS SWITCH, refer to the
operating instructions on the switch nameplate.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

RoutineMaintenance ..................................................................D-2

PeriodicMaintenance..................................................................D-2

TABLE OF CONTENTS - MAINTENANCE SECTION

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DC-600

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 dis­connect 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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

• Control board.

• Firing board.

• Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.

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DC-600

E-1 E-1

•

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

TheoryofOperation .....................................................................E-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Input Circuit and Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Control Circuit, Firing Circuit and Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Protective Devices and Shutdown Circuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

CONTROL

TRANSFORMER

•

Secondary

Thermostat

Theromstat

1CR Coil

CONTACTOR

CR1

Pilot

Light

Primary

POWER
SWITCH

115VAC

w

FIGURE E.1 BLOCK LOGIC DIAGRAM

TERMINAL

•

FAULT PROTECTION

CR2

32VAC

32VAC

32VAC

14-pin

115VA C

Amphenol

Receptacle

T

115VAC

S

E

T

R

R

M

I

I

P

N
A

2

L

42VAC

MAIN
R
E
C

TRANSFORMER

115VAC

OUTPUT

TERMINAL

SWITCH

Fan

Motor

FIRING
BOARD

S

G

I

A

G

T

N

E

A
L

O
N

N
E

C
T

SCR BRIDGE

CONTROL

CHOKE

OUTPUT

SIGNAL

LATCHING
RESISTOR

STRIP 1

OUTPUT

CONTROL

CONTROL

BOARD

F
E
E
D
B
A
C
K

SHUNT

OUTPUT

CONTROL

SWITCH

F

E

E

D

B

A

C

K

MODE

SWITCH

POSITIVE

TERMINAL

NEGATIVE
TERMINAL

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

E-2 E-2

•

THEORY OF OPERATION

FIGURE E.2 - INPUT AND TRANSFORMER

•

CR1

115VAC

Pilot

Light

w

Secondary

Thermostat

Primary

Theromstat

1CR Coil

POWER

SWITCH

TERMINAL

•

FAULT PROTECTION

CR2

32VAC

32VAC

32VAC

14-pin

115VA C

Amphenol

Receptacle

T

115VAC

S

E

T

R

R

M

I

I

P

N
A

2

L

42VAC

MAIN
R
E
C
O
N

N

E

C

T

TRANSFORMER

115VAC

Fan

Motor

OUTPUT

TERMINAL

SWITCH

FIRING
BOARD

S

G

I

A

G

T

N

E

A
L

SCR BRIDGE

CONTROL

CHOKE

OUTPUT

SIGNAL

LATCHING
RESISTOR

STRIP 1

OUTPUT

CONTROL

CONTROL

BOARD

F
E
E
D
B
A
C
K

SHUNT

CONTROL

F

E

E

D

B

A

C

K

OUTPUT

SWITCH

MODE

SWITCH

POSITIVE

TERMINAL

NEGATIVE
TERMINAL

CONTROL

TRANSFORMER

CONTACTOR

GENERAL DESCRIPTION

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 TRANS­FORMER

The desired three-phase input power is connected to
the DC-600 through an input contactor located in the
input box at the rear of the machine. Two phases of the
input line are also connected to the control transformer.
The secondary of the control transformer supplies 115
VAC power to the control board and to the input con­tactor through the fault protection relay.

A reconnect panel allows the user to configure the
machine for the desired input voltage. This three­phase 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 cur­rent output. The finishes or “neutrals” of the main sec­ondary coils are connected together, and the six starts
of the secondary windings are connected to the SCR
rectifier assembly.

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 pro­vides 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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

E-3 E-3

•

THEORY OF OPERATION

FIGURE E.2 - FIRING BOARD,CONTROL BOARD AND RECTIFICATION

•

CR1

115VAC

Pilot

Light

w

Secondary

Thermostat

Primary

Theromstat

1CR Coil

POWER

SWITCH

TERMINAL

•

FAULT PROTECTION

CR2

32VAC

32VAC

32VAC

14-pin

115VA C

Amphenol

Receptacle

T

115VAC

S

E

T

R

R

M

I

I

P

N
A

2

L

42VAC

MAIN
R
E
C
O
N

N

E

C

T

TRANSFORMER

115VAC

Fan

Motor

OUTPUT

TERMINAL

SWITCH

FIRING
BOARD

S

G

I

A

G

T

N

E

A
L

SCR BRIDGE

CONTROL

CHOKE

OUTPUT

SIGNAL

LATCHING
RESISTOR

STRIP 1

OUTPUT

CONTROL

CONTROL

BOARD

F
E
E
D
B
A
C
K

SHUNT

CONTROL

F

E

E

D

B

A

C

K

OUTPUT

SWITCH

MODE

SWITCH

POSITIVE

TERMINAL

NEGATIVE
TERMINAL

CONTROL

TRANSFORMER

CONTACTOR

FIRING CIRCUIT, CONTROL CIR­CUIT AND RECTIFICATION

RECTIFICATION

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).

CONTROL BOARD

The control board receives current feedback informa­tion 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.

An output choke is connected between the neutral con­nection 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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

E-4 E-4

•

THEORY OF OPERATION

FIGURE E.2 - GENERAL DISCRIPTION

•

CR1

115VAC

Pilot

Light

w

Secondary

Thermostat

Primary

Theromstat

1CR Coil

POWER

SWITCH

TERMINAL

•

FAULT PROTECTION

CR2

32VAC

32VAC

32VAC

14-pin

115VA C

Amphenol

Receptacle

T

115VAC

S

E

T

R

R

M

I

I

P

N
A

2

L

42VAC

MAIN
R
E
C
O
N

N

E

C

T

TRANSFORMER

115VAC

Fan

Motor

OUTPUT

TERMINAL

SWITCH

FIRING
BOARD

S

G

I

A

G

T

N

E

A
L

SCR BRIDGE

CONTROL

CHOKE

OUTPUT

SIGNAL

LATCHING
RESISTOR

STRIP 1

OUTPUT

CONTROL

CONTROL

BOARD

F
E
E
D
B
A
C
K

SHUNT

CONTROL

F

E

E

D

B

A

C

K

OUTPUT

SWITCH

MODE

SWITCH

POSITIVE

TERMINAL

NEGATIVE
TERMINAL

CONTROL

TRANSFORMER

CONTACTOR

PROTECTIVE DEVICES AND
SHUTDOWN CIRCUITS

THERMAL PROTECTION

This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and high ambi­ent 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 illuminat­ed. No welding is possible during this cool down peri­od. The machine will reset automatically when the ther­mostat cools.

OVER CURRENT PROTECTION

The power source is also protected against overcur­rents in the SCR bridge assembly through an electron­ic protection circuit. This circuit senses currents over
780 amps on the power source and opens the input
contactor should the overcurrent remain for a predeter­mined 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

.

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 mini­mum 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 reset­ting the POWER ON/OFF toggle switch.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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 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 con­trolled by the Gate.

An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cath­ode voltage. Since there is a standard PN junction
between gate and cathode, the voltage between these
terminals must be slightly greater than 0.6V . Once the
SCR has fired, it is not necessary to continue the flow
of gate current. As long as current continues to flow
from anode to cathode, the SCR will remain on. When
the anode to cathode current drops below a minimum
value, called holding current, the SCR will shut off. This
normally occurs as the AC supply voltage passes
through zero into the negative portion of the sine wave.
If the SCR is turned on early in the positive half cycle,
the conduction time is longer, resulting in greater SCR
output. If the gate firing occurs later in the cycle, the
conduction time is less, resulting in lower SCR output.

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DC-600

E-6 E-6

NOTES

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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

Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-32

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

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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.

---------------------------------------------------------------------------------------------------------------------------

This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob­lems, wire feeding problems, and welding
problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con­tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with­out removing the case wrap-around cover.

Step 3. RECOMMENDED
COURSE OF ACTION

The last column labeled “Recommended
Course of Action” lists the most likely com­ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com­ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed
one possibility at a time until you locate the
cause of your problem.

All of the referenced test procedures referred
to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

to eliminate

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

-----------------------------------------------------------------------------------------------------------------------------------

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-3 F-3

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

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.

CAUTION

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.

2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

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:

PC board can be damaged by static electricity.

- Remove your body’s static
charge before opening the static­shielding bag. Wear an anti-static
wrist strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

frame.

- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.

- 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-shield­ing bag.

- 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 prop­er failure analysis.

4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.

: It is desirable to have a spare (known good)

NOTE

PC board available for PC board troubleshooting.

NOTE

: Allow the machine to heat up so that all

electrical components can reach their operating
temperature.

5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.

6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.

NOTE

: Following this procedure and writing on the

warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The Machine is dead - The Input contactor does not operate.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check for blown or missing
fuses in input lines.

2. Check the three phase input line
voltage at the machine. The
input voltage must match the
rating plate and reconnect
panel.

RECOMMENDED

COURSE OF ACTION

1. The ON/OFF Switch (S1) may
be faulty

2. The Control Transformer (T2)
may be faulty. Perform the

Control Transformer Test.

3. The primary or secondary ther­mostats may be open. Check or
replace. Also check the associ­ated 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
Board Test.

Input contactor (CR1) chatters.

