red-d-arc im669-d dc-600 - lincoln electric global sites · dc-600 red-d-arc ii safety ii arc rays...

RED-D-ARC

DC-600

IM669-DNovember, 2008

Red-D-Arc Spec-Built Welding Equipment

This RED-D-ARC welder is built to RED-D-ARC Extreme Dutydesign specifications by Lincoln Electric.

Safety Depends onYou

This welder 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 EQUIPMENTWITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT.And, most importantly, think before you act and be careful.

For use with machines having Code Numbers: 10663, 11073, 11134, 11340, 11542

The Global Leader in Welder Rentals

OPERATOR’S MANUAL

(

DC-600 RED-D-ARC

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ʻ95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your rightside, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

DC-600 RED-D-ARC

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

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

are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

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

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployerʼs safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

DC-600 RED-D-ARC

iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturerʼsrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturerʼs recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Jan, 07

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

DC-600 RED-D-ARC

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dansles positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.

c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ʻ93

vv

Thank You for selecting one of our QUALITY products. We want you to takepride in operating this product ••• as much pride as we have inbringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code (if available)______________________________________________________

Serial Number (if available)__________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above.

CUSTOMER ASSISTANCE POLICYThe business of our company is manufacturing and selling high quality welding equipment. Our challenge is tomeet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us foradvice or information about their use of our products. We respond to our customers based on the best informa-tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume noliability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including anywarranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matterof practical consideration, we also cannot assume any responsibility for updating or correcting any such informa-tion or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.

We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within thecontrol of, and remains the sole responsibility of the customer. Many variables beyond our control affect theresults obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing.

vi vi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications ............................................................................................. A-1Safety Precautions ..................................................................................................... A-2Select Proper Location.................................................................................................A-2

Stacking.................................................................................................................A-2Tilting .....................................................................................................................A-2

Electrical Input Connections ....................................................................................... A-3Fuses and Wire Sizes............................................................................................A-3Ground Connection .............................................................................................. A-3Input Power Supply Connections...........................................................................A-3

Reconnect Procedure ................................................................................................ A-4Output Connections ................................................................................................... A-5

Electrode, Work and #21 Lead ..............................................................................A-5Auxiliary Power and Control Connections .............................................................A-6Terminal Strips.......................................................................................................A-7

________________________________________________________________________Operation .........................................................................................................Section B

Safety Precautions ............................................................................................... B-1General Description ............................................................................................. B-1Recommended Processes and Equipment ...........................................................B-1Design Features and Advantages ........................................................................B-2Welding Capability ............................................................................................... B-2Meaning of Graphical Symbols on Case Front ......................................................B-2Meaning of Graphical Symbols on Rating Plate ....................................................B-3Meaning of Graphical Symbol for Ground Connection ..........................................B-3Controls and Settings ...........................................................................................B-4Auxiliary Power in MS - Receptacle.......................................................................B-5Overload, Overcurrent and Fault Protection ..........................................................B-5Operating Steps ................................................................................................... B-6Remote Control of Machine Operation ..................................................................B-6Welding Procedure Recommendations ............................................................... B-6Semi-Automatic and Automatic Wire Feeding with a DC-600 and Wire Feeders ..........................................................................B-7

NA-3 Automatic Wire Feeder...................................................................B-7, B-8NA-5 Automatic Wire Feeder ..........................................................................B-9LN-8 Semi-Automatic Wire Feeder .................................................................B-9LN-7 & LN-9 Semi-Automatic Wire Feeders ...................................................B-9

________________________________________________________________________

Accessories .....................................................................................................Section CWire Feeders and Tractors....................................................................................C-1Field Installed Options...........................................................................................C-1

Remote Output Control (K857 or K857-1) ......................................................C-1Remote Control Adapter Cable (K864) ...........................................................C-1Undercarriages (K817P, K842).......................................................................C-1Paralleling Kit (K1611-1) .................................................................................C-1TIG Module (K930-2) ......................................................................................C-1

Factory or Field Installed Options ..................................................................C-1, C-2Multi-Process Switch (K804-1)........................................................................C-2

Connections for Semi-Automatic or Automatic Wire Feeder Control ....................C-3________________________________________________________________________

vii viiTABLE OF CONTENTS

Page

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Routine and Periodic Maintenance........................................................................D-1Testing the GFCI Receptacle ................................................................................D-1

________________________________________________________________________Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.............................................................................E-2 thru E-7

________________________________________________________________________Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F

________________________________________________________________________PARTS PAGES .......................................................................................................P-362

________________________________________________________________________

60% Duty Cycle

122/61/49

A-1INSTALLATION A-1

TECHNICAL SPECIFICATIONS – DC-600

Volts at Rated Amperes444444

Auxiliary PowerSee the OPERATION section

for Auxiliary Power information by model

Amps600680750

Maximum Open Circuit Voltage72V

Duty Cycle100% Duty Cycle60% Duty Cycle50% Duty Cycle

Output Range70A/13V-780A/44V (CV)90A/24V-780A/44V (CC)

INPUT - THREE PHASE ONLY

OUTPUT

1Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.

RECOMMENDED INPUT WIRE AND FUSE SIZES

StandardVoltage

230/460/575/60

100% Duty Cycle

108/54/43

50% Duty Cycle

134/67/54

Input Current at Rated Output

RATED OUTPUT

INPUTVOLTAGE /

FREQUENCY

230460575

TYPE 75°C(SUPER LAG)OR BREAKERSIZE (AMPS)1

175 Amp90 Amp70 Amp

TYPE 75°CGROUND WIRE

IN CONDUITAWG(IEC-MM2) SIZES

6 (14)8 (8.4)8 (8.4)

TYPE 75°CCOPPER WIRE

IN CONDUITAWG(IEC-MM2) SIZES30°C (86°F) Ambient

2 (34)6 (14)8 (8.4)

INPUT AMPERERATING ON

NAMEPLATE

1085443

HERTZ

606060

PHYSICAL DIMENSIONSHEIGHT30.75 in781 mm

WIDTH22.25 in567 mm

DEPTH39.0 in

988 mm

WEIGHT522 lbs.237 kg.

DC-600 RED-D-ARC

STACKING

Three DC-600 machines can be stacked.

DO NOT stack more than three machines in onegrouping.

DO NOT stack the DC-600 on another type ofmachine.

Follow these guidelines when stacking:

1. Select a firm, level surface capable of sup-porting the total weight of up to three machines (1570 pounds/712 kilograms).

2. Set the bottom machine in place.

3. Stack the second machine on top of it by aligning the two holes in the base rails of the second machine with the two pins on top front of the bottom machine.

4. Repeat process for third machine.

NOTE: The machines must be stacked with the CaseFront of each machine flush with each other. See

Figure A.1.

FIGURE A.1 - Stacking DC-600 machines

TILTINGThe DC-600 must be placed on a stable, level surfaceso it will not topple over.

A-2INSTALLATION A-2

Read entire Installation Section before installingthe DC-600.

SAFETY PRECAUTIONS

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel shouldinstall this machine.

• Turn the input power OFF at the disconnect switch or fuse boxbefore working on the equipment.

• Do not touch electrically hot parts.

• Always connect the IDEALARC DC-600 groundingterminal to a good electrical earth ground.

• Set the DC-600 Power ON/OFF PUSH BUTTON tothe OFF position when connecting power cord toinput power.

-----------------------------------------------------------------------------------------

SELECT PROPER LOCATION

Place the welder where clean cooling air can freelycirculate in through the front louvers and out throughthe rear louvers. Dirt, dust or any foreign material thatcan be drawn into the welder should be kept at a mini-mum. Failure to observe these precautions can resultin excessive operating temperatures and nuisanceshut-downs.

