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Lincoln Electric Idealarc DC600 9773MSP User Manual

Lincoln Electric Idealarc DC600 9773MSP
114 pages
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IDEALARC DC-600
World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel (216) 481-8100
For use with machines having Code Numbers:
9773MSP
9774
9776M
9778M
9779M
9780M
9793MSP
9910M
SVM108-A
August, 1998
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.
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Table of Contents

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Lincoln Electric Idealarc DC600 9773MSP Specifications

General IconGeneral
BrandLincoln Electric
ModelIdealarc DC600 9773MSP
CategoryWelding System
LanguageEnglish

Summary

Safety Precautions

Electric Shock Hazards

Explains risks and precautions related to electric shock when operating welding equipment.

Arc Rays Hazards

Details risks from arc rays and necessary protective measures for eyes and skin.

Fumes and Gases Hazards

Covers dangers of welding fumes and gases, emphasizing ventilation and respiratory protection.

Welding and Cutting Sparks Hazards

Warns about fire and explosion risks from sparks and hot materials, requiring fire prevention.

Cylinder Safety Precautions

Outlines safety measures for handling compressed gas cylinders to prevent explosions.

Electrically Powered Equipment Safety

Covers safety related to electrical input and grounding for powered equipment.

Engine-Powered Equipment Safety

Details safety guidelines specific to operating and maintaining equipment with engines.

Electric and Magnetic Fields Safety

Addresses potential hazards from EMF fields and precautions for pacemaker wearers.

Installation Section

Technical Specifications

Provides detailed technical data, ratings, and dimensions for the IDEALARC DC-600.

Installation Safety Precautions

Outlines essential safety measures to be followed before and during the installation process.

Proper Location and Stacking

Details recommended placement for air circulation and instructions for safely stacking multiple units.

Tilting Precautions

Emphasizes the need for a stable, level surface to prevent the machine from toppling.

Electrical Input Connections

Explains how to connect electrical input power to the machine, matching voltage and frequency.

Ground Connection Requirements

Details the importance of grounding the machine frame to a good electrical earth ground.

Input Power Supply Connections

Guides on connecting three-phase AC power leads to the input contactor terminals.

Reconnect Procedure for Voltage Selection

Guides users through changing machine voltage settings via the reconnect panel for different power sources.

Output Connections

Details how to connect electrode and work leads to the output terminals and secure strain relief loops.

Wire Feeder Control Connections

Provides instructions for connecting semi-automatic or automatic wire feeder control cables to the machine.

Stick Welding/Air Carbon Arc Connection

Explains how to connect for stick welding or air carbon arc cutting operations.

Operation Section

Operation Safety Precautions

Highlights critical safety warnings specific to operating the welding equipment.

General Description

Introduces the IDEALARC DC-600, its SCR control, and supported welding processes.

Recommended Processes and Equipment

Lists recommended welding or cutting processes and compatible equipment for the machine.

Operational Features and Controls

Describes the standard controls and features available on the machine's front panel.

Design Features and Advantages

Highlights key design features that contribute to the machine's performance and usability.

Welding Capability and Duty Cycle

Details the machine's welding capacity and duty cycle ratings, including thermal protection.

Controls and Settings Explained

Describes the function and location of all operator controls and adjustments on the front panel.

Operating Steps

Provides a step-by-step guide for starting and operating the machine in local control mode.

Remote Control Operation

Explains how to control the machine's output from a remote location using specific accessories.

Welding Procedure Recommendations

Offers guidance on selecting welding modes and settings for different processes and applications.

Wire Feeder Integration

Details setup and operation for specific wire feeders like NA-3, NA-5, LN-8, LN-7, and LN-9.

Accessories Section

Options and Accessories Overview

Lists available optional accessories and their functions for enhancing machine capabilities.

Multi-Process Switch Installation

Explains how to install and connect the Multi-Process Switch for versatile welding operations.

Wire Feeder Connections

Details connecting various wire feeders (NA-3, NA-5, LN-8, LN-9, LN-7) to the IDEALARC DC-600.

Undercarriage and Meter Options

Describes optional accessories like undercarriages for mobility and meters for monitoring.

Maintenance Section

Maintenance Safety Precautions

Stresses safety measures, particularly electric shock hazards, before performing maintenance.

Routine and Periodic Maintenance

Outlines daily checks and periodic cleaning tasks required to maintain the machine.

Theory of Operation Section

Power Supply and Transformer Operation

Explains how input voltage, contactor, and the main transformer supply power and regulate output.

Output, Rectification, and Control

Details the process of output generation, rectification via SCRs, and feedback control mechanisms.

Protection Devices and SCR Function

Covers protective circuits against overloads/temperature and the basic function of Silicon Controlled Rectifiers (SCRs).

Troubleshooting and Repair Section

How to Use the Troubleshooting Guide

Provides instructions on using the guide to identify and resolve machine malfunctions effectively.

PC Board Troubleshooting Procedures

Guides on diagnosing and replacing potentially faulty printed circuit boards, including static precautions.

Output Problem Diagnosis

Lists common output issues, possible causes, and recommended corrective actions for troubleshooting.

Welding Problem Diagnosis

Covers troubleshooting steps for issues related to arc starting and overall arc characteristics during welding.

Component Test Procedures

Details specific tests for components like transformers, firing boards, control boards, and SCRs.

Input Contactor Maintenance

Explains procedures for cleaning or replacing the main input contactor (CR1).

SCR Assembly Removal

Provides instructions for removing individual SCRs or the complete SCR output bridge assembly.

Lift Bail and Transformer Removal

Details procedures for removing major assemblies like the lift bail, transformer, and choke.

Retest After Repair Procedures

Outlines retesting steps and acceptable voltage/current values after performing repairs.

Electrical Diagrams Section

Control PC Board Layout

Shows the physical layout of the control PC board (G1504-4 and above).

Firing PC Board Layout

Illustrates the physical layout of the firing PC board (G1486-5 and above).

Wiring Diagrams

Provides wiring diagrams for various machine codes, illustrating electrical connections and component locations.

Operating Schematic

Presents a functional block diagram showing the overall electrical operation of the machine.

Control Board Schematic

Shows the detailed schematic of the control PC board for G1504-4 and above.

Firing Board Schematic

Shows the detailed schematic of the firing PC board for G1486-5 and above.

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