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

CAUTION

1. The pilot relay (CR2) may have
bad contacts. Check or replace
relay.

2. Check for loose or faulty wiring
between pilot relay (CR2) and
input contactor (CR1) coil con­nections.See Wiring Diagram.

3. The input contactor (CR1) may
be faulty.-Replace.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Input contactor pulls in when
ON/OFF Switch is closed but imme­diately drops out.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

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 termi­nal strip and the 14pin MS con­nector and make sure the
Output Terminals Switch is in
the REMOTE position.

2. If the problem persists after per­forming step 1 the problem is in
the DC600.

RECOMMENDED

COURSE OF ACTION

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

and Shutdown Circuits.

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
Diagram.

4. The Control Board may be
faulty. See the PC Board
Troubleshooting Guide.

Machine shuts off (input contactor drops out) when the welder output terminals are made electrically "hot". (Output Terminals Switch ON).

1. Remove all welding cables and
control cables from the DC 600.
If the machine does NOT shut
off and normal open circuit volt­age is present at the welder out­put terminals the problem is
external to the DC600. Either
the remote leads #75, #76 or
#77 are grounded to the nega­tive output circuit or there is a
short on the welding output ter­minals.

2. If the machine still shuts off
when all control and welding
cables are removed then the
problem is internal to the
DC600.

1. Check for grounds and or shorts
in the #75, #76, #77 circuit. See
the Wiring Diagram.

2. Check for grounds and shorts in
the welder output terminals and
associated leads. See the

Wiring Diagram.

3. Check the output shunt and
associated leads. See the

Wiring Diagram.

4. Perform the C ontrol Board
Test.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Machine input contactor operates but machine has no weld output with the Output terminal Switch ON. Fan runs and pilot light glows.

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 con­nector.

The machine does not have maxi­mum weld output.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check LED 10 on the Firing
Board and LED 6 on the Control
Board. Both Should be ON.

2. Check all of the LEDs on both
PC Boards for proper operation.

1. Check all three phase input

lines at the DC600. Make
sure input voltages match
machine rating and recon­nect panel.

RECOMMENDED

COURSE OF ACTION

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
Tes t.If both LEDs are ON and
there is still no output go to Step

2.

2. The Firing Board or Control
Board may be defective. See the

PC Board Troubleshooting
Guide.

1. Check the Output Control
Potentiometer (R1) and
associated wiring for loose or
faulty connections. See
wiring diagram.

The weld output terminals are always electrically "hot".

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
hooked to #2 and #4 on the ter­minal strip. If the problem dis­appears the fault is in the control
cable or wire feeder.

2. If some open circuit voltage is
present (over 3VDC.) after per­forming Step #1. then the prob­lem is within the DC600.

3. Perform the Control Board
Test.

4. Perform the Firing Board Test.

5. Perform the SCR Output
Bridge Test.

6. Perform the Main Transformer
Test.

1. Check for an internal short
between leads #2 and #4. See
wiring diagram.

3. Perform Firing Board Test.

4. Perform Control Board Test.

5. Perform the SCR Output

Bridge Test.

6. The SCR Snubber(s) may be
"leaky". Check or replace.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Machine has maximum weld output and no control.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

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
Potentiometer (R1) at the
DC600. If the problem is solved
check the remote control unit
(or wire feeder) and associated
control cable.

RECOMMENDED

COURSE OF ACTION

1. Check the LOCAL/REMOTE
Switch (SW3) and associated
wiring.

2. Check feedback leads #222
(negative output terminal),
#215, and #210 (output shunt)
for loose or faulty connections.
See Wiring Diagram.

3. Check the #75 lead for continu­ity (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

PC Board Troubleshooting
Guide.

Machine has minimum output and no control.

1. If a remote control unit is NOT
connected to the DC-600, the
LOCAL/REMOTE Switch must
be in the "LOCAL" position.

2. If a remote control cable is con­nected, the control leads may
be "shorted" to the positive weld
output.

3. Make certain the three phase
input voltage is correct and
matches the machine rating and
the reconnect panel.

5. Perform the SCR Output

Bridge Test.

1. Check the Output Control
Potentiometer (R1) and associ­ated wiring.

2. Check the LOCAL/REMOTE
Switch (SW3), the Weld Mode
Switch (SW4) and associated
wiring.

3. Perform the Control Board
Test.

4. Perform the Firing Board Test.

5. Perform the SCR Output
Bridge Test.

6. Perform the Main Transformer
Test.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Poor arc starting when the DC600 is in the CV Sub-Arc or CV Innershield Modes.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure the proper welding
procedures are being used.
(wire feed speed, arc voltage
and wire size)

2. Check weld cables for loose or
faulty connections.

RECOMMENDED

COURSE OF ACTION

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. Perform the Firing Board Test.

3. Perform the SCR Output

Bridge Test.

4. The Control Board may be
faulty.

Poor arc characteristics in all processes.

1. Check for the correct input volt­ages on the three phase input
lines at the DC600.

2. Make sure the proper welding
procedures are being used (wire
feed speed, arc voltage and wire
size).

3. Check the welding cables for
loose or faulty connections.

1. Check the Mode Switch (SW4)
and the associated wiring for
loose or faulty connections. See
the Wiring Diagram.

2. Check the voltage at the shunt
(leads 210 and 215).When weld
current is present there should
be a millivolt signal at the board
(6.25mv/100 amps). If not cor­rect, the shunt may be defective

3. Perform the Firing Board Test.

4. Perform the SCR Output
Bridge test.

5. The Control Board may be
faulty.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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 trou­bleshooting 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 LOCAL
OUTPUT TERMINAL SWITCH ON

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-10 F-10

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING GUIDE (continued)

FIGURE F.1 – FIRING BOARD LEDs

J5

LED8

LED9

LED7

(205) 8
(206) 7
(207) 6
(208) 5

4
3
2
1

16 (204)
15 (203)
14
13 (231)
12 (215)
11
10
9

LED5

LED6

LED3

LED4

G3742-[ ]

FIRING BOARD

1. With DC-600 set for the Test Conditions all ten
LEDs on the Firing Board should be lit.

2. LEDs 7, 8 & 9 indicate that the three 34vac sup­plies from the Main Transformer are present on the
Firing Board. They should all be ON whenever the
Power Switch is ON.

• If any are not ON check the voltages at P5

LED that
was off

7
8
9

Check AC voltage between pins specified,
it should be approximately 34VAC .
P5 pins 15 & 16 (wires 203,204)
P5 pins 7 & 8 (wires 205,206)
P5 pins 5 & 6 (wires 207,208)

LED1

LED10

LED2

FIRING BOARD

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.

• It is important that all six LEDs are the same bril­liance as each other.

If none are lit, check the voltage at lead 231
(P5 - Pin13). See the Control Board Test.If
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.

J6

J7

J8

J4

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

• 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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-11 F-11

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING GUIDE (continued)

FIGURE F.2 – CONTROL BOARD LEDs

1

(291) 8

(290) 7

(255) 6

2 (256)

J2

5 (231)

(222)12

J3

1 (210)

1

LED2

J1

LED1

LED3

LED4

LED6

CONTROL BOARD

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.

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).

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
Circuits.

LED5

DC600 CONTROL

G3409-1

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
ON to reset the welder. See Protective Devices
and Shutdown Circuits.

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)

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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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DC-600

F-12 F-12

NOTES

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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 trou­bleshooting 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 pres­ence of the 42vac trigger supply voltage.

MATERIALS NEEDED

Multi-meter
Misc. Hand Tools
Wiring Diagram or Machine Schematic

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-14 F-14

TROUBLESHOOTING AND REPAIR

INTERNAL TRIGGER CIRCUIT TEST (continued)

FIGURE F.3 – FIRING BOARD

LED5

LED6

LED8

LED3

LED4

G3742-[ ]

LED9

LED7

LED1

LED2

LED10

FIRING BOARD

(205) 8
(206) 7
(207) 6
(208) 5

J5

16 (204)
15 (203)
14

4
3
2
1

13 (231)
12 (215)
11
10
9

J6

J7

J8

J4

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

PROCEDURE

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.

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

Figure F.1.

2. If LED 10 and LEDS 1 thru 6 light when the trigger

circuit is activated, the wiring and circuitry to the fir­ing board is good. If there is no output at the studs,
perform the Firing Board Test and see the PC

Board Troubleshooting Guide.

3. If LED 10 does not light when the trigger circuit is

activated check the 10 amp Circuit Breaker. See

Figure F.2.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

4. With a Voltmeter, check for 42vac at TS-2, termi-

nals2&42.SeeFigure F.2. If not present, check
wiring per the SimlpifiedTrigger Diagram (Figure
F.5). If OK, perform the Main Transformer Test.

5. Remove the main input supply power to the DC-

600.

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.

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
F.1 and F.2. If a resistance of any value is indicat­ed, check the associated wires and plugs.

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.