WARNING

DC-600 RED-D-ARC

FALLING EQUIPMENT can causeinjury.• Do not lift this machine using lift bale if

it is equipped with a heavy accessorysuch as trailer or gas cylinder.

• Lift only with equipment of adequate lifting capacity.• Be sure machine is stable when lifting.• Do not stack more than three high.• Do not stack the DC-600 on top of any other

machine.---------------------------------------------------------------------

WARNING

STACKING HOLE

STACKING PINS

A-3INSTALLATION A-3

INPUT POWER SUPPLY CONNECTIONS

A qualified electrician should connect the input powersupply leads.

1. Follow all national and local electrical codes.

2. Use a three-phase line.

3. Remove Input Access Door at upper rear ofmachine.

4. Follow Input Supply Connection Diagram locatedon the inside of the door.

5. Connect the three-phase AC power supply leadsL1, L2, and L3 to the input contactorterminals in the Input Box Assembly by passingthem thru the three aligned .50” diameter holes inthe baffle and tighten them in the terminal connec-tors. Be sure to close the baffle by inserting thetab into the slot in the baffle. See Figure A.3.

FIGURE A.3 - Input Power SupplyConnections

INPUT POWER SUPPLYCABLE WITH BUSHINGOR BOX CONNECTOR

INPUTCONTACTOR (CR1)

RECONNECTPANEL ASSEMBLY

DC-600 RED-D-ARC

ELECTRICAL INPUT CONNECTIONS

Before installing the machine check that the input sup-ply voltage, phase, and frequency are the same as thevoltage, phase, and frequency as specified on thewelder Rating Plate located on the Case BackAssembly. Welder is rated for 230/460/575V input andis shipped from the factory connected for 460 input.Input power supply entry is through the hole in theCase Back Assembly. See Figure A.2 for the locationof the machineʼs input cable entry opening, InputContactor (CR1), and reconnect panel assembly fordual voltage machines.

FIGURE A.2 - Rear Panel

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses ordelay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machinebeing used. They are also called inverse time or ther-mal/magnetic circuit breakers.

DO NOT use fuses or circuit breakers with a loweramp rating than recommended. This can result in “nui-sance” tripping caused by inrush current even whenmachine is not being used for welding at high outputcurrents.

Use input and grounding wire sizes that meet localelectrical codes or see the Technical Specificationspage in this manual.

GROUND CONNECTION

Ground the frame of the machine. A ground terminal marked with the symbol ( ) is located insidethe Case Back of the machine near the input contac-tor. Access to the Input Box Assembly is at the upperrear of the machine. See your local and national elec-trical codes for proper grounding methods.

INPUT SUPPLYCABLE ENTRY

OPENING INPUTCONTACTOR (CR1)

RECONNECTPANEL ASSEMBLY

FIGURE A.4-Reconnect Panel Board Positions for 230/460/575 VAC Machines

A-4INSTALLATION A-4

RECONNECT PROCEDURE

Multiple voltage machines are shipped connected tothe highest input voltage listed on the machineʼs ratingplate. Before installing the machine, check that theReconnect Panel in the Input Box Assembly is con-nected for the proper voltage.

Failure to follow these instructions can causeimmediate failure of components within themachine.

When powering welder from a generator be sureto turn off welder first, before generator is shutdown, in order to prevent damage to the welder.------------------------------------------------------------------------

To reconnect a multiple voltage machine to a differentvoltage, remove input power and change the positionof the reconnect board on the Reconnect Panel.Follow The Input Connection Diagram located on theinside of Case Back Input Access Door. These con-nection diagrams for the following codes are listedbelow.

1. For 230/460/575, see Figure A.4. (M15666)

2. For Voltages not listed, see the Input ConnectionDiagram pasted on the inside of the Case Back Input Access Door.

CAUTION

DC-600 RED-D-ARC

A-5INSTALLATION A-5

OUTPUT CONNECTIONS

See Table A.1 for recommended DC-600 cable sizes for combined lengths of electrode and work cables.

TABLE A.1DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable

at 100% Duty CycleELECTRODE, WORK AND #21 LEAD

Cable SizeParallel CablesCable Length

1/0 (53mm2)2

2

2

Lengths up to 150 ft. (46m)

2/0 (85mm2)150 ft.(46m) to 200 ft (61m)

3/0 (107mm2)200 ft.(61m) to 250 ft.(76m)

CONNECTIONS

A. Connect Electrode and Work Leads toOutput Terminals.

1. Set the ON/OFF toggle switch to OFF.

2. Locate the retractable strain relief loops directlybelow the output terminals in the lower right andlower left corners of the Case Front Assembly.See Figure A.5.

3. Pull out the retractable strain relief loops.

4. Insert the electrode lead through the loop directlybelow the desired polarity (positive or negative).Pull through enough cable to reach the output terminals.

5. Connect electrode lead to the desired terminal(positive/negative).

6. Tighten the output terminal nut with a wrench.

7. Connect the work lead to the other output terminal following steps 4-6.

FIGURE A.5 - Output Terminals.

B. Connect #21 Work Sense Lead to ProperTerminal

There are two work sense lead connection points (+21and -21) on terminal strip (T.S.2) located behind thehinged access panel on the right side of the casefront. See 14 Pin MS Type Receptacle section orTerminal Strip Section for connection procedure.

DC-600 RED-D-ARC

A-6INSTALLATION A-6

AUXILIARY POWER AND CONTROL CONNECTIONS

Located at the left side of the front of the welderbehind a hinged cover is a 115VAC GFCI receptaclefor auxiliary power. On the right side of the case frontis a 14 Pin MS type receptacle for connection of auxil-iary equipment such as wire feeders. Also, terminalstrips with 115VAC and connections for auxiliaryequipment are located behind the hinged accesspanel on the right side of the case front. (see AuxiliaryPower Table for details)

115VAC GFCI RECEPTACLE (60 HERTZ MODELSONLY)

The 115VAC GFCI receptacle is protected by a circuitbreaker located on the nameplate. The receptacle is aNEMA 5-15R.

AUXILIARY POWER TABLEVoltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various ModelsAuxiliary 60 HzPower Models

Connections

At GFCI 115V 15AReceptacle

Terminal strip 115V 15Aterminals 31 & 32

MS-Receptacle 115V 15Apins A & J

MS-Receptacle 42V 10Apins I & K

FIGURE A.6 FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE

PIN LEAD NO. FUNCTION

A 32 115 VACB GND Chassis ConnectionC 2 Trigger CircuitD 4 Trigger CircuitE 77 Output ControlF 76 Output ControlG 75 Output Control

H 21 Work Sense Connection2

I 41 42 VAC

J 31 115 VAC1.

K 42 42 VACL --- ---M --- ---N --- ---

F=76

G=75

H=21

I=41

J=31K=42

A=32

B=GND

C=2

D=4

E=77

L N

M

1.115VAC circuit is on all models.

2.As shipped from the factory Lead #21 from the 14 Pin connector isconnected to “-21” on the terminal strip (T.S.2). This is the config-uration for positive welding. If welding negative polarity, connectlead #21 to the “+21” connection point on the terminal strip(T.S.2).

14 PIN MS TYPE RECEPTACLE(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)

Refer to the figure A.6 for the available circuits in the14 pin receptacle.

42 VAC is available at receptacle pins I and K.A 10 amp circuit breaker protects this circuit.

115 VAC is available at receptacle pins A and J (AllModels). A 15 amp circuit breaker protects this circuit.Note that the 42 VAC and 115 VAC circuits are electri-cally isolated from each other.

