Lincoln Electric SVM188-A Safety Precautions, Electric Shock can Kill, Select Proper Location

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A-3

INSTALLATION

A-3

SAFETY PRECAUTIONS

STACKING

 

Read entire Installation Section before installing

Three DC-600 machines can be stacked.

 

the DC-600.

DO NOT stack more than three machines in one

 

ELECTRIC SHOCK CAN KILL.

grouping.

 

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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.

__________________

SELECT PROPER LOCATION

Place the welder where clean cooling air can freely cir- culate in through the front louvers and out through the rear louvers. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shut- downs.

LIMIT ON STACKING

WARNING

Lift only with equipment of ade- quate lifting capacity.

Be sure machine is stable when

 

lifting.

 

• Do not lift this machine using lift

 

bail if it is equipped with a heavy

 

accessory such as trailer or gas

 

cylinder.

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.

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

Follow these guidelines when stacking:

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

2.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.

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.

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DC-600

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Contents DC-600 ISAFETYi Can be dangerous SafetyElectric Shock can kill Fumes and GasesFor Electrically Powered equipmentSûreté Pour Soudage a L’Arc Précautions DE SûretéElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications DC-600 InstallationSelect Proper Location Safety PrecautionsElectric Shock can Kill Ground Connection Fuse and Wire SizesElectrical Input Connections Connection for Highest Rating Plate VOLTAGE, 50 or 60 HZ Reconnect ProcedureConnection for 440 Volts 50 or 60 HZ V 60HZ See Machine Rating Plate for Required Input Supply Voltage Connections Output ConnectionsELECTRODE, Work and #21 Lead Terminal Strip 2 T.S.2 Auxiliary Power Control ConnectionsTerminal Strip 1 T.S.1 DC-600 Table of Contents Operation Section Operation Safety PrecautionsRecommended Processes and Equipment Design Features AdvantagesGeneral Description Output Control Output Voltage Current Meanings of Graphical Symbols on Case FrontOFF Input Power Welding CapabilityControls and Settings Meaning of Graphical Symbol for Ground CON- NectionOVERLOAD, OVERCURRENT, and Fault Protection Auxiliary Power in MS-RECEPTACLEOperating Steps Remote Control of Machine OperationWelding Procedure Recommendations Remote NA-3 Automatic Wire FeederLN-7 and Other Constant Wire Feeders LN-8 or LN-9 SEMI-AUTOMATIC Wire FeederDC-600 Table of Contents Accessories Section Field Installed Options AccessoriesWire Feeders and Tractors Factory or Field Installed OptionsFigure C.2 MULTI-PROCESS Switch Cable Connections Accessories Table of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceSafety Precautions Electric Shock can Kill 1TABLE of CONTENTS-THEORY of Operation Section E-1 Input Circuit and Main TRANS- Former Theory of OperationFiring Board Firing CIRCUIT, Control CIR- Cuit and RectificationRectification Thermal Protection SCR Operation DC-600 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairControl Feeder. See Protective Devices Check all three phase input Output Control J1,Pin2. See Wiring Diagram Wiring Diagram Materials Needed PC Board Troubleshooting GuideTest Description PC Board Troubleshooting Guide Figure F.2 Control Board LEDs Control BoardDC-600 Internal Trigger Circuit Test Internal Trigger Circuit Test Procedure75 76 Internal Trigger Circuit TestDC-600 Firing Board Test Firing Board Test Control Board Test Figure F.7 Control Board Control Board TestMain Transformer Voltage Test Figure F.8 Input Contactor and Reconnect Panel Main Transformer Voltage TestFigure F.9 Transformer Secondaries Main Transformer Voltage Test Control Transformer Test Control Transformer Test ProcedureInput Contactor Test Voltage Test Input Contactor TestSCR Bridge Test SCR Bridge Test Anode Cathode Remove Insulating PaintActive Test Scope Settings Maximum Output Setting no Load Minimum Output Setting no Load 35TROUBLESHOOTING and REPAIRF-35 2V/Div Volts DC-600 Input Contactor CR1 CLEANING/REPLACEMENT Contactor Replacement Procedure Input Contactor CLEANING/REPLACEMENT ProcedureCleaning Procedure SCR Rectifier Bridge Removal and Replacement Procedure SCR Rectifier Bridge 42TROUBLESHOOTING and REPAIRF-42Removal and Replacement Procedure Removal ProcedureInsulator Lock Washer Plain Washer Output Snubber Lead Replacement ProcedureDC-600 Main Transformer and Choke Removal and Replacement Main Transformer and Choke Removal and ReplacementRemoval Procedure Weld Maximum Open Circuit Voltages Input Idle Amps and WattsDC-600 Table of Contents Diagram Section Electrical Diagrams Wiring Diagram 230/460/575 Volt Machines G3506-1 Schematic Complete Machine G3575 Schematic Control PC Board G3408-1 Control PC Board Assembly G3409-1 Schematic Firing PC Board G3741-1