DC-600

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

5

6

4

7

3

8

2

9

1

10

DC-600

SWITCH

A=32

K=42

J=31

TS 2 TS 1

21-21+ 41 4 2 31 32

14-PIN

RECEPTACLE

2

C

K

42

4

D

I

41

BREAKER

42

TERMINAL
STRIP TS 2

14 PIN

CONNECTOR

75 76 77

FIGURE F.5 - SIMPLIFIED TRIGGER DIAGRAM

10AMP

CIRCUIT

To 42A at Main

Transformer

OUTPUT

2

4

41

2

TERMINAL

SWITCH

4

B=GND

I=41

LN

C=2

D=4

E=77

F=76

H=21

G=75

M

FIRING BOARD

11J 5

10J5

291

TO

CONTROL

BOARD

290

2

4J5

LED10

4

9J5

41

1J5

LATCHING
RESISTOR
ENABLE

FIRING
CIRCUIT
ENABLE

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

To 41 at Main

Transformer

DC-600

F-16 F-16

NOTES

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

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 trou­bleshooting 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

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DC-600

F-18 F-18

TROUBLESHOOTING AND REPAIR

FIRING BOARD TEST (continued)

FIGURE F.6 FIRING BOARD

J5

LED8

LED9

LED7

(205) 8
(206) 7
(207) 6
(208) 5

4
3
2
1

16 (204)
15 (203)
14
13 (231)
12 (215)
11
10
9

PROCEDURE

ELECTRIC SHOCK

• Do not touch electrically hot parts.

LED5

LED6

WARNING

LED3

LED4

G3742-[ ]

can kill.

LED1

LED10

LED2

FIRING BOARD

7. Trigger the DC-600 using the Output Terninal

Switch and see that LEDs 1 thru 6 and LED 10
come on.

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.

8. If LED 10 does not come ON, perform the Internal

Trig g er Test.

J6

J7

J8

J4

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

1. Disconnect the AC input power to the DC-600
machine.

2. Locate the firing board on the left side of the con­trol box.

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.

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
PC Board Troubleshooting Guide.

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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.
If so perform the SCR Bridge Test.

10. If LEDs 7,8 &9 are ON and any of LEDs 1 thru 6

are not the same briliance as the others, Perform
the SCR Bribge Test. If OK, replace the Firing
Board.

11. If LEDs 1 thru 6 do not change as the output con-

trol is varied:

• Check the Output Control Potentiometer.

• Make sure that the Local/Remote Switch is in
Local and functioning properly.

• Perform the Control Board Test. If OK, replace
the Firing Board

DC-600

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 trou­bleshooting 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

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DC-600

F-20 F-20

TROUBLESHOOTING AND REPAIR

CONTROL BOARD TEST (continued)

FIGURE F.7 CONTROL BOARD

1

(291) 8

(290) 7

(255) 6

2 (256)

J2

5 (231)

(222)12

PROCEDURE

J3

1 (210)

1

LED2

J1

LED1

LED3

LED6

WARNING

ELECTRIC SHOCK

• Do not touch electrically hot parts.

can kill.

LED5

LED4

DC600 CONTROL

G3409-1

4. If the machine stays ON and all LEDs are correct,
the problem is external to the machine. If LED4 still
comes ON:

• Check the Output Studs and associated wiring for
a ‘shorted’ or ‘grounded’ condition.

• Check for grounds in the control circuit (Output
Control, Local/Remote Switch & TS1).

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

1. Turn the POWER Switch ON. LEDs 1 and 3 should
turn ON.

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.

• 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).

• Disconnect any control cables, welding leads or

jumpers from the terminal strips (TS1& TS2).

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

• Control Board may be defective.

NOTE: LED 4 should be OFF except in a “shutdown“

condition. If ON and machine is still function­ing, replace the Control Board.

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:

• 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.

6. LED 6 indicates a signal from the Firing Board that

the DC-600 is “triggered”. If not ON, perform the
Internal Trigger Test.

DC-600

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 trou­bleshooting 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 wind­ings and the phase angle windings are correct.

MATERIALS NEEDED

Misc. Hand Tools
Multimeter
Wiring Diagram or Machine Schematic

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DC-600

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

1. Disconnect the main input power from the DC-600.

2. Inspect the input contactor, reconnect panel and
primary leads to the main transformer for loose or
faulty connections. See Figure F.8.

3. Confirm that the reconnect panel is configured cor­rectly for the three-phase AC input power supplied
to the DC-600. See the connection diagram locat­ed on the inside of the input box assembly.

4. Connect the correct AC three-phase input power to
the DC-600.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically hot parts.

5. Turn the power switch (SW1) to the ON position.

6. Make sure the input contactor (CR1) energizes.

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 .

a. L1 to L2

b. L2 to L3

c. L1 to L3

• If the voltages are not correct at the line side of

the input contactor, check the input fuses and
leads.

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.

a. T1 to T2

b. T2 to T3

c. T1 to T3

• If the correct voltages are not present, perform

the Input Contactor Test.

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DC-600

F-23 F-23

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER VOLTAGE TEST (continued)

FIGURE F.9 – TRANSFORMER SECONDARIES

A

A

SECONDARY LEADS

(6 PLACES)

PROCEDURE

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

RECEPTACLE

TS 2

A

COMMON BUSS

NOTE: All of the secondary voltages will vary if the
input line voltages vary. If any one or more of the volt­age checks are incorrect, check for loose or faulty con­nections. See the Wiring Diagram. If the leads and
connections are OK, the main transformer may be
faulty.

5

6

4

7

3

8

2

9

1

10

DC-600

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

21-21+ 41 4 2 31 32

PROCEDURE

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 cor­rect 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 termi­nal strip, the circuit breaker and the receptacle. See
the Wiring Diagram.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

12. Test for 42 VAC between leads #41 and #2 on the
terminal strip. See Figure F.10. If the correct volt­age 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
strip, and the circuit breaker. See the Wiring
Diagram.

DC-600

F-24 F-24

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER VOLTAGE TEST (continued)

FIGURE F.11 – FIRING BOARD

LED5

LED6

LED8

LED3

LED4

G3742-[ ]

LED9

LED7

LED1

LED2

LED10

FIRING BOARD

(205) 8
(206) 7
(207) 6
(208) 5

J5

16 (204)
15 (203)
14

4
3
2
1

13 (231)
12 (215)
11
10
9

J6

J7

J8

J4

PROCEDURE

WARNING

ELECTRIC SHOCK

• Do not touch electrically hot parts.

13. Remove the input power to the DC-600. Remove
the screws from the control box cover and careful­ly lower the cover and locate plug J5 on the Firing
Board. See Figure F.11.

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.

can kill.

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)

18. If the correct primary voltages are applied to the
main transformer and any of the secondary volt­ages are missing or not correct, the transformer
may be faulty.

NOTE: Always check the wiring between the trans­former windings and the test points before replac­ing the transformer.

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DC-600

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 trou­bleshooting 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 wind­ing.

MATERIALS NEEDED

Misc. Hand Tools
Multimeter
Wiring Diagram or Machine Schematic

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DC-600

F-26 F-26

TROUBLESHOOTING AND REPAIR

CONTROL TRANSFORMER TEST (continued)

FIGURE F.12 - CONTROL TRANSFORMER

Control

Transformer

Power
Switch

Secondary
Thermostat

A

PROCEDURE

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.

H2, H3 or H4 (see Input Diagram)

L3 T3
L2 T2
L1 T1

H1

3. Measure the voltage from X1 to X2. It should be
approximately 120VAC.

4. If this reading is incorrect check the connections on
the Primary and Secondary lads. If OK, the trans­former may be defective.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

• 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.

• The Secondary leads (red) are connected to the
Power Switch (X1) and the Secondary
Thermostat (X2).

2. Connect the Input Power and make certain that
rated voltage is present at L1 and L3.

NOTE: The DC-600 does not need be to turned ON.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically hot parts.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Common causes of control transformer failure

are;

• Improper connection of the Primary leads.

• A defective (shorted) Input Contactor coil.

IMPORTANT

Before installing a new transformer perform the
Input Contactor Test.

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 e­mailed to you.

DC-600

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 trou­bleshooting 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

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DC-600

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

271

W

(L3)

V

(L2)

U

(L1)

Cover Plate Screws

T3

T2

T1

PROCEDURE

VOLTAGE TEST

1. Disconnect the input power and remove the Input
Access Panel from the rear of the machine

2. Connect an AC voltmeter to the two coil terminals
of the Contactor See Figure F.13.

3. Apply the 3 phase power to the DC-600 and turn
the Power Switch ON.

WARNING

L3 T3
L2 T2
L1 T1

CONTACT TEST

1. Disconnect the input power and remove leads 271
and 272 from the CR1 coil terminals. See Figure
F.13.

2. Remove the contactor cover plate, blow out any
dust or dirt with low pressure air.

3. Examine the contacts for signs of arcing, sticking or
pitting. If any of these conditions exist, the
Contactor should be replaced.

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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

ELECTRIC SHOCK can kill.

• Do not touch electrically hot parts.

4. If the meter shows 120vac and the Contactor does
not operate, it is defective.

5. If the 120VAC is not present at the coil:

• Check the Power Switch, Thermostats and asso-

ciated wiring. See the Wiring Diagram.

• Also check the Control Board LEDs to be certain

that the machine is not in a “shut down” condition.
See the PC Board Troubleshooting Guide.

• Check the CR 2 relay for proper operation.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: A noisy or shorted contactor can damage the

Control Transformer.