DC-600 RED-D-ARC

A-7INSTALLATION A-7

TERMINAL STRIPS

Terminal strips are available behind the cover on thecase front to connect wire feeder control cables thatdo not have a 14 Pin MS-type connector. These termi-nals supply the connections as shown in the followingTerminal Strip charts. NOTE: There are two worksense lead connection points on the terminal strip.Connect both the work sense lead #21 from the 14 pinconnector and #21 lead of the control cable to “-21”when welding positive polarity or to “+21” when weld-ing negative polarity.

TERMINAL STRIP 1 (T.S.1)

TERMINAL STRIP 2 (T.S.2)

Lead No. Function

75 Output Control76 Output Control77 Output Control

1.115VAC circuit is on all models.

2.As shipped from the factory Lead #21 from the 14 Pin connector isconnected to “-21” on the terminal strip (T.S.2). This is the config-uration for positive welding. If welding negative polarity, connectlead #21 to the “+21” connection point on the terminal strip(T.S.2).

Lead No. Function

+21 Work Connection (Electrode Negative)-21 Work Connection (Electrode Positive)2

41 42 VAC 4 Trigger Circuit 2 Trigger Circuit 31 115 VAC1

32 115 VAC1

DC-600 RED-D-ARC

GENERAL DESCRIPTION

The DC-600 is an SCR controlled three phase weldingand cutting power source. It uses a single rangepotentiometer to control:

• Submerged Arc Semi-Automatic or AutomaticWelding

• Open Arc Semi-Automatic or Automatic Welding• Stick Welding• Air/Carbon Arc Cutting (Carbon Rod Sizes up to

3/8” Diameter)

The DC-600 has a three-position Welding ModeSwitch to enable the user to operate in one of threemodes:

• Constant Current (CC) Stick (also used for AAC)• Constant Voltage (CV) Submerged Arc• Constant Voltage (CV) Innershield (also used for

GMAW)

The optional Multi-Process Switch allows the user toswitch between semi-automatic or automatic weldingand stick welding or air/carbon arc cutting without dis-connecting the wire feeder equipment control, elec-trode,and work leads.

RECOMMENDED PROCESSES ANDEQUIPMENT

The DC-600 is designed for GMAW (MIG), FCAW,and submerged arc (SAW) within the capacity of themachine. It can also be used for stick welding(SMAW) and for air carbon arc (AAC) cutting with car-bon rods up to 3/8" diameter.

The DC-600 is provided with a three position modeswitch that selects CV Innershield, CV SubmergedArc, or CC Stick.

The DC-600 can be easily connected to wire feedingequipment, including:

• Semi-automatic wire feeders LN-7, LN-7 GMA,LN-742, LN-8, LN-9, LN-9 GMA, LN-10, DH-10LN-15, LN-23P, and LN-25.

• Automatic wire feeders NA-3, NA-5, and NA-5R.• Tractors LT-7 and LT-56

B-1OPERATIONB-1

ELECTRIC SHOCKcan kill.

• Do not touch electrically live partsor electrode with skin or wetclothing.

• Insulate yourself from work andground.

• Always wear dry insulating gloves.

• Do not use AC welder if your clothing, gloves orwork area is damp or if working on, under orinside work piece.

Use the following equipment:- Semiautomatic DC constant voltage(wire) welder.- DC manual (stick) welder.- AC welder with reduced voltagecontrol.

• Do not operate with panels removed.• Disconnect input power before servicing.------------------------------------------------------------------------

FUMES AND GASEScan be dangerous.• Keep your head out of fumes.• Use ventilation or exhaust to

remove fumes from breathing zone.-----------------------------------------------------------------------

WELDING, CUTTING and GOUGING SPARKScan cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on containers thathave held combustible.

-----------------------------------------------------------------------

ARC RAYScan burn.

• Wear eye, ear and body protection.------------------------------------------------------------------------

SAFETY PRECAUTIONS

Read and understand entire section before operat-ing machine.

Observe additional Safety Guidelines detailed inthe beginning of this manual.

WARNING

DC-600 RED-D-ARC

DC-600 RED-D-ARC

WELDING CAPABILITY

The DC-600 has the following Output and Duty Cyclebased on operation for a 10 minute period:

600 Amps, 44 Volts at 100%680 Amps, 44 Volts at 60%750 Amps, 44 Volts at 50%

MEANINGS OF GRAPHICAL SYM-BOLS ON CASE FRONT

Input POWER ON/OFF Switch

SYMBOL MEANING

ON

OFF

INPUT POWER

Input power on when light is illuminated(except for abnormal conditions).

Always indicates POWER ON/OFFswitch is in ON position.

Pilot Light

OUTPUT CONTROL

OUTPUT VOLTAGEAND CURRENT

Clockwise Increase of OutputVoltage and Current

TERMINALS ON/REMOTE Switch

OUTPUT TERMINALSENERGIZED

Remote Control of Output Terminals(Energized or Non-Energized)

B-2OPERATIONB-2

DESIGN FEATURES AND ADVANTAGES

• Excellent arc characteristics for optimum constantvoltage submerged arc and Innershield weldingperformance.

• A control circuit designed to provide good startingfor a large variety of processes and procedures.

• Output Control Potentiometer that provides easysingle range continuous control.

• Output Control Switch that provides simple switch-ing from local to remote control.

• Output Terminals Switch to energize output termi-nals either local or remote.

• White neon pilot light to confirm that the InputContactor is energized.

• DC Ammeter and Voltmeter• 42VAC 10 Amp auxiliary power available for the

wire feeder, circuit breaker protected.• Single MS-type (14 pin) connector for wire feeder.• 115VAC 15 Amp auxiliary power available for the

wire feeder, circuit breaker protected.• 115VAC 15 Amp GFCI receptacle available on 60

Hertz models, circuit breaker protected.• Multi-functional terminal strip for easy connection

of wire feeding control cables. • Recessed output terminals to avoid any person or

object from accidentally coming into contact withthe output terminals and labeled " + " and " - " foreasy identification.

• Thermostatically protected power source.• Electronic protection circuit to protect power

source against overloads.• Input line voltage compensation to provide an

essentially constant output.• SCR electronically controlled welder output pro-

vides extra long life, especially for highly repetitivewelding applications.

• Solid state 2 and 4 circuit for extra long life.• Two circuit solid state control system provides

maximum performance and circuit protection.• Low profile case provides maximum use of space.• Convenient access to all controls.• Output lead strain relief loops to prevent terminal

and cable damage.• Easily removed case side, even when stacked.• Outdoor operation because enclosure is designed

with air intake louvers that keep dripping waterfrom entering the unit. Transformer, SCR bridge,and choke have special corrosion resistant paintfor added protection.

DC-600 RED-D-ARC

3 Phase transformer with rectifiedDC output

Line Connection

Three Phase Input Power

Designates welder complies withNational Electrical ManufacturersAssociation requirements EW 1Class I with 100% duty cycle at600Amps output.

Designates welder complies withboth Underwriters Laboratories (UL)standards and Canadian StandardsAssociation (CSA) standards. (60Hertz Models)

Gas Metal Arc Welding (GMAW)

Flux Cored Arc Welding (FCAW)

MEANING OF GRAPHICALSYMBOLS ONRATING PLATE (LOCATED ONCASE BACK)

NEMA EW 1 (100%)

Shielded Metal Arc Welding (SMAW)

Submerged Arc Welding (SAW)

MEANING OF GRAPHICALSYMBOL FOR GROUND CON-NECTION

Signifies the equipment connectionpoint for the protective earth ground

R

NRTL/C

B-3OPERATIONB-3

LOCAL/REMOTE Switch

SYMBOL MEANING

Control Of Output Voltage andCurrent is Via DC-600's Control Dial

Remote Control of Output Voltageand Current

MODE Switch

CC STICK: Shielded Metal ArcWelding (SMAW), this switchposition is also used for AirCarbon Arc Cutting (AAC)

CV SUBMERGED ARC:Constant Voltage Submerged

Arc Welding (SAW)

CV INNERSHIELD: Flux CoredArc Welding (FCAW), this switch

position is also used for GasMetal Arc Welding (GMAW).

