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OUTPUT PROBLEMS
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
CAUTION
Machine input contactor operates
but machine has no weld output with
the Output terminal Switch ON. Fan
runs and pilot light glows.
NOTE: Alternate Trigger methods.
• Operate Wire Feeder trigger.
• Place a jumper across 2 & 4 on
the terminal strip T.S.2. or
across pins C & D in 14 pin con-
nector.
1. Check LED 10 on the Firing
Board and LED 6 on the Control
Board. Both Should be ON.
2. Check all of the LEDs on both
PC Boards for proper operation.
1. If both LEDs are OFF,try an
alternate method of triggering.
If LEDs come ON and machine
weld output is restored check
the Weld Terminal Switch (S2)
and the associated wiring. If not,
see the Internal Trigger Circuit
Test.If both LEDs are ON and
there is still no output go to Step
2.
2. The Firing Board or Control
Board may be defective. See the
PC Board Troubleshooting
Guide.
TROUBLESHOOTING AND REPAIR
F-6 F-6
DC-600
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The machine does not have maxi-
mum weld output.
1. Check all three phase input
lines at the DC600. Make
sure input voltages match
machine rating and recon-
nect panel.
2. Put LOCAL/REMOTE Switch
(SW3) in "LOCAL" position.
If problem is solved then
check remote control unit or
wire feeder.
1. Check the Output Control
Potentiometer (R1) and
associated wiring for loose or
faulty connections. See
wiring diagram.
3. Perform the Control Board
Test.
4. Perform the Firing Board Test.
5. Perform the SCR Output
Bridge Test.
6. Perform the Main Transformer
Test.
The weld output terminals are
always electrically "hot".
1. Remove any external leads
hooked to #2 and #4 on the ter-
minal strip. If the problem dis-
appears the fault is in the control
cable or wire feeder.
2. If some open circuit voltage is
present (over 3VDC.) after per-
forming Step #1. then the prob-
lem is within the DC600.
1. Check for an internal short
between leads #2 and #4. See
wiring diagram.
3. Perform Firing Board Test.
4. Perform Control Board Test.
5. Perform the SCR Output
Bridge Test.
6. The SCR Snubber(s) may be
"leaky". Check or replace.