5. With an ohmmeter, check across each set of con-

tacts for continuity (0 ⏐ ’s). See Figure F.13.

L1 t0 T1

L2 to T2

L3 to T3

If there is any resistance, replace the contactor.

6. Remove the 120VAC supply and re-check the con­tacts for an open condition. If any resistance is
measured, replace the contactor.

DC-600

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 trou­bleshooting 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 assem­bly 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)

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DC-600

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

1. Disconnect the input power from the DC-600.

2. Remove the top and side panels and drop the
nameplate to access the PC Boards.

3. Unplug the Molex connectors from both the Control
Board and the Firing Board.

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.

5. Using the analog ohmmeter:

• 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’.

• Reverse the meter leads and measure all the
same points. The readings should be very high or
‘open’, and typically, will all be similar.

6. If any of the test points shows a low resistance, dis­connect the Snubber Board from that SCR. If the
reading is still low, the SCR is defective.

7. Continue to the Active Test.

The Active test will require constructing a test cir­cuit or use of a commercial SCR Tester. See
Figure F.15.

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DC-600

F-31 F-31

TROUBLESHOOTING AND REPAIR

SCR BRIDGE TEST(continued)

FIGURE F.15 – ACTIVE SCR TEST

PROCEDURE

ACTIVE TEST

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.

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.

2. Connect the Tester to SCR 1 as shown in Figure

F.17.

a. Connect Tester lead (A) to the anode.
b. Connect Tester lead (C) to the cathode.
c. Connect Tester lead (G) to the gate.

3. Close switch SW-1.
NOTE: Switch SW-2 should be open.

4. Check the meter for zero voltage.
a. If the voltage reading is higher than zero, the

SCR is shorted.

b. If the reading is zero volts, continue to Step 6.

6. Close switch SW-2 for 2 seconds and release and
read the meter.
a. If the voltage is 3-6 volts while the switch is

closed and after the switch is open, the SCR is
functioning.

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.

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.

8. Reconnect the Tester leads. See Figure F.17.
a. Connect Tester lead (A) to the cathode.
b. Connect Tester lead (C) to the anode.
c. Disconnect Test lead (G) from the gate.

9. Close switch SW-1.

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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

11. Repeat steps 2 through 10 for each SCR.

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DC-600

F-32 F-32

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

CONSTANT CURRENT MODE – NO LOAD

0 volts

2ms50V

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 divi­sion represents 2 milliseconds in
time.

Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega­tive high inductance terminal.

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep .....2 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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DC-600

F-33 F-33

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

CONSTANT VOLTAGE INNERSHIELD

MAXIMUM OUTPUT SETTING – NO LOAD

0 volts

2ms50V

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 divi­sion represents 2 milliseconds in
time.

Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega­tive high inductance terminal.

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep .....2 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-34 F-34

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

CONSTANT VOLTAGE INNERSHIELD

MINIMUM OUTPUT SETTING – NO LOAD

0volts

2ms20V

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 divi­sion represents 2 milliseconds in
time.

Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega­tive high inductance terminal.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep .....2 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

F-35 F-35

TROUBLESHOOTING AND REPAIR

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

CONSTANT VOLTAGE INNERSHIELD MODE

0 volts

2ms20V

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 divi­sion 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 nega­tive high inductance terminal.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep .....2 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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DC-600

F-36 F-36

TROUBLESHOOTING AND REPAIR

TYPICAL SCR GATE VOLTAGE WAVEFORM

CONSTANT VOLTAGE INNERSHIELD

MAXIMUM OUTPUT SETTING – NO LOAD

0 volts

2V

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.

5ms

SCOPE SETTINGS

Volts/Div.......................2V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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DC-600

F-37 F-37

TROUBLESHOOTING AND REPAIR

ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

CONSTANT VOLTAGE INNERSHIELD

ONE OUTPUT SCR NOT FUNCTIONING

0 volts

2ms20V

This is NOT the typical DC open cir­cuit 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 rep­resents 2 milliseconds in time.

Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to nega­tive high inductance terminal.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep .....2 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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DC-600

F-38 F-38

NOTES

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DC-600

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 electr ical trou­bleshooting 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

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DC-600

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

271

W

(L3)

V

(L2)

U

(L1)

Cover Plate Screws

T3

T2

T1

CLEANING PROCEDURE

1. Remove the main input supply power to the
machine.

2. Locate and get access to the input contactor (CR1)
in the input box. See Figure F.18.

3. Remove the input contactor cover plate using a
phillips head screwdriver.

WARNING

Do not apply input power to the
machine with the input contactor
cover plate removed.

L3 T3
L2 T2
L1 T1

CONTACTOR REPLACEMENT
PROCEDURE

1. Disconnect main input supply power to the
machine.

2. Locate and get access to the input contactor (CR1)
in the input box. See Figure F.18.

3. Disconnect the main input supply power leads L1,
L2, and L3 to the input contactor.

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.

4. Disconnect the output leads T1, T2, and T3 from
the input contactor.

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4. Blow out any dirt or dust in or around the contacts
with a low pressure air stream.

5. Inspect the contacts for signs of excessive wear,
pitting, or contacts fused (stuck) together.

a. If any of these conditions are present, replace

the input contactor assembly.

NOTE: Lincoln does not supply contactor parts. They

may be available through the manufacturer.

6. Replace the input contactor cover plate.

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5. Identify and label the leads connected to the input
contactor coil. See the Wiring Diagram.

6. Disconnect the leads from the input contactor coil
(leads X1, #256 and #255A). See the Wiring

Diagram.

7. Remove the three self-tapping mounting screws
using a 5/16” socket wrench.

8. Remove the input contactor.

9. Insert the replacement input contactor and install it
following the procedures in reverse order.

NOTE: Be sure to reconnect all leads correctly.

DC-600

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 electr ical trou­bleshooting 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

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DC-600

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

A

A

215

LEAD (6 PLACES)

MOUNTING

BOLTS (4)

SECONDARY

LEFT SIDE

OF CHOKE

A

A

A

A

A

A

A

A

A

A

GATE LEAD

CONNECTOR

BUSHING

OUTPUT

SNUBBER

"A" LEAD, WHITE
(6 PLACES)

"C" LEAD, RED
(6 PLACES)

OUTPUT

SHUNT

REMOVAL PROCEDURE

1. Remove the input power to the DC-600.

2. Remove the case sides and top and lower the
nameplate.

NOTE: Before removing the Rectifier Assembly pay

particular attention to the original place­ment and location of the electrical connec­tions to assure proper reassembly. Tag any
leads where the Lincoln lead number is not
evident.

3. Disconect J4 from the firing PC Board and push it
and the plastic bushing through the bottom of the
control box.

210

A

CONNECTION

STRAP

A

A

A

5. Disconnect the #210(2) and #215(5) leads from the
Shunt, noting their positioning for proper reassem­bly. See Figure F.17.

6. Unbolt the Shunt from the Connection Strap at the
Positive Output Stud. See Figure F.17.

7. Remove the four (4) mounting bolts, noting the
placement of the insulators and hardware for prop­er 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.

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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.

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NOTE: Lincoln Electric does not recommend

replacement of individual SCRs. In the event
of a failure, the entire assembly should be
replaced.

DC-600

F-43 F-43

TROUBLESHOOTING AND REPAIR

SCR RECTIFIER BRIDGE

REMOVAL AND REPLACEMENT PROCEDURE (cont.)

FIGURE F.18 – RECTIFIER REPLACEMENT

Thread Forming Screw

Rectifer Mounting

Bracket

Fig. 18 ‘A’

OUTPUT

SHUNT

A

Plain Washer

Insulator

Bridge Mounting

Bracket

Insulator

Insulator

MOUNTING

BOLTS (4)

215

210

A

CONNECTION

STRAP

Transformer

Secondary Lead

SECONDARY

LEAD CONNECTION

(6 PLACES)

A

Lock Washer

OUTPUT

SNUBBER

CONNECTION

A

A

5/16-18 Hex Nut

Fig. 18 ‘B’

A

A

A

A

A

A

Plain Washer

‘A’ Lead from

Heat Sink

Negative Output Lead

Output Snubber Lead

Snubber

3/8-16 x 1 Cap Screw

Choke Lead

Lock Washer

3/8-16 Hex Nut

Plain Washers (2)

Fig18‘C’

A

A

A

A

A

REPLACEMENT PROCEDURE

NOTE: Any instructions packaged with the replace-

ment SCR Bridge assembly will supercede
these instructions.

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.

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 DC­600 using the original hardware or the hardware
provided with the new assembly. See Figure
F.18’A’.

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.

4. Reconnect the transformer secondary and snubber
‘A’ leads to the assembly. See Figure F.18’B’.

5. Mount the Output Snubber to the left side bracket
and connect the lead to the Choke. See Figure
F.18’C’.

NOTE: Torque all bolts for the following minimum

settings:

1/4” bolts 6 ft/lbs.

5/16” bolts 11 ft/lbs.

3/8” bolts 19 ft/lbs.

1/2” bolts 45 ft/lbs.

6. Bolt the shunt to the Positive Output Stud connec­tion strap and connect the # 210 and #215 leads as
they were on the original assembly.