Output Terminal Connections

Positive Output Terminal

Negative Output Terminal

WARNING Identification

Warning Identification

Circuit Breaker

Circuit Breaker (two breakers: 15Afor 115V circuit and 10A for 42V

circuit)

DC-600 RED-D-ARC

B-4OPERATIONB-4

CONTROLS AND SETTINGSAll operator controls and adjustments are located on the Case Front Assembly of the DC-600. See Figure B.1 forthe location of each control.

FIGURE B.1 - CONTROL PANEL KEYS

1. Input POWER ON/OFF SwitchThis toggle switch turns the machine on or off.Putting the switch in the ON “ ” position ener-gizes the machineʼs input contactor applying inputpower to the machine. Switching the switch to theOFF “ ” position de-energizes the inputcontactor.

2. POWER LightWhen the POWER switch is in the ON position themachineʼs white POWER light will illuminate. If theinput contactor de-energizes the machine in anabnormal situation the pilot light will still illuminate.In this situation it may be necessary to reset themachine by switching the POWER switch to theOFF and then to the ON position. (See Overload,Overcurrent, and Fault Protection Section)

3. OUTPUT CONTROLThis control provides continuous control of themachineʼs output voltage and current from mini-mum to maximum (typical full pot range between

15 to 44 volts and 90 to 750 amps) as it is rotatedclock-wise. Voltage or current control is deter-mined by setting of Mode Switch (CV or CC).

4. OUTPUT TERMINALS ON/REMOTE SwitchWhen this switch is in the REMOTE “ ” posi-tion, the DC-600ʼs output terminals will be electri-cally “cold” until a remote device such as a wirefeeder closes the #2 and #4 circuit in the MS-receptacle or terminal strip (T.S.2). When thisswitch is in the ON “ ” position the machineʼsoutput terminals will be electrically energized allthe time.

5. LOCAL/REMOTE SwitchWhen this switch is set to the LOCAL “ “ posi-tion, control of the output voltage and current is viathe OUTPUT CONTROL on the DC-600ʼs controlpanel. When this switch is set to the REMOTE“ ” position, control is through a remotesource such as a wire feeder via the #75, #76, and#77 leads in the MS-receptacle or terminal strip(T.S.1).

1

2

3

4

5 6

7

8

9

10

DC-600

1312

7

5

11

2

1

49863

10

B-5OPERATIONB-5

6. Mode SwitchThis switch allows for selecting the weldingprocess to be used:CC STICK-for SMAW and AACCV SUBMERGED ARC- for SAWCV INNERSHIELD- for FCAW and GMAW

7. 115VAC GFCI Receptacle (60 Hertz Models)This receptacle provides up to 15 amps of 115VAC auxiliary power.

8. 115VAC 15 Amp Circuit BreakerThis breaker protects the 115 VAC auxiliary cir-cuits located in the gfci receptacle, terminal strip(T.S.2) and MS-receptacle.

9. 42VAC 10 Amp Circuit BreakerThis breaker protects the 42VAC auxiliary circuitslocated in the terminal strip (T.S.2) and MS-recep-tacle.

10.14 Pin MS-ReceptacleThis connector provides easy connection for a wirefeeder control cable. It provides connections forauxiliary power, output switching, remote outputcontrol, wire feeder voltmeter sense lead andground. Refer to 14 Pin MS Type Receptacle in theInstallation Section for information about the cir-cuits made available at this receptacle.

11.Terminal Strip Cover PanelRotate this panel to gain access to the circuitsmade available at the two terminal strips (T.S.1and T.S.2). These terminal strips contains thesame circuits as the 14 pin MS-receptacle. Thereis a box connector adjacent to this cover for routingleads to the terminal strips.

12.Negative Output TerminalThis output terminal is for connecting a weldingcable. To change welding polarity and for properwelding cable size refer to Electrode and WorkCables in the Installation Section.

13.Positive Output TerminalThis output terminal is for connecting a weldingcable. To change welding polarity and for properwelding cable size refer to Electrode and WorkCables in the Installation Section.

AUXILIARY POWER IN MS-RECEPTACLE

42 volt AC auxiliary power, as required for some wirefeeders, is available through the wire feeder MS-receptacle. A 10 amp circuit breaker protects the 42volt circuit from overloads.

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

OVERLOAD, OVERCURRENT, ANDFAULT PROTECTION

This welder has thermostatic protection from exces-sive duty cycles, overloads, loss of cooling, and highambient temperatures. When the welder is subjectedto an overload or loss of cooling, a thermostat willopen. The input contactor will open and remain openuntil the machine cools; the white POWER light staysilluminated. No welding is possible during this cooldown period. The machine will reset automaticallywhen the thermostat cools.

The power source is also protected against overcur-rents in the SCR bridge assembly through an elec-tronic protection circuit. This circuit senses currentsover 780 amps on the power source and opens theinput contactor should the overcurrent remain for apredetermined time (the white POWER light stays illu-minated). The predetermined time varies with theamount of overcurrent; the greater the overcurrent,the shorter the time. The input contactor will remainopen until the power source is manually started byresetting the POWER ON/OFF toggle switch.

The power source circuitry is protected from faults onleads 75, 76, or 77. If any of these leads are connect-ed to either the positive or negative output leads, theDC-600 will either shut down completely (input con-tactor opens and white POWER light stays illuminat-ed), or will operate at minimum output thus preventingany damage to the DC-600. If DC-600 shuts down, itmust be manually started by resetting the POWERON/OFF toggle switch.

DC-600 RED-D-ARC

DC-600 RED-D-ARC

B-6OPERATIONB-6

OPERATING STEPS

The following procedures are for using the DC-600 inthe local control mode of operation. For remote controlof the machine, see the Remote Control of MachineOperation section.

Before operating the machine, make sure you have allmaterials needed to complete the job. Be sure you arefamiliar with and have taken all possible safety pre-cautions before starting work. It is important that youfollow these operating steps each time you use themachine.

1. Turn on the main AC power supply to themachine.

2. Connect the #21 work lead to either + or - on ter-minal strip (T.S.2).

3. Set the Welding Mode switch to welding processbeing used:

• CC STICK (for SMAW and AAC)

• CV SUBMERGED ARC (for SAW)

• CV INNERSHIELD (for FCAW and GMAW)

4. Turn the POWER ON/OFF Toggle Switch to the“ON” position

• The white pilot light glows.

• The fan starts.

5. Set OUTPUT CONTROL Potentiometer to desiredvoltage or current.

6. Set the OUTPUT TERMINALS switch to either“ON” ( output terminals energized) or “REMOTE”(output terminals energized when #2 and #4closed by remote device such as wire feeder)

7. Make the weld.

REMOTE CONTROL OF MACHINEOPERATION

The toggle switch on the control panel labeled“Remote - Panel” gives the operator the option of con-trolling the machine output from a remote location. Ifin the Remote position a wire feeder with remote con-trol capabilities or a remote control device such as aK775 must be connected to terminals 75, 76, and 77.Refer to Accessories Section for wire feeder remoteinformation.

WELDING PROCEDURE RECOMMENDATIONS

Select Welding Mode Switch position based on type ofwelding to be done.

1. Innershield Welding (FCAW)/MIG (GMAW)Welding: Use the CV INNERSHIELD mode.

2. Submerged Arc Welding (SAW): Use the CVSUBMERGED ARC mode. If performing highspeed welding, switch between the CVSubmerged Arc and the CV Innershield mode anduse the mode that produces the best weldingresults.

