Lincoln Electric SVM188-A service manual Figure C.2 MULTI-PROCESS Switch Cable Connections

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C-3

ACCESSORIES

C-3

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

When the MULTI-PROCESS SWITCH is in the "Stick or Air/Carbon Arc" position, only those terminals are energized. The wire feeder nozzle or gun and electrode are not electrically "hot" when in this mode.

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.

TERMINAL

STRIP COVER

BOX

CONNECTOR

21+

21- 41

4

2

31 32

75 76 77

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

LEADS

NEGATIVE (–)

 

–

 

+

POSITIVE (+)

OUTPUT

 

 

 

OUTPUT

STUD

 

 

 

 

 

STUD

ELECTRODE

ELECTRODE

CABLE

CABLE

WIRE

WORK

+

STICK AIR/CARBON

 

 

 

 

ARC WELDING

FEEDER

 

 

 

 

EQUIPMENT

 

ELECTRODES

 

 

 

 

WORK

 

 

WORK

CABLE

JUMPER (IF NEEDED

CABLE

 

SEE INSTRUCTIONS)

 

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3.Open the terminal strip hinged cover located on the Case Front Assembly.

4.The MULTI-PROCESS SWITCH is mounted to the case front with four 1/4” self-tapping screws. The screw holes are 13.8” apart side to side and 4.5” apart top to bottom, Run one of the 1/4” screws part way in and out of the screw holes to open them up. Make sure that the two sleeved control leads do not get pinched when hanging the switch; route them out the side to the right of the switch. Support the switch in position and start the four screws, then tighten them.

5.Route the MULTI-PROCESS SWITCH control leads through the strain-relief box connectors and into the terminal strip. Connect wire feeder control cable as specified in specific connection diagram and make other terminal strip connections as specified on the connection diagram for the Lincoln wire feeder being used.

6.Connect the control leads from the MULTI- PROCESS SWITCH to terminals #2 and #4 on the DC-600's terminal strip.

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

FIGURE C.2 - MULTI-PROCESS SWITCH CABLE CONNECTIONS.

8.Connect the left cable from the MULTI-PROCESS SWITCH (facing the front of the machine) to the DC-600 negative (-) output terminal. See Figure C.2.

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

•Insert the wire feeder electrode and work cables through the strain relief loop on the left side of the DC-600 (facing the front of the machine).

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

10.Connect wire feeder control cable and make other terminal strip connections as specified on the con- nection diagram for the Lincoln wire feeder being used.

11.Set the DC-600 OUTPUT TERMINALS switch to

REMOTE.

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 InstallationElectric Shock can Kill Safety PrecautionsSelect Proper Location Electrical Input Connections Fuse and Wire SizesGround 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 ELECTRODE, Work and #21 Lead Output ConnectionsConnections Terminal Strip 1 T.S.1 Auxiliary Power Control ConnectionsTerminal Strip 2 T.S.2 DC-600 Table of Contents Operation Section Operation Safety PrecautionsGeneral Description Design Features AdvantagesRecommended 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-RECEPTACLEWelding Procedure Recommendations Remote Control of Machine OperationOperating 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 Safety Precautions Electric Shock can Kill MaintenanceRoutine and Periodic Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Input Circuit and Main TRANS- Former Theory of OperationRectification Firing CIRCUIT, Control CIR- Cuit and 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 Test Description PC Board Troubleshooting GuideMaterials 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 Cleaning Procedure Input Contactor CLEANING/REPLACEMENT 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
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