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.

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DC-600

F-44 F-44

NOTES

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DC-600

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 electr ical trou­bleshooting 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

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DC-600

F-46 F-46

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER AND CHOKE

REMOVAL AND REPLACEMENT (continued)

FIGURE F.19 – TRANSFORMER REMOVAL

FIRING BOARD
CONNECTORS

(J-4 & J-5)

CONTROL

PAN EL

OUTPUT

SHUNT

A

SECONDARY

THERMOSTAT

215

210

A

CONNECTION

STRAP

30 Ω

RESISTOR

SECONDARY

LEAD (6 PLACES)

A

BAFFLES

NEGATIVE

OUTPUT LEAD

A

A

A

A

A

MOUNTING
HARDWARE
(4 PLACES)

A

INPUT

ACCESS

COVER

A

A

OUTPUT

CHOKE

A

A

A

A

AUXILIARY

LEADS

A

PRIMARY

LEADS

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.

2. Remove the fiber baffles that are around the Choke
and Transformer and save for installation when the
new transformer is installed.

3. Disconnect the Transformer Primary leads from the
reconnect panel.

NOTE: Pay close attention to the positioning of the

brass and steel hex nuts for reassembly.

4. Pull the leads out of the Input Box. This will require
removing some of the RTV sealant from the inside of
the box.

NOTE: Tag any leads where the Lincoln lead num-

bers are not evident to facilitate reassembly.

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.

NOTE: Cut ties and remove sleeving as necessar y

to perform the following steps. Note the
positioning for reassembly.

6. Disconnect leads #271 and #272 from th e Contactor
coil and pull them through the back of the Input Box.

7. Disconnect the leads from the Secondary
Thermostat and separate the X2 lead from te #256
lead.

8. Pull the three leads from Step 4 and the #271 lead­towards the Control Box.

9. Disconnect the #41, #2, and #4 leads from the
Terminal Strip and separate the “piggy-back” con­nections.

10. Separate the three in-line connectors between J5

of the Firing Board and J2 of the Control Board
(Leads 231, 290, & 291).

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).

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DC-600

F-47 F-47

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER AND CHOKE

REMOVAL AND REPLACEMENT (continued)

FIGURE F.20 – TRANSFORMER REMOVAL

Thread Forming Screw

Rectifer Mounting

Bracket

Plain Washer

Insulator

Bridge Mounting

Bracket

Insulator

Insulator

RECTIFIER
MOUNTING

(4 Places)

Lock Washer

Transformer

Secondary Lead

SECONDARY

LEAD CONNECTION

(6 PLACES)

A

5/16-18 Hex Nut

OUTPUT

SNUBBER

CONNECTION

A

A

A

Negative Output Lead

Plain Washer

‘A’ Lead from

Snubber

Heat Sink

A

A

A

A

A

A

TIG WELDED

CHOKE

CONNECTION

CHOKE

MOUNTING

(4 Places)

LIFT BALE

MOUNTING

(4 Places)

Output Snubber Lead

3/8-16 x 1 Cap Screw

Choke Lead

Lock Washer

3/8-16 Hex Nut

Plain Washers (2)

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

REMOVAL PROCEDURE (cont.)

12. Disconnect the five (5) #215 and the two(2) #210
leads from the Shunt, noting their positions for
reassembly. .

NOTE: It is important that the twisted pair (feed-

back leads) and the meter leads be recon­nected correctly to the Shunt.

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.

15. Attach a hoist to the lift bale with very slight ten­sion to provide support during the following Steps.

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

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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.

18. Remove the SCR assembly. See the SCR
Rectifier Bridge Removal Procedure. Some of
this procedure is already done. Save the hardware
and insulators for reassembly.

19. Carefully grind the welds from the right hand
choke connection to separate the common sec­ondary strap from the choke. Do not cut the choke
lead or reduce it’s size any more than necessary.
See Figure F.20.

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.

21. Remove the 4 bolts holding the lift bale assembly
to the transformer and lift it off and remove the
choke.

NOTE: The hole in the lift bale assembly is to

allow access to the mounting bolts with a
socket and extension.

DC-600

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

1. Place the flat washers and the choke on top of the
transformer and the lift bale assembly over both.

XXXXXXXXXXX

5. Connect the transformer secondary and snubber
leads to the SCR assembly. See Figure F.19 for
proper assembly. Torque all bolts per the following:

XXXXXXXXXXX

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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.

NOTE: Cover the transformer assembly with

‘damp’ shop cloths before performing Step
3 to prevent weld spatter from damaging
the transformer.

3. Thouroughly clean the choke lead and the sec­ondary 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.

4. Mount the SCR Bridge assembly using the hard­ware and insulators removed in Step 18 of the
removal procedure. See Figure F.18.

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1/4” bolts 6 ft/lbs.

5/16” bolts 11 ft/lbs.

3/8” bolts 19 ft/lbs.

1/2” bolts 45 ft/lbs.

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.

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.

8. Replace the baffles and any sleeving, cable ties or
sealants that were removed during the disassembly
procedure.

DC-600

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 Maximum Idle Amps Maximum Idle KW

208/3/60 11.0 1.0
230/3/60 10.0 1.0
380/3/60 6.0 1.0
416/3/60 5.5 1.0
460/3/60 5.0 1.0
550/3/60 4.2. 1.0
575/3/60 4.0 1.0

200/3/50 21.0 1.3
220/3/50 19.1 1.3
230/3/50 18.3 1.3
380/3/50 11.0 1.3
400/3/50 10.5 1.3
415/3/50 10.1 1.3
440/3/50 9.6 1.3
500/3/50 8.4 1.3
550/3/50 7.7 1.3

MAXIMUM OPEN CIRCUIT VOLTAGES

Mode Input Hertz Open Circuit Volts

CC Stick 60 66/70

CV MIG 60 44/47

Auxiliary Output (#31-#32) 60 122/128 VAC

Auxiliary Output (#41-#42) 60 44/48 VAC

MINIMUM ACCEPTABLE OUTPUT VOLTAGE - AT MAXIMUM OUTPUT SETTINGS

Mode Control Settings Load

CC Stick Output Control at Maximum 815 Amps @ 44.0 Volts (Min)

Arc Force Control at

Minimum

CV MIG Output Control at Maximum 815 Amps @ 44.0 Volts (Min)

Auxiliary Output (#31-#32) N/A 5 Amps @ 120/126 VAC (Min)

Auxiliary Output (#41-#42) N/A 5 Amps #41/45 VAC (Min)

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DC-600

F-50 F-50

NOTES

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

DC-600

G-1 G-1

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

TABLE OF CONTENTS - DIAGRAM SECTION

*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.

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DC-600

EN-170

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DC

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CRM38710

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THIS DOCUMENT CONTAINS PROPRIETARYINFORMATION OWNED BYLINCOLN GLOBA

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ABLEMUST BE O

F THE PROPE

R

C

APACITY FORTHE

CURREN

T A

ND DU

TY

CYC

LE

O

F I

MMED

IATE AND F

UTUR

E APPLICATIONS.

"P

OSITIVE". TO

CHAN

GE THE POLARITY, TURN

TH

E

DC-

600OFF, A

ND R

EVERSE THE LEADS AT

TH

E MULTI

-PROC

ESS SWIT

CH.

CONNEC

TIO

N D

IAGRAM,

CONNEC

T ELE

CTRODE

AND

WORK LEADS TO THESE TERMINALS

IN

STEADO

F THE PO

WER

SO

URCE

OU

TPUT TERMINALS.

TH

ESENOTES APPLY ONLY TO

DC-

600WITH

A

MU

LTI

-PROC

ESS SWITCH INS

TALLE

D.

N

.E.TH

IS DIA

GRA

M S

HOW

S T

HE "STIC

K" POLARITY

N

.F.

USING AWIR

E FEE

DER

, K-31

7 ORK-

318

N

.A.

LEADS 4 T

HRU

9 ARENOT PRESENT O

N

SINGLE VOLTAGE O

VER

345 V.

RECONNECT

PANEL

H1

TO
SUPPLY
06/02/
2005

L3

L2

L1

271

272

2

1

9

8

7

TO

PRIMAR

Y COILS

CODE

EL

ECTR

ICA

L

RECONNECT

H2

H1

TO

SUPPLY

L

INES

L3

L2

L1

271

TO

PRIMAR

Y COILS

CODE

EL

ECTR

ICA

L

RECONNECT

PANEL

H2

380/500V. & 460/575V.

FOR

LOW VOLTAG

E)

(SHO

WN C

ONNECT

ED

15

14

13

3

2

1

6

5

4

9

8

7

TO

PRIMAR

Y COILS

CODE

EL

ECTR

ICA

L

RECONNECT

PANEL

6

5

4

11

10

12

PANEL(SHO

WN
CONNECTED
FOR380V

.)

460V., 380/500V. & 460/575V.

MACHIN

ES.