3. Air/Carbon Arc Cutting (CAC) / Stick Welding(SMAW) / High Current, Large Puddle SubmergedArc Welding (SAW): Use the CC STICK mode.When the DC-600 is used for Air/Carbon Arc cut-ting, the OUTPUT CONTROL potentiometershould be set to "9" initially. Based on the size ofthe carbon being used or the process, turn thepotentiometer to a lower setting as required by theprocess. You can use carbon rods up to 3/8" indiameter at currents as high as 750 amps withexcellent arc control. The welder protection circuitprotects the machine from extremely high shortcircuiting pulses.

DC-600 RED-D-ARC

B-7OPERATIONB-7

SEMI-AUTOMATIC ANDAUTOMATIC WIRE FEEDING WITHTHE DC-600 AND WIRE FEEDERS

When using the DC-600 with semi-automatic or auto-matic wire feeding equipment and for stick welding orair/carbon arc cutting, it is recommended that theoptional MULTI-PROCESS SWITCH be used. Thisswitch permits you to easily change the polarity of theconnected wire feeding equipment or switch to stickwelding or air/carbon arc cutting.

NA-3 AUTOMATIC WIRE FEEDER

1. Set the DC-600 LOCAL/REMOTE Switch toREMOTE. Set the OUTPUT TERMINALS switchto REMOTE. NOTE: Later model NA-3 automaticwire feeders are capable of cold starts when theNA-3 Mode switch is in the CV or CC mode posi-tion. Some earlier models are capable of coldstarting only in the CC mode position. Cold start-ing enables you to inch the wire down to the work,automatically stop, and automatically energize theflux hopper valve.

2. Set the DC-600 welding mode switch for thedesired process: CV SUBMERGED ARC, CVINNERSHIELD mode or CC STICK mode.

3. Set the NA-3 mode Switch Position to either CV orCC to match the DC-600 mode selected in step 2.

4. Refer to the NA-3 operators manual for instruc-tions on how to use the NA-3 in conjunction withthe DC-600.

5. Follow the following guidelines for good arc strik-ing detailed below for each welding mode.

GOOD ARC STRIKING GUIDELINES FOR THE NA-3 WITH THE DC-600 IN THE CV INNERSHIELD, CVSUBMERGED ARC OR CC STICK WELDINGMODES.

Following are some basic arc striking techniques thatapply to all wire feed processes. Using these proce-dures should provide trouble-free starting. These pro-cedures apply to single, solid wires and Innershieldwires.

1. Cut the electrode to a sharp point.

2. Set the NA-3 Open Circuit Voltage Control to thesame dial setting as the Arc Voltage Control. Ifthis is a new welding procedure, a good startingpoint is to set the Open Circuit Voltage Control to# 6.

NOTE: The open circuit voltage of the DC-600 varies from approximately 16 volts to 56volts in the CV INNERSHIELD or CVSUBMERGED ARC modes. The open circuit volt-age is constant in the CC STICK mode.

3. Run a test weld. Set proper current, voltage, andtravel speed.

a. For the best starting performance, the NA-3 Open Circuit Voltage Control and VoltageControl setting should be the same. Set theInch Speed Control for the slowest inchspeed possible.

b. To adjust the Open Circuit Voltage Control toget the best starting performance, makerepeated starts observing the NA-3 voltmeter.

When the voltmeter pointer swings smoothly up tothe desired arc voltage, without undershooting orovershooting the desired arc voltage, the OpenCircuit Voltage Control is set properly.

If the voltmeter pointer overshoots the desiredvoltage and then returns back to the desired volt-age, the Open Circuit Voltage Control is set toohigh. This can result in a bad start where the wiretends to "Blast off."

If the voltmeter pointer hesitates before coming upto the desired voltage, the Open Circuit VoltageControl is set too low. This can cause the elec-trode to stub.

4. Start and make the weld.

a. Cold starts. For cold starts, be sure the workpiece is clean and the electrode makes posi-tive contact with the work piece.

b. Hot "On the Fly" starts. For hot starts, travelshould begin before the wire contacts thework piece.

DC-600 RED-D-ARC

B-8OPERATIONB-8

ARC STRIKING WITH DC-600 AND THE NA-3START BOARD

When electrical strikeouts exceed 1 3/4” (44.4mm) anNA-3 Start Board may be required to improve arcstriking.

When the NA-3 Start Board is used to improve arcstriking, use the following procedures:

1. Set start time at 0.

2. Set NA-3 start current and start voltage at mid-range.

3. Set the NA-3 output current and voltage to theproper settings for the welding procedure to beused.

4. Turn the Start Board Timer to maximum.

5. Set Start Board current and voltage control.

a. Set the Start Board current control to 1 1/2dial numbers below that set on the NA-3 cur-rent control.

b. Set the Start Board voltage control equal withthe NA-3 voltage control setting.

NOTE: These Start Board current and voltagesettings result in a start up current that is lowerthan the NA-3 current setting and approximatelyequal with the NA-3 voltage setting for the desiredwelding procedure.

6. Establish the correct arc striking procedure withthe NA-3 Start Board timer set at maximum.

a. For the best starting performance, the NA-3Open Circuit Voltage Control and VoltageControl setting should be the same. Set theInch Speed Control for the slowest inchspeed possible.

b. To adjust the Open Circuit Voltage Control toget the best starting performance, makerepeated starts observing the NA-3 voltmeter.

When the voltmeter pointer swings smoothly up tothe desired arc voltage, without undershooting orovershooting the desired arc voltage, the OpenCircuit Voltage Control is set properly.

If the voltmeter pointer overshoots the desiredvoltage and then returns back to the desired volt-age, the Open Circuit Voltage Control is set toohigh. This can result in a bad start where the wiretends to "Blast off."

If the voltmeter pointer hesitates before coming upto the desired voltage, the Open Circuit VoltageControl is set too low. This can cause the elec-trode to stub.

c. Set NA-3 Start Board current and voltage asclose to the welding procedure current andvoltage as possible.

NOTE: The Start Board current and voltageshould be as close as possible to the welding pro-cedure current and voltage, while still getting sat-isfactory starts.

d. Set the start time to as low a time as possiblewhile still getting satisfactory starts.

7. Start and make the weld.

DC-600 RED-D-ARC

B-9OPERATIONB-9

DC-600 POWER SOURCE SETTING WHENCONNECTED TO NA-5 WIRE FEEDER

When using the DC-600 with the NA-5 wire feeder, setthe controls on the DC-600 as follows for the best per-formance:

1. Turn OFF main AC input power supply to the DC-600.

2. Connect the electrode cables to terminal polarityto be used.

3. Connect the #21 work lead (on T.S.2) to thesame polarity as the work cable connection.

4. Set the DC-600 LOCAL/REMOTE Switch toREMOTE.

5. Set the DC-600 OUTPUT TERMINALS switch toREMOTE.

6. Set the DC-600 WELDING MODE SWITCH to theposition that matches the welding process beingused.

a. For submerged arc welding, set WELDINGMODE SWITCH to CV SUBMERGED ARCposition.

b. For all open arc welding processes setWELDING MODE SWITCH to CV INNER-SHIELD position.

LN-8 SEMI-AUTOMATIC WIRE FEEDER

To use the LN-8 Semi-Automatic Wire Feeder with DC-600

1. Set the DC-600 WELDING MODE SWITCH toeither CV INNERSHIELD mode or CVSUBMERGED ARC mode depending on the weld-ing process being used.

2. Set the DC-600 LOCAL/REMOTE SWITCH to theREMOTE position.


4. Set the LN-8 Welding Mode Switch to the CV posi-tion. The LN-8 Welding Mode Switch is locatedon the variable voltage (CC) board.

