Lincoln Electric SVM188-A Safety, Electric Shock can kill, Fumes and Gases, Can be dangerous

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ii

SAFETY

 

 

 

 

 

 

 

 

ii

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

 

ARC RAYS can burn.

 

 

 

3.a. The electrode and work (or ground) circuits

 

 

 

 

 

 

4.a. Use a shield with the proper filter and cover

 

are electrically “hot” when the welder is on.

 

 

 

 

 

 

 

 

 

 

 

 

 

plates to protect your eyes from sparks and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do not touch these “hot” parts with your bare

 

 

 

 

 

 

the rays of the arc when welding or observing

 

skin or wet clothing. Wear dry, hole-free

 

 

 

 

 

 

open arc welding. Headshield and filter lens

 

gloves to insulate hands.

 

 

 

 

 

 

should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.

 

4.b. Use suitable clothing made from durable flame-resistant

 

Make certain the insulation is large enough to cover your full

 

 

 

 

material to protect your skin and that of your helpers from

 

area of physical contact with work and ground.

 

 

 

 

the arc rays.

 

 

 

 

 

 

 

 

In addition to the normal safety precautions, if welding

 

4.c. Protect other nearby personnel with suitable, non-flammable

 

must be performed under electrically hazardous

 

 

 

 

screening and/or warn them not to watch the arc nor expose

 

conditions (in damp locations or while wearing wet

 

 

 

 

themselves to the arc rays or to hot spatter or metal.

 

 

clothing; on metal structures such as floors, gratings or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

scaffolds; when in cramped positions such as sitting,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUMES AND GASES

 

 

kneeling or lying, if there is a high risk of unavoidable or

 

 

 

 

 

 

 

 

accidental contact with the workpiece or ground) use

 

 

 

 

 

 

can be dangerous.

 

 

 

the following equipment:

 

 

 

 

 

 

 

 

 

• Semiautomatic DC Constant Voltage (Wire) Welder.

 

 

 

 

 

 

5.a. Welding

may

produce fumes

and

gases

 

• DC Manual (Stick) Welder.

 

 

 

 

 

 

 

hazardous to health. Avoid breathing these

 

 

 

 

 

 

 

 

• AC Welder with Reduced Voltage Control.

 

 

 

 

 

 

 

fumes and gases.When welding, keep

 

 

 

 

 

 

 

 

 

your head out of the fume. Use enough

3.c. In semiautomatic or automatic wire welding, the electrode,

 

 

 

 

 

 

 

ventilation and/or exhaust at the arc to keep

 

electrode reel, welding head, nozzle or semiautomatic

 

 

 

 

fumes and gases away from the breathing zone. When

 

welding gun are also electrically “hot”.

 

 

 

 

welding with electrodes which require special

 

 

 

 

 

 

ventilation such as stainless or hard facing (see

3.d. Always be sure the work cable makes a good electrical

 

 

 

 

instructions on container or MSDS) or on lead or

 

connection with the metal being welded. The connection

 

 

 

 

cadmium plated steel and other metals or coatings

 

should be as close as possible to the area being welded.

 

 

 

 

which produce highly toxic fumes, keep exposure as

 

 

 

 

 

 

low as possible and below Threshold Limit Values (TLV)

3.e. Ground the work or metal to be welded to a good electrical

 

 

 

 

using local exhaust or mechanical ventilation. In

 

(earth) ground.

 

 

 

 

confined spaces or in some circumstances, outdoors, a

 

 

 

 

 

 

respirator may be required. Additional precautions are

3.f.

Maintain the electrode holder, work clamp, welding cable and

 

 

 

 

also

required

when

welding

on

galvanized

steel.

 

welding machine in good, safe operating condition. Replace

 

5. b. The operation of welding fume control equipment is affected

 

damaged insulation.

 

 

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

 

 

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

 

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

 

welding

procedure

and

 

application

involved.

 

 

 

 

 

 

 

3.h. Never simultaneously touch electrically “hot” parts of

 

 

 

 

Worker exposure level should be checked upon installation

 

 

 

 

and periodically thereafter to be certain it is within applicable

 

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

 

 

OSHA PEL and ACGIH TLV limits.

 

 

 

 

 

between the two can be the total of the open circuit voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of both welders.

 

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

 

 

 

3.i. When working above floor level, use a safety belt to protect

 

 

 

 

coming

from degreasing, cleaning

or

spraying

operations.

 

 

 

 

The heat and rays of the arc can react with solvent vapors to

 

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

 

 

form phosgene, a highly toxic gas, and other irritating prod-

 

 

 

 

 

 

3.j.

Also see Items 6.c. and 8.

 

 

 

 

ucts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.d. Shielding gases used for arc welding can displace air and

 

 

 

 

 

 

cause injury or death. Always use enough ventilation,

 

 

 

 

 

 

especially in confined areas, to insure breathing air is safe.

 

 

 

5.e. Read and understand the manufacturer’s instructions for this

 

 

 

 

 

 

 

 

 

equipment and the consumables to be used, including the

 

 

 

 

 

 

material safety data sheet (MSDS) and follow your

 

 

 

 

 

 

employer’s safety practices. MSDS forms are available from

 

 

 

 

 

 

your

welding

distributor or

from

the manufacturer.

 

 

 

5.f. Also see item 1.b.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Aug ‘06

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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 InstallationSafety Precautions Electric Shock can KillSelect Proper Location Fuse and Wire Sizes Electrical Input ConnectionsGround Connection 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 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 Operation Safety PrecautionsDesign Features Advantages General DescriptionRecommended Processes and Equipment 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-RECEPTACLERemote Control of Machine Operation Welding Procedure RecommendationsOperating Steps 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 Maintenance Safety Precautions Electric Shock can KillRoutine and Periodic Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Input Circuit and Main TRANS- Former Theory of OperationFiring CIRCUIT, Control CIR- Cuit and Rectification RectificationFiring Board 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 PC Board Troubleshooting Guide Test DescriptionMaterials Needed 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 Input Contactor CLEANING/REPLACEMENT Procedure Cleaning ProcedureContactor Replacement 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