ELECTRIC

AL SYMBOLS PERE1537

1

2

12

34

1 3

4

6

1

1

610

5

1

4

8

5

8

J3

J5

J7

CONNECTOR

CAV

ITYNUM

BERINGSEQUEN

CE

(V

IEWEDFROMCOMPONENT SIDEOF BOA

RD)

J6

J4

J2

1

8

J1

272

H1

TO

SUPPLY

L

INES

L3

L2

L1

271

H3

272

1

2

3

H1

TO

SUPPLY

L

INES

L3

L2

L1

271

H2

272

1

2

3

CR1

CR1

CR1

CR1

INPU

T

CONTACT

OR

INPU

T

INPU

T

INPU

T

CONTACT

OR

CONTACT

OR

CONTACT

OR

N

.B.THER

E ISNO 10, 11 AND 12

CONNEC

TIO

N

CODE

EL

ECTR

ICA

L

H1

TO

SUPPLY

L

INES

L3

L2

L1

271

H3

272

CR1

INPU

T

CONTACT

OR

SINGLE VOLTAGE 440V & 46

0V

226

238

236

R1

237

75

10K 2

W

215

232

224

81

77

76

76

75 77

T.S.1

80

280

229

280

210

215

11

2

2

3

3

4

4
5

5
6

6
7
8
9

1

2

80

232

75

222

233
256

235

231
255

J1

J2

J3

CONTR

OL

P.C. BOA

RD

11

2

2
33
4

4

5

5
6

6
7
8
9

J4

J5

P.C. BOA

RD

2

4

215

+

-

WORK

ELE

CTRODE

T

O STICK ELE

CTRODEHOLDER OR

AI

R-CARBONARC

TO

RCH

T

O "

WOR

K" USEDWITHSTI

CK

OR

AIR

-CARBONARC

STICK WORK LEA

D NOT

U

SEDW

HEN JUMPER

IS

USED.

OP

TIONAL USERSUPPLIEDJUMPERF

OR

TH

OSE SITUATIONS W

HER

E IT

IS N

OT

C

ABLES FOR STICK AND SEMI

-AUTOM

ATI

C

W

EL

DIN

G.

N.D.

N

.E.

N.D., N

.F.

OP

TIONAL

MULTI

-PROC

ESS

SWIT

CH

210

210

210

215

OUTPUT SHUNT
(50MV @

800

AM

PS)

OUTPUT

CH

OKE

C7

222

OUTPUT

N.D.

(+)

(-)

R2

32A

31

FA

N

MOTOR

272

273

SEC. LEA

D

THERM

OS

TAT

256

PR

IMA

RY

THERM

OS

TAT

256

PILOT
LIG

HT

235

255271

W

S

S

F

F

32A

207

208

3

15

6

9

12

S

F

205

206

2

14

5

8

11

AUX

. 1

S

F

203

204

F

31

S

69V

1

PR

I.

4

7

PR

I.

10

SE

C.

SE

C.

LEADS 4

PANEL

SCR

SCR

SCR

SCR

SCR

SCR

1

2

3

4

5

6

OUTPUT

SNU

BBE

R

G6

G4

G2

OUTPUTRECTIFIER

ASSEMBLY

SCR

SNU

BBE

RS

+

-

G1

G3

G5

NEC

ESSARY TO HAVE SEPARATE G

ROUND

AA A

A

A

A

C C C

C

C

C

N

.A.

13

CR2

10

7
8
9

10

11

12

J7

1
2
3
4
5
6
7
8

10
11
12

1
2
3

4

J6

A
B

B'
C

C'

A'

G1
G2
G3
G4
G5
G6

208
207
206
205

261
262
263
342

P22

13
14
15
16

FI

RINGCIRCU

IT

215
231
214
203
204

T

WISTED

TO

GE

THER

1
2
3

4

J

23

FOR

OPTIONAL

222

PARALLELI

NG

KIT

30 O

HM

100

W

41

2

4

.05

.05

mFd

mFd

S3

CONTR

OL

OUTPUT

S

WI

TCH

LOCAL/
REMO

TE

WELDINGMODE

S

WI

TCH

S4

(SHOWN

IN

CC

STICK POSITIO

N)

FAULT

PROTEC

TIO

N

R

ELAY

42A

S

F

41

42

BR

EAKE

R

10A

CIRCU

IT

21

41

4

31

32

21

-

+

32A

2

S2

OUTPUT

TERM.

SWITCH

4

2

T.S.2

N

.B.

N

.B.

T1MAINT

RANSFORMER

THRU

9 TO

RECONNECT

2

4

41

237

236

+

-

AM

210

215

32

31

255

X1

X2

T2

H1

H2

H3

CONTR

OL

TRANSFORMER

+

-

VM

222

210

222
06/
02/
200
5

222

210

M

AY VARY. SEEIMMANU

AL FORLOCATIO

N.

N.C

.LOC

ATIONO

F THIS LEADONT.S.2 TERMINAL STRIP

3

2

1

7

14

8

16

S1

SWITCH

42

15A

BR

EAKE

R

CIRCU

IT

229

290

291

291

290

ON

220/380/44

0 VOLTMACHIN

ES.

220/380/440 VOLT

DUAL E

XCEP

T 380/500V

AND

SINGLE VOLTAGE

UNDER 346V

.

(SHO

WN C

ONNECT

ED FORLOW VOLTAG

E)

(EXCEP

T 440 & 460V.)

PER NATIONA

L

TO

GR

OUND

PER NATIONA

L

TO

GR

OUND

TO GROUND

PER NATIONA

L

TO

GR

OUND

PER NATIONA

L

TO

GR

OUND

PER NATIONA

L

41

3

INPUT
PO

WER

255

224

81

226

238

R

.F.

CH

OKE

AS'BLY

R

.F.

CH

OKE

AS'BLY

R

.F.

CH

OKE

AS'BLY

R

.F.

CH

OKE

AS'BLY

214

320V
160J

TP

1

.05

mF

d

600

V

C1

C

LEV

ELAN

D, OHIO U

.S.A

.

R

DU

PLEX(ON60HZ.

MACHIN

ES ONLY)

69V

42V

34V

34V

34V

215

42

233

222

AJ

K

N

L

M

I

H

G

B

C

D

E

F

14 PI

N

(FRONT

REC

EPT.

75

76

77

21

41

31

42

32

2

4

GND

N.C.

VIEW

)

R

.F.

CH

OKE

AS'BLY

320V

320V

160

J

160

J

COM

NC

NO

G3506PR INT

E

FINAL PRINTEDFORMTOBEONONE8.25x 11.00ADHESIVEBACKEDLABELSHEETPERE3269-1

G-2

WIRING DIAGRAM - G3506

ELECTRICAL DIAGRAMS

G-2

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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.

EN-170

S

O

L

ID

E

D

G

E

G3506-1

DC

-600

W

IRING

DIA

GRAM

(230/4

60/57

5)

NONE

G3506

DO NOTSCALETHIS DRAWING

EQ

UIPMENT

TYPE:

SUBJECT:

SCALE:

UF

CRM36965

1

PAGE ___ OF

___

1

E

NGINEERINGCONTROLLE

D

MANUFACTURE

R:

No

THIS DOCUMENT CONTAINS PROPRIETARYINFORMATION OWNED BYLINCOLN GLOBA

L, INC.

AND MAYNOT BE DUPLICATED, COMMUNICATED

TO O

THER PARTIES OR US

ED FOR

ANYPURPOS

E WITHOUTTHE EXPRES

S WRIT

TEN PERMISSION

OF LINCOLN GLOBAL, INC.

PRO

PRIETARY & C

ONFIDENTIAL:

t

MAT

ERIAL TOLER

ANC

E (" ") TO AGREE

WITH PUBLISH

ED STANDARD

S.

ON ALLANGLE

S I

S ± .5 OF

A DEGR

EE

ON 3PLACE DE

CIM

ALS

IS

± .002 in.(±0.05

mm)

ON 2 PLAC

E D

ECIMALS I

S ± .02 in. (±0.5 mm)

UNLESS OTHERWISE SPECIFIED TOLERANCE:

M

ANUF

ACTURING TOLER

ANCEP

ER E2056

R

EVISED GRAPHIC

S FORCR2.

CHAN

GE DET

AIL:

REFER

ENCE:

MATERI

AL

DISPOSITION:

AP

PROVAL

DATE:

PROJECT
NUMBER:

DOCUMEN

T

NUMBER:

DOCUMEN

T

REV

ISI

ON:

IF PRINT

ED

@ A1SIZ

E

UNITS:

IN

CH

3/20/

2008

ddie

tz

-

DRAWN BY:

ENGINEER:

CLEVEL

AND

APPROVED:

CONTROL:

E

G3506-1

Insight

C

LEV

ELAN

D, OHIO U

.S.A

.

R

NO

TES:

N.D.WE

LDINGC

ABLEMUST BE O

F THE PROPE

R

C

APACITY FORTHE

CURREN

T A

ND DU

TY

CYC

LE

O

F I

MMED

IATE AND F

UTUR

E APPLICATIONS.

"P

OSITIVE". TO

CHAN

GE THE POLARITY,TURN

TH

E

DC-

600OFF, A

ND R

EVERSE THE LEADS AT

TH

E MULTI

-PROC

ESS SWIT

CH.

CONNEC

TIO

N D

IAGRAM,

CONNEC

T ELE

CTRODE

AND

WORK LEADS TO THESE TERMINALS

IN

STEADO

F THE PO

WER

SO

URCE

OU

TPUT TERMINALS.