5. Refer to the LN-8 Operatorʼs Manual for instruc-tions on how to use the LN-8.

LN-7 AND LN-9 SEMI-AUTOMATIC WIREFEEDERS OR OTHER CONSTANT WIREFEEDERS

To use the LN-7, LN-9, or other constant wire feedspeed semi-automatic wire feeders with DC-600

1. Set the DC-600 WELDING MODE SWITCH toeither CV INNERSHIELD mode or CVSUBMERGED ARC mode depending on the weld-ing process being used.

NOTE: These semi-automatic wire feeders can-not be used in the CC Stick mode.

2. Set the DC-600 LOCAL/REMOTE SWITCH.

a. LN-7: Use either an optional K775 RemoteControl Box Assembly or set the DC-600 LOCAL/REMOTE SWITCH in theLocal position.

b. LN-9: Refer to the LN-9 Operatorʼs Manual forinstructions of how to use the LN-9.

c. Other Constant Wire Feeders: Refer to WireFeeders Operatorʼs Manual.


DC-600 RED-D-ARC

C-1ACCESSORIESC-1

WIRE FEEDERS AND TRACTORS

The DC-600 can be used to power any of the follow-ing Lincoln Wire Feeders and Tractors:

Semi-Automatic Wire Feeders:DH-10 LN-9 GMALN-7 LN-10 LN-7 GMA LN-15P LN-742 LN-23P LN-8 LN-25 LN-9

Automatic Wire Feeders:NA-3 NA-5RNA-5

Tractors: LT-7 LT-56

FIELD INSTALLED OPTIONS

Remote Output Control (K857 or K857-1with K864 Adapter)

An optional “remote out control” is available. TheK857 or K857-1 are the same remote control optionsthat are used on other Lincoln power sources. TheK857 or K857-1 consist of a control box with 25 feet(7.6 meters) or 100 feet (30.3 meters)

The K857 and K857-1 have a 6-pin connector andK857 require a K864 adapter cable which connects tothe 14-pin connector on the case front.

Remote Control Adapter Cable (K864)

A "V" cable 12" (.30 m) long to connect a K857 orK857-1 Remote Control (6-pin connector) with an LN-7 wire-feeder (14-pin connector) and the machine (14-pin connector). If a remote control is used alone thewire-feeder connection is then not used.

Undercarriages (K817P, K842)

For easy moving of the machine, an optional under-carriage (K842) is available with mountings for twogas cylinders at rear of welder.

Paralleling Kit (K1611-1)

Permits paralleling of two DC-600's for welding cur-rents of up to 1200 amps, 100% duty cycle.

Tig Module (K930-2)

Portable high frequency generator for AC/DC TIGwelding.

FACTORY OR FIELD INSTALLEDOPTIONS

Multi-Process Switch (K804-1)

The MULTI-PROCESS SWITCH gives you the abilityto:• Switch between "stick welding or air/carbon arc

cutting" and using a semi-automatic or automaticwire feeder.

• Change the polarity of a semi-automatic or auto-matic wire feeder without changing any electricalcable connections.

See Figure C.1

FIGURE C.1 - MULTI-PROCESS SWITCH

STRA IGHT PLUG (14 P IN )TO POWER SOURCE

CABLE RECEPTACLE (6 SOCKET )

CABLE RECEPTACLE (14 SOCKET )

TO : K857 OR K867-1REMOTE CONTROL

TO: LN-7 WIRE FEEDERS

– +

WIREFEEDERCABLES

STICK ORAIR/CARBONARC CABLES

STICK OR-AIR-

CARBON-ARC

+

-

DC-600 RED-D-ARC

C-2ACCESSORIESC-2

The MULTI-PROCESS SWITCH has two sets of out-put terminals. You connect the wire feeder unit cablesto the set of terminals on the left side of the box andthe stick or air/carbon arc cables to the set of termi-nals on the right side (facing the front of the machine)as shown in Figure C.1. The output terminals are pro-tected against accidental contact by hinged covers.

When the MULTI-PROCESS SWITCH is in the "Stickor Air/Carbon Arc" posit ion, only those terminals are energized. The wire feeder nozzle orgun and electrode are not electrically "hot" when inthis mode.

Follow these steps to install the MULTI-PROCESSSWITCH:

1. Confirm that the DC-600 POWER ON/OFF switchis in the OFF position.

2. Disconnect main AC input power to the DC-600.

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

4. The MULTI-PROCESS SWITCH is mounted tothe case front with four 1/4” self-tapping screws.The screw holes are 13.8” apart side to side and4.5” apart top to bottom, Run one of the 1/4”screws part way in and out of the screw holes toopen them up. Make sure that the two sleevedcontrol leads do not get pinched when hangingthe switch; route them out the side to the right ofthe switch. Support the switch in position and startthe four screws, then tighten them.

5. Route the MULTI-PROCESS SWITCH controlleads through the strain-relief box connectors andinto the terminal strip. Connect wire feeder controlcable as specified in specific connection diagramand make other terminal strip connections asspecified on the connection diagram for theLincoln wire feeder being used.

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

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

FIGURE C.4 - MULTI-PROCESS SWITCHCABLE CONNECTIONS.

8. Connect the left cable from the MULTI-PROCESSSWITCH (facing the front of the machine) to theDC-600 negative (-) output terminal. See FigureC.2.

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

a. Insert the wire feeder electrode and workcables through the strain relief loop on the leftside of the DC-600 (facing the front of themachine).

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

10. Connect wire feeder control cable and make otherterminal strip connections as specified on theconnection diagram for the Lincoln wire feederbeing used.


WORKCABLE

WORK

ELECTRODES

21-21+ 41 4 2 31 32 75 76 77

TERMINALSTRIP COVER

BOX CONNECTOR

POSITIVE (+)OUTPUT

STUD– +

NEGATIVE (–)OUTPUT

STUD

ELECTRODECABLE

WORKCABLE

ELECTRODECABLE

JUMPER (IF NEEDEDSEE INSTRUCTIONS)

+

CONTROLLEADS

STICK AIR/CARBONARC WELDINGEQUIPMENT

WIREFEEDER

C-3ACCESSORIESC-3

12. Connect stick or air/carbon arc electrode and workcable. See Figure C.2.

a. Insert the electrode and work cables throughthe strain relief loop on the right side (facingthe front of the machine) of the DC-600.

b. Connect the electrode cable to the "Positive"terminal on the right side of the MULTI-PROCESS SWITCH.

c. Connect the work cable to the "Negative" ter-minal on the right side of the MULTI-PROCESS SWITCH.

NOTE: The instructions above are for connectingthe stick polarity positive. To change the polarity,turn the DC-600 OFF, and reverse the cables.

NOTE: When it is not necessary to have separateground cables for stick and semi-automatic orautomatic welding, connect a jumper from theMULTI-PROCESS SWITCH "Work" terminal tothe MULTI-PROCESS SWITCH "negative" termi-nal. See Figure C.2.

To operate the MULTI-PROCESS SWITCH, refer tothe operating instructions on the switch nameplate.

CONNECTIONS FOR SEMI-AUTO-MATIC OR AUTOMATIC WIRE FEED-ER CONTROL

1. Set the DC-600 ON/OFF switch to OFF.

2. Set the DC-600 LOCAL/REMOTE switch toREMOTE.


4. Set the DC-600 MODE switch to the weldingprocess being used.

5. Refer to the proper connection diagram in the DIA-GRAMS section for more information.

DC-600 RED-D-ARC

DC-600 RED-D-ARC

D-1MAINTENANCED-1

SAFETY PRECAUTIONS

ELECTRIC SHOCK CAN KILL.

• Only qualified personnelshould perform this mainte-nance.

• Turn the input power OFF atthe disconnect switch or fusebox before working on thisequipment.

