Lincoln Electric SVM188-A service manual Auxiliary Power in MS-RECEPTACLE

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OPERATION

B-6

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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 “ ” posi- tion, the DC-600’s output terminals will be electri- cally “cold” until a remote device such as a wire feeder closes the #2 and #4 circuit in the MS-recep- tacle or terminal strip (T.S.2). When this switch is in

the ON “ ” position the machine’s output termi- nals 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

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-recep- tacle.

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.

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 termi- nal 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-recep- tacle. A 10 amp circuit breaker protects the 42 volt cir- cuit from overloads.

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

OVERLOAD, OVERCURRENT, AND FAULT PROTECTION

This welder has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambi- ent temperatures. When the welder is subjected to an overload or loss of cooling, a thermostat will open. The input contactor will open and remain open until the machine cools; the white POWER light stays illuminat- ed. No welding is possible during this cool down peri- od. The machine will reset automatically when the ther- mostat cools.

The power source is also protected against overcur- rents in the SCR bridge assembly through an electron- ic protection circuit. This circuit senses currents over 780 amps on the power source and opens the input contactor should the overcurrent remain for a predeter- mined time (the white POWER light stays illuminated). The predetermined time varies with the amount of overcurrent; the greater the overcurrent, the shorter the time. The input contactor will remain open until the power source is manually started by resetting the POWER ON/OFF toggle switch.

DC-600

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Contents DC-600 ISAFETYi Safety Electric Shock can killFumes and Gases Can be dangerousPowered equipment For ElectricallyPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications DC-600Safety Precautions Electric Shock can KillSelect Proper Location Fuse and Wire Sizes Electrical Input ConnectionsGround Connection Reconnect Procedure Connection for Highest Rating Plate VOLTAGE, 50 or 60 HZConnection for 440 Volts 50 or 60 HZ V 60HZ See Machine Rating Plate for Required Input Supply Voltage Output Connections ELECTRODE, Work and #21 LeadConnections Auxiliary Power Control Connections Terminal Strip 1 T.S.1Terminal Strip 2 T.S.2 DC-600 Table of Contents Operation Section Safety Precautions OperationDesign Features Advantages General DescriptionRecommended Processes and Equipment Meanings of Graphical Symbols on Case Front OFF Input PowerWelding Capability Output Control Output Voltage CurrentMeaning of Graphical Symbol for Ground CON- Nection Controls and SettingsAuxiliary Power in MS-RECEPTACLE OVERLOAD, OVERCURRENT, and Fault ProtectionRemote Control of Machine Operation Welding Procedure RecommendationsOperating Steps NA-3 Automatic Wire Feeder RemoteLN-8 or LN-9 SEMI-AUTOMATIC Wire Feeder LN-7 and Other Constant Wire FeedersDC-600 Table of Contents Accessories Section Accessories Wire Feeders and TractorsFactory or Field Installed Options Field Installed OptionsFigure C.2 MULTI-PROCESS Switch Cable Connections Accessories Table of Contents Maintenance Section Maintenance Safety Precautions Electric Shock can KillRoutine and Periodic Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Input Circuit and Main TRANS- FormerFiring CIRCUIT, Control CIR- Cuit and Rectification RectificationFiring Board Thermal Protection SCR Operation DC-600 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair PC Board Troubleshooting ProceduresControl Feeder. See Protective Devices Check all three phase input Output Control J1,Pin2. See Wiring Diagram Wiring Diagram PC Board Troubleshooting Guide Test DescriptionMaterials Needed PC Board Troubleshooting Guide Control Board Figure F.2 Control Board LEDsDC-600 Internal Trigger Circuit Test Procedure Internal Trigger Circuit TestInternal Trigger Circuit Test 75 76DC-600 Firing Board Test Firing Board Test Control Board Test Control Board Test Figure F.7 Control BoardMain Transformer Voltage Test Main Transformer Voltage Test Figure F.8 Input Contactor and Reconnect PanelFigure F.9 Transformer Secondaries Main Transformer Voltage Test Control Transformer Test Procedure Control Transformer TestInput Contactor Test Input Contactor Test Voltage TestSCR Bridge Test Anode Cathode Remove Insulating Paint SCR Bridge TestActive 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 Input Contactor CLEANING/REPLACEMENT Procedure Cleaning ProcedureContactor Replacement Procedure SCR Rectifier Bridge Removal and Replacement Procedure 42TROUBLESHOOTING and REPAIRF-42 Removal and Replacement ProcedureRemoval Procedure SCR Rectifier BridgeReplacement Procedure Insulator Lock Washer Plain Washer Output Snubber LeadDC-600 Main Transformer and Choke Removal and Replacement Removal and Replacement Main Transformer and ChokeRemoval Procedure Weld Input Idle Amps and Watts Maximum Open Circuit VoltagesDC-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