TH

ESENOTES APPLY ONLY TO

DC-

600WITH

A

MU

LTI

-PROC

ESS SWITCH INS

TALLE

D.

N

.E.TH

IS DIA

GRA

M S

HOW

S T

HE "STIC

K" POLARITY

N

.F.USING AWIR

E FEE

DER

, K-31

7 ORK-

318

6

5
4

9

8

7

TO

PRIMAR

Y COILS

CODE

EL

ECTR

ICA

L

RECONNECT
PANEL

ELECTRIC

AL SYMBOLS PERE1537

1

2

12

34

1 3

4

6

1

1

610

5

1

4

8

5

8

J3

J5

J7

CONNECTOR

CAV

ITYNUM

BERINGSEQUEN

CE

(V

IEWEDFROMCOMPONENT SIDEOF BOA

RD)

J6

J4

J2

1

8

J1

H1

TO

SUPPLY

L

INES

L3

L2

L1

271

H2

272

A

CR1

INPU

T

CONTACT

OR

226

238

236

R1

237

75

10K 2

W

215

232

224

81

77

76

76

75 77

T.S.1

80

280

210

215

1

2

3

4
5
6
7
8
9

1

2

233
256

231

255

J2

J3

CONTR

OL

P.C. BOA

RD

11

2

2

33

4

4

5

5

6

6
7
8
9

J4

J5

P.C. BOA

RD

2

4

215

+

-

WORK

ELE

CTRODE

T

O STICK ELE

CTRODEHOLDER OR

AI

R-CARBONARC

TO

RCH

T

O "

WOR

K" USEDWITHSTI

CK

OR

AIR

-CARBONARC

STICK WORK LEA

D NOT

U

SEDW

HEN JUMPER

IS

USED.

OP

TIONAL USERSUPPLIEDJUMPERF

OR

TH

OSE SITUATIONS W

HER

E IT

IS N

OT

C

ABLES FOR STICK AND SEMI

-AUTOM

ATI

C

W

EL

DIN

G.

N.D.

N

.E.

N.D.,N

.F.

OP

TIONAL

MULTI

-PROC

ESS

SWIT

CH

210

210

210

215

OUTPUT SHU

NT

(50MV

@800

AMPS)

OUTPUT

CH

OKE

C7

222

(+)

(-)

R2

32A

31

FA

N

MOTOR

272

273

SEC. LEA

D

THERM

OS

TAT

256

PR

IMA

RY

THERM

OS

TAT

256

PILOT
LIG

HT

233

235

255

271

W

S

S

F

F

32A

207

208

3

18

6

9

S

F

205

206

2

14

5

8

S

F

203

204

F

31

S

69 V

16

PR

I.

4

7

PR

I.

SE

C.

SE

C.

SCR

SCR

SCR

SCR

SCR

SCR

1

2

3

4

5

6

OUTPUT

SNU

BBE

R

G6

G4

G2

OUTPUTRECTIFIER

ASSEMBLY

SCR

SNU

BBE

RS

+

-

G1

G3

G5

NEC

ESSARY TO HAVE SEPARATE G

ROUND

AA A

A

A

A

C C C

C

C

C

N

.G.

1

CR2

10

J7

1
2
3

4

5
6
7
8

10
11
12

1
2
3

4

J6

A
B

B'
C

C'

A'

G1
G2
G3
G4

G5

G6

208
207
206
205

261
262
263
342

P22

13
14
15
16

FI

RINGCIRCU

IT

215
231

214
203
204

T

WISTED

TO

GE

THER

1
2
3

4

J

23

FOR

OPTIONAL

222

214

PARALLELI

NG

KIT

30 100

W

41

2

4

.05

.05

mFd

mFd

S3

CONTR

OL

OUTPUT

S

WI

TCH

LOCAL/

REMO

TE

WELDINGMODE

S

WI

TCH

S4

(SHOWN

IN

CC

STICK POSITIO

N)

FAULT

PROTEC

TIO

N

R

ELAY

42A

S
F

41

42

BR

EAKE

R

10A

CIRCU

IT

21

41

4

31

32

21

-

+

32A

2

S2

OUTPUT

TERM.

SWITCH

4

2

T.S.2

T1MAINT

RANSFORMER

2

4

41

237

236

+

-

AM

210

215

32

31

DU

PLEX(ON60HZ

MACHIN

ES ONLY)

255

X1

X2

T2

H1

H2

H3

CONTR

OL

TRANSFORMER

+

-

VM

222

210

AJ

K

N

L

M

I

H

G

B

C

D

E

F

14 PI

N

(FRONT

REC

EPT.

75

76

77

21

41

31

42

32

2

4

GND

42

222

222

222

210

N.C.

M

AY VARY. SEE

IM

MANU

AL FORLOCATIO

N.

N.C

.LOC

ATIONO

F THIS LEADONT.S.2 TERMINAL STRIP

7

14

8

16

VIEW

)

S1

SWITCH

42

15A

BR

EAKE

R

CIRCU

IT

229

290
291

291

290

PER NATIONA

L

TO

GR

OUND

41

13

17

15

N

.G. TAPEUP SEPARATELY TO PROVIDE AT

LEAST 600V I

NSU

LATIO

N.

230/460/57

5V

(SHO

WN C

ONNECT

ED

FOR

LOW VOLTAG

E)

3

2

1

15,14,13

18,17,16

N.G.N.

G.

H3

H4

N.

G.

ALL PRIMA

RY
LEADS TO
RECONNECT
PANEL

INPUT

PO

WER

255

229

280

215

1
2
3
4
5
6

80

232

75

222

J1

7
8

9
10
11

12

224

81

226

238
235

R

.F.

CH

OKE

AS'BLY

R

.F.

CH

OKE

AS'BLY

R

.F.

CH

OKE

AS'BLY

R

.F.

CH

OKE

AS'BLY

320V
160J

TP

1

.05

mFD

600

V

C1

DUPLEX RECEPTACLETOBEWIRED AS
SHOW N FOR A

LL

CODESEXCEPT

1066

3.

GF

CI RECEPTA CLE FOR CODE

1066

3 TO

HA

VE LE

AD 31 CONNECTED TO THE

WHITE

LI

NE. LEAD 32TO BECONN ECTED

TO THE HO T

LI

NE.

69 V

42

V

34 V 34 V

34 V

C7

OUTPUT

N.D.

.05

.05

mFd

mFd

320V

320V

160

J

160

J

OUTPUT

N.D.

320V

320V

G3506-1PRI NT

E

COM

NC

NO

FINALPRINTED FORMTOBEONONE8.25x 11.00ADHESIVEBACKEDLABEL SHEET PERE3269-1

G-3

WIRING DIAGRAM - 230/460/575 VOLT MACHINES - G3506-1

ELECTRICAL DIAGRAMS

G-3

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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.

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

G-4

SCHEMATIC - COMPLETE MACHINE - G3575

ELECTRICAL DIAGRAMS

G-4

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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

G-5

SCHEMATIC - CONTROL PC BOARD - G3408-1

ELECTRICAL DIAGRAMS

G-5

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

EN-170

S

O

L

ID

E

D

G

E

G3409-1

D

C 600

CONTR

OL PC BOARD ASSEMBLY

-

G1504-

4

DO NOTSCALETHIS DRAWING

EQ

UIPMENT

TYPE:

SUBJECT:

SCALE:

UF

CRM39073

1

PAGE ___ OF

___

1

E

NGINEERINGCONTROLLE

D

MANUFACTURE

R:

No

THIS DOCUMENT CONTAINS PROPRIETARYINFORMATION OWNED BYLINCOLN GLOBA

L, INC.

AND MAYNOT BE DUPLICATED, COMMUNICATED

TO O

THER PARTIES OR US

ED FORANY

PURPOS

E WITHOUTTHE EXPRES

S WRIT

TEN PERMISSION

OF LINCOLN GLOBAL, INC.

PRO

PRIETARY & C

ONFIDENTIAL:

t

MAT

ERIAL TOLER

ANC

E ("") TO AGREE

WITHPUBLISHEDST

ANDARD

S.