Do not touch electrically hot parts.------------------------------------------------------------------------

ROUTINE AND PERIODIC MAINTENANCE

1. Disconnect input AC power supply lines to themachine before performing periodic maintenance,tightening, cleaning, or replacing parts.

Perform the following daily:

1. Check that no combustible materials are in thewelding or cutting area or around the machine.

2. Remove any debris, dust, dirt, or materials thatcould block the air flow to the machine for cooling.

3. Inspect the electrode cables for any slits or punctures in the cable jacket, or any condition thatwould affect the proper operation of the machine.

Perform Periodically:

Clean the inside of the machine with low pressure airstream. Clean the following parts. When using air, becareful to adequately protect your eyes.

• Main transformer and choke.

• Electrode and work cable connections.

• SCR rectifier bridge and heat sink fins.

• Control board.

• Firing board.

• Fan Assembly.NOTE: The fan motor has sealed bearings whichrequire no maintenance.

WARNING

TESTING THE GFCI RECEPTACLE

1. Turn the welder ON. Press the reset button fully.Plug a lamp or radio into the GFCI (and leave itplugged in) to verify that the power is ON. If there isno power, go to Troubleshooting Section.

2. Press the TEST button in order to trip the device.This should stop the flow of electricity, making thelamp or radio shut OFF. Note that the REST buttonwil l pop out. If the power stays on, go toTroubleshooting Section. If the power goes OFF,the GFCI receptacle is working properly. To restorepower, press the RESET button.

3. Press the TEST button (then RESET button) everymonth to assure proper operation.

NOTE: The GFCI receptacle is in a 115v circuit where theneutral is f loating with respect to ground.Consequently if a GFCI tester is plugged into theGFCI receptacle, the tester will show that there is an“open ground”. The indication of an”open ground” isnormal and the GFCI will function properly in theevent of a ground fault current as the GFCI isdesigned to do.

DC-600 RED-D-ARC

E-1TROUBLESHOOTINGE-1

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician and machine operator and willinvalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe allsafety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

DC-600 RED-D-ARC


CAUTION: Sometimes machine failures appear to bedue to PC board failures. These problems can some-times be traced to poor electrical connections. Toavoid problems when troubleshooting and replacingPC boards, please use the following procedure:

1. Determine to the best of your technical ability thatthe PC board is the most likely component causingthe failure symptom.

2. Check for loose connections at the PC board toassure that the PC board is properly connected.

3. If the problem persists, replace the suspect PCboard using standard practices to avoid static elec-trical damage and electrical shock. Read the warn-ing inside the static resistant bag and perform thefollowing procedures:

P.C. Board can be damaged by static electricity.

• Remove your bodyʼs staticcharge before opening thestatic-shielding bag. Wear ananti-static wrist strap. Forsafety, use a 1 Meg ohmresistive cord connected to agrounded part of the equip-ment frame.

• If you donʼt have a wrist strap,touch an unpainted, ground-ed, part of the equipmentframe. Keep touching theframe to prevent static build-up. Be sure not to touch anyelectrically live parts at thesame time.

• Tools which come in contact with the P.C. Boardmust be either conductive, anti-static or static-dissi-pative.

ELECTRIC SHOCK can kill.Have an electrician install and ser-vice this equipment. Turn the inputpower OFF at the fuse box beforeworking on equipment. Do nottouch electrically hot parts.

• Remove the P.C. Board from the static-shielding bagand place it directly into the equipment. Donʼt set theP.C. Board on or near paper, plastic or cloth whichcould have a static charge. If the P.C. Board canʼt beinstalled immediately, put it back in the static-shield-ing bag.

• If the P.C. Board uses protective shorting jumpers,donʼt remove them until installation is complete.

• If you return a P.C. Board for credit, it must be in thestatic-shielding bag. This will prevent further damageand allow proper failure analysis.

4. Test the machine to determine if the failure symp-tom has been corrected by the replacement PCboard.

NOTE: It is desirable to have a spare (known good)PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electri-cal components can reach their operating tempera-ture.

5. Remove the replacement PC board and substitute itwith the original PC board to recreate the originalproblem.

a. If the original problem does not reappear by sub-stituting the original board, then the PC board wasnot the problem. Continue to look for bad connec-tions in the control wiring harness, junction blocks,and terminal strips.

b. If the original problem is recreated by the substitu-tion of the original board, then the PC board wasthe problem. Reinstall the replacement PC boardand test the machine.

6. Always indicate that this procedure was followed when warranty reports are to be submit-ted.

NOTE: Following this procedure and writing on thewarranty report, “INSTALLED AND SWITCHED PCBOARDS TO VERIFY PROBLEM,” will help avoiddenial of legitimate PC board warranty claims.

PC BOARD TROUBLESHOOTING PROCEDURES

ATTENTIONStatic-SensitiveDevicesHandle only atStatic-SafeWorkstations

Reusable ContainerDo Not Destroy

WARNING

DC-600 RED-D-ARC

E-3TROubLEShOOTINGE-3

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local Field ServiceFacility.

PRObLEMS(SYMPTOMS)

Major Physical or ElectricalDamage is Evident

The Machine is dead. The Inputcontactor does not operate.

Input contactor (CR1) chatters.

Variable or sluggish welding arc.

Output Control Pot. not functioningin “LOCAL” control.

No output control in “REMOTE”control.

115VAC GFCI receptacle notworking. (60HZ machines only)

POSSIbLE CAuSE

Contact the Service Dept. (216)383-2531 or 1-888-935-3877

1. Check for blown or missing fusesin input lines.

2. Check the three phase input linevoltage at the machine. Theinput voltage must match the rat-ing plate and reconnect panel.

3. Power ON/OFF switch may bedefective.

1. The input line voltage may below. Check all three phases.

2. Make sure input line voltagematches machine rating and thereconnect panel is connectedcorrectly for the line voltage.

1. Poor electrode or work lead con-nection.

2. Welding cables too small.

3. Welding current or voltage toolow.

1. LOCAL/REMOTE Switch (S3)faulty or in wrong position.

2. Faulty OUTPUT CONTROL Pot.

1. LOCAL/REMOTE Switch (S3)faulty or in wrong position.

2. Faulty Remote Control Unit.

1. 115VAC Circuit Breaker tripped.

RECOMMENDEDCOuRSE OF ACTION

OuTPuT PRObLEMS

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Field Service Facility for technical troubleshooting assistance before you proceed.

CAuTION

Observe all Safety Guidelines detailed throughout this manual

DC-600 RED-D-ARC



CAUTION

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local Field ServiceFacility.

PROBLEMS(SYMPTOMS)

Machine input contactor operatesbut machine has no weld output.Fan runs and pilot light glows.

Machine has maximum weld out-put and no control.

POSSIBLE CAUSE

1. Place OUTPUT TERMINAL Switchto “ON”, or install a jumper from #2to #4 on machine terminal strip. Ifmachine weld output is restoredthe problem is in the wire feeder orcontrol cable.

2. If remote control is not being usedmake certain the LOCAL/REMOTESWITCH (SW3) is in the "Local"position.

3. Check 42V Circuit Breaker in thefront panel.Reset if necessary.

4. Check for loose or faulty weldcable connections.

5. Trigger circuit not working.

1. LOCAL/REMOTE Switch (S3) inwrong position.

2. LOCAL/REMOTE Switch (S3) isfaulty, or an open lead going to theLOCAL/REMOTE Switch (S3).

RECOMMENDEDCOURSE OF ACTION

OUTPUT PROBLEMS


DC-600 RED-D-ARC



CAUTION

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local AuthorizedField Service Facility.

PROBLEMS(SYMPTOMS)

Machine has minimum output andno control.