ON ALLANGLE

S I

S ± .5 OF

A DEGR

EE

ON3PLACE DE

CIM

ALS

IS

± .002 in.(±0.05

mm)

ON 2PLAC

E D

ECIMALS I

S ± .02 in. (±0.5 mm)

UNLESS OTHERWISESPECIFIED TOLERANCE:

M

ANUF

ACTURING TOLER

ANCEPERE

2056

R

EVISEDC2 THRU

C4

CHANGEDETAIL:

REFER

ENCE:

MATERI

AL

DISPOSITION:

AP

PROVAL

DATE:

PROJECT
NUMBER:

DOCUMEN

T

NUMBER:

DOCUMEN

T

REV

ISI

ON:

IF PRINT

ED

@ A1SIZ

E

UNITS:

IN

CH

11

-16-

2007

fivor

y

-

DRAWN BY:

ENGINEER:

CLEVEL

AND

APPROVED:

CONTROL:

C

G3409-1

Insight

C1

1

S13490-48

47/16

0

C2,

C3,

C4

3

T1157

7-38K .02/

600

C5,

C14

2

S1349

0-39

18/15

C6,

C18

2T11577-26

.1/100

C7

1

S13490-12

10/25

C8

1

T11

577-32

.01/200

C30

1

S13490-19

1.8/2

0

C12

1

S13490-25

4.7/35

C13

1

S13490-63

.47/50

C16

1

S13490-10

2 .047/100

C17

1

S13490-61

6/150

C19

1

S13490-4

.022/200

C20

1

S13490-40

2.7/5

0

C25

1

S13490-67

2/50

D1,

D2,D3,D4,D7,D9,

D10,

D19, 10

T12

199-2

1N4007

D5,D11,D12,D13,D14,D15,

D16, 33

T121

99-1

1N4004

D33,

D34,D35,D36,D37,D38,

D

Z1

1T12702-42

1N5353 ZENER DI

ODE

D

Z2,DZ16

2

T1270

2-33

1N5347B

D

Z5

1T12702-29

1N4744A

D

Z7

1T12702-19

1N4742A

D

Z9,DZ12

2

T1270

2-38

1N4751

D

Z13,DZ14,D

Z15

3T12702-30

1N5225B

Q1,Q2,Q4,Q8,Q10

5

T127

04-36

2N4857

Q3,Q5,Q6,Q11

4

T127

04-68

2N4401

Q9,Q12

2

T12

704-69

2N4403

Q

U1

1

T1270

7-4

2N6027

R1,

R2

2T14900-1200 20W

R3

1

T14

648-17270 5W

R4,

R46

2

S1940

0-3320

332

1/4W

R6,R23,R48,

R154

4

S19400-825

2 8

2.5K 1/4W

R7,R22,R24,R29,R44,

R45,

7

S19400-10011K 1/4W
R102
R8,R72,R78,R79,R88,

R97,

8

S19400-22112.21K 1/4W

R9,R34,R42,R56,R57,R64,

R71 11 S19400-68116.81K 1/4W

R10,

R11,

R155

3

S2400

0-3300

330/

.75W

R12,

R61,R93,

R106

4

S194

00-4752

47.

5K 1/4W

R13,

R62,

R120

3

S1940

0-4753

475K 1/4W

R16,

R118

2

S1940

0-1372

13.7K 1/4W

R17

1

S1940

0-3011

3.01K 1/4W

R18,

R101

2

T10

812-7720K 1/2W TRI

MMER

R20,

R21,

R50

3

S1940

0-1003

100K 1/4W

R26,

R38

2

T10

812-68

1K 1/2W TRIM

MER

R28,

R87,

R108

3

S1940

0-4750

475

1/4W

R30,

R104

2

S19400-26

70 267 1

/4W

R36,

R94,

R126,

R127

4

S1940

0-1502

15K 1/4W

R39,

R63,

R80

3

T10

812-3950K 1/2W TRI

MMER

R43,

R68,R82,R90,

R92

5

S19400-221222.1K 1/4W

R47,R110,

R117

3

S19400-13011.3K 1/4W

R66

1

S19400-562256.2K 1/4W

R69,R100,

R109

3

S19400-68

10 681 1

/4W

R74

1

S19400-3923392K 1/4W

R111

1

S19400-47R5 4

7.5 1/

4W

R112

1

S19400-10

00 100 1

/4W

R148,

R149

2

S19400-243

2 2

4.3K 1/4W

SCR1

1

S1516

1-19

8A.,400V. S

CR

TP1

1T13640-11

45J

TP2,TP3

2

T13

640-18160J

X2,

X3

2

S15128-4

IC,LM224,OP-AMP

N.

B.

C9,C21,C22,C23,C24,C26,

C27, 11 S16668-5

.022/5

0

D40,

D41,D42,D43,D44,D45,

D46

D

Z17

1

T1270

2-41

1N5359B Z

ENE

R DI

ODE

D

Z4

1T12702-27

1N4740A ZENER DI

ODE

LE

D1,LED2,LED3,LED4,LED5, 6

T136

57-2RE

D L

ED

LE

D6

R5,R98,

R123,

R136

4

S194

00-1503150K 1/4W

R103,

R150

R19,

R58,R65,R81,

R105,

R133,

7 S194

00-1002

10K 1/4W

R134

R121,

R137

R25,

R51,R67,R73,R77,

R107,

8

S19400-1004

1M 1/4W

R31,

R85,R99,

R151

4

S194

00-1501

1.5K 1/4W

R52,

R141

2

S19400-2213221K 1/4W

R40,

R83,R89,

R139

4

S194

00-6812

68.

1K 1/4W

R70,

R86,

R140

3

S1940

0-1821

1.82K 1/4W

R95,

R138

2

S19400-332233.2K 1/4W

R113

1

T12

300-68250 10W

X4

1

S151

28-10

IC,431,VOLTAGEREF.

R152

1

S19400-20012.0K 1/4W

R153

1

T14

648-2320 5W

D26,

D28,D29,D30,D31,D32,

ITEM

R

EQ'D

PARTNO.IDEN

TIFICATI

ON

R14,

R124

2

S19400-39R2 3

9.2 1/

4W

R135

1

S19400-392239.2K 1/4W

{

X1

1

S151

28-16

IC,LT1014,LIN.INT. CI

R.

R53,

R54,R55,

R159

4

S240

00-1000100/.75W

R96,R125,R156,

R157

J1

1

S24020-12HEADER,VERTIC

AL

J2

1

S24020-10HEADER,VERTIC

AL

D47,

D48

D17,

D18,D22,D23,D25,

D20,

D21

C34

1

S16668-3100pF/10

0

C32,

C33

2

T115

77-58

.0047/30

00V

C28,

C29,C31,

C35

R27,

R37,R41,R76,R91,

R114,

R115 7 S19400-47514.75K

R15,

R160

2

S19400-24312.43K 1/4W

J3

1

S24020-2G HE

ADER,VERTIC

AL, GOL

D

N

OTES

N.B. D

O N

OT COATWITH ENCAPSULAT

ION MATERIAL.

N.D.R

ESISTORFEET

MUST BE FLAT AGAINST BOARD. APPLY

TO BOAR

D.

N.

C. O .30 AREA TO BE F

REE O

F ENCAPSULAT

ION MATERIAL

BOTH SIDE

S OF BOARD(TOTAL 5

PLACES)

ITEM

2

TO R1 ANDR2 RE

SISTORFEET

TO AN

CHOR

C

APA

CITORS

= MFD/V

OLTS

R

ESISTORS=O

HMS

1

2

BOARD BLANK

N.D.

.04oz.

E2861

RTV

COATING

I

TEM

REQ'DPARTNO.

IDENT

IFICATION

1 G3409-C CONTROL P.C.

FOR

PARTS O

RDER

S:

AND

INCLUD

E T1159

0-9

0.

SEALTRIMMERSWITHA

DROPOF

E401

8.

N.C.

N.B.

N.B.

1

N.D.

DC

600 CONTRO

L

G3409-

1

R2

R1

R160

R154

R157

R156

R125

R42

R127

R126

R120

R73

R118

R16

R4

R123

R34

R102

R28

R100

R82

R7

R17

R15

R8

R89

R9

R36

R98

R52

R40

R12

R20

R19

R91

R21 R22

R24

R23

R30

R31

R29

R27

R25

R6

R41

R45

R44

R43

R48

R47R46

R50

R51

R56

R57

R58

R62

R61

R66

R67

R65

R64

R81

R13

R79

R78

R83

R87

R88

R86

R85

R92

R93

R90

R95

R94

R96

R97

R99

R103

R104

R115

R68

R72

R70

R69

R71

R74

R76

R121

R77

R108

R109

R110

R117

R106

R105

R5

R107

R114

R111

R112

R133

R134

R135

R136

R137

R138

R139

R140

R141

R148

R149

R14

R124

R37

R150

R151

R152

C34

C35

C21

C23

C24

C9

C28

C29

C27

C26

C22

C31

C16

C7

+

C25

+

C12

C5

C14

C20

C13

C30

C1

C19

C17

C

6

C18

C

8

C

4

C

3

C

2

C33

C32

DZ1

4

DZ13

DZ15

DZ5

DZ4

DZ7

DZ9

DZ12

D47

D48

D4

D3

D2

D1

D31

D9

D10

D7

D15

D11

D12

D14

D13

D17

D20

D19

D18

D16

D30

D22

D21

D23

D25

D26

D28

D29

D33

D32

D34

D37

D38

D35

D5

D36

D40

D41

D42

D46

D43

D44

D45

DZ16

DZ2

DZ1

DZ17

X1

X2

X3

X4

LED1

LED5

LED2

LED3

LED4

LED6

TP1

J2

J1

J3

R155

R159

R10

R53

R54

R55

R11

R

38

R

63

R

39

R

80

R

26

R101

R

18

R113

R3

R153

Q8

Q10

Q4

Q2

Q1

Q6

Q5

Q9

Q3

Q12

Q11

QU1

TP2

TP3

S

CR1

G-6

CONTROL PC BOARD ASSEMBLY - G3409-1

ELECTRICAL DIAGRAMS

G-6

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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.

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

G-7

SCHEMATIC - FIRING PC BOARD - G3741-1

ELECTRICAL DIAGRAMS

G-7

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.