The machine does not have maxi-mum weld output.

POSSIBLE CAUSE

1. If a remote control unit is NOTconnected to the terminal strip#75, #76, and #77 terminals, oris not connected to the 14 pinMS receptacle the LOCAL/REMOTE SWITCH must be inthe "Local" position.

2. If a remote control cable is con-nected to terminals #75, #76 and#77 or is connected to the 14 pinMS receptacle the leads may be"shorted" to the positive weldoutput.

3. Make certain the Three Phaseinput voltage is correct andmatches the machine rating andthe reconnect panel.

1. Check all Three-Phase inputlines at the DC-600. Make sureinput voltages match machinerating and reconnect panel.

2. Put LOCAL/REMOTE SWITCH(SW3) in "LOCAL" position. Ifproblem is solved then checkremote control unit or wire feed-er.

3. Check for loose welding cableconnections.


OUTPUT PROBLEMS


DC-600 RED-D-ARC



CAUTION


PROBLEMS(SYMPTOMS)

Machine shuts off (input contactordrops out) when the welder outputterminals are made electrically"hot".(#2 to #4 closure at terminal strip.)or OUTPUT TERMINALS switchis in ON position.

The DC600 will NOT shut off whenthe Power Switch is turned toOFF.

The weld output terminals arealways electrically "hot".

POSSIBLE CAUSE

1. Remove all welding cables andcontrol cables from the DC-600.Jumper #2 to #4 at the terminalstrip or set OUTPUT TERMI-NALS switch to ON position. Ifthe machine does NOT shut offand normal open circuit voltageis present at the welder outputterminals the problem is exter-nal to the DC-600. Either theremote leads #75, #76 or #77are grounded to the negativeoutput cable or there is a shorton the welding output terminals.

2. If the machine still shuts offwhen all control and weldingcables are removed then theproblem is internal to the DC-600.

1. Contact your local AuthorizedField Service Facility.

1. Remove any external leadshooked to #2 and #4 on the ter-minal strip or any connectionsto the 14 pin MS connector. SetOUTPUT TERMINALS switchto the OFF position. If the prob-lem disappears the fault is inthe control cable or wire feeder.

2. If some open circuit voltage ispresent (over 3VDC.) after per-forming Step #1. then the prob-lem is within the DC-600.


OUTPUT PROBLEMS


DC-600 RED-D-ARC



CAUTION


PROBLEMS(SYMPTOMS)

Poor arc starting when the DC-600 is in the CV Sub-Arc or CVInnershield Modes.

Machine has output but trips offimmediately when wire feed unittrigger is activated.

Poor arc characteristics in allprocesses.

POSSIBLE CAUSE

1. Make sure the proper weldingprocedures are being used. (wirefeed speed, arc voltage and wiresize).

2. Check weld cables for loose orfaulty connections.

1. Remove output cables from DC-600. If problem is resolved checkfor external short between weld-ing cables. Also check controlcable (#75, #76, & #77) forgrounds or shorts.

1. Check for the correct input volt-ages on the three phase inputlines at the DC-600.

2. Make sure the proper weldingprocedures are being used.(wirefeed speed, arc voltage and wiresize).

3. Check the welding cables forloose or faulty connections.


WELDING PROBLEMS


F-1DIAGRAMSF-1

DC-600 RED-D-ARC

DU

PLEX

REC

EPTA

CLE

TO

BE

WIR

ED A

SSH

OW

N F

OR

ALL

CO

DES

EX

CEP

T 10

663.

GFC

I REC

EPTA

CLE

FO

R C

OD

E 10

663

TOH

AV

E LE

AD

31

CO

NN

ECTE

D T

O T

HE

WH

ITE

LIN

E. L

EAD

32

TO B

E C

ON

NEC

TED

TO T

HE

HO

T LI

NE.

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

.

F-2DIAGRAMSF-2

DC-600 RED-D-ARC

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

.

DC-600 RED-D-ARC

F-3DIAGRAMSF-3

S2

0409

1-28-94

CO

NN

EC

TIO

N O

F L

N-7

42

TO

TH

E C

V-6

55

, D

C-6

55

OR

DC

-60

0 P

OW

ER

SO

UR

CE

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

ELECTRODE CABLE

-+

14 PIN

AMPHENOL

POWER

SOURCE

LINCOLN

TO WORK

LN-742

WIRE

FEEDER

Powe

r Sou

rce

befo

re c

onne

cting

the

wire

feed

er.

Turn

off (0) t

he p

ower

swi

tch

on th

e W

elding

AND

14-PIN

CABLE

PLUG

, REAR

VIEW

AND

14-PIN

CABLE

PLUG

, FRONT

VIEW

K=42

C=2

D=4

E=77

F=76

G=75

H=21I=41

K=42

I=41 H=21

G=75

F=76

E=77

D=4

C=2

PIN C D E F G H I K

42412175767742

LEAD

42V AC

42V AC

WORK

OUTPUT CONTROL

OUTPUT CONTROL

OUTPUT CONTROL

TRIGGER

CIRCUIT

TRIGGER

CIRCUIT

(SEE

APPROPRIATE

WIRING

DIAGRAM)

FUNCTION

FUNCTIONS ARE LISTED

FOR

REFERENCE

ONLY

AND

EACH

MAY

OR

MAY

NOT BE

PRESENT IN

YOUR

EQUIPMENT.

14-SOCKET

BO

X RECEPTACLE

, FRONT

VIEW

14-SOCKET

BO

X RECEPTACLE

, REAR

VIEW

LN-742

INPUT CABLE

ASSEMBLY

N.C

. PINS NOT LISTED

ARE NOT CONNECTED

ON

CABLE

.

N.A

. WELDING

CABLE

MUST

BE SI

ZED

FOR

CURRENT

AND

DUTY

CYCLE

OF APPLICATION

.N

.B. DIAGRAM

SHOWS ELECTRODE POSITI

VE. TO

CHANGE POLARIT

Y, TURN

POWER

"OFF

",

REVERSE

ELECTRODE AND

WORK

CABLES AT

POWER

SOURCE AND

SET

WIRE FEEDER

VOLTMETER

POLARIT

Y SWITCH

ON

POWER

SOURCE TO

PROPER

POLARIT

Y.

N.D

. IF

USING

K58

9-1,

REMOTE

CONTROL KIT

,

SET

POWER

SOURCE CONTROL SWITCH

TO

"REMOTE

" POSITION

.

N.D

.

F-4DIAGRAMSF-4

DC-600 RED-D-ARC

N.C

. Ta

pe u

p bo

lted

conn

ectio

n if

lead

#21

is e

xten

ded.

N.D

. Co

nnec

t the

con

trol c

able

gro

und

lead

to th

e fra

me

term

inal

mar

ked

nea

r the

pow

er s

ourc

e te

rmin

al s

trip.

The

pow

er

s

ourc

e gr

ound

ing

term

inal

(mar

ked

and

loca

ted

near

the

pow

er

s

ourc

e in

put p

ower

con

nect

ions) m

ust b

e pr

oper

ly co

nnec

ted

to

e

lect

rical

gro

und

per t

he p

ower

sou

rce

oper

atin

g m

anua

l.

N.E

. If

an o

ptio

nal r

emot

e vo

ltage

con

trol i

s us

ed, c

onne

ct it

to

this

term

inal s

trip.

N.A.

Wel

ding

cab

les

mus

t be

of p

rope

r cap

acity

for t

he c

urre

nt a

nd

duty

cyc

le o

f im

med

iate

and

futu

re a

pplic

atio

ns. Se

e LN-7

O

pera

ting M

anua

l for

pro

per s

izes.

N.B.

If LN-7

is eq

uipp

ed w

ith a

met

er k

it, e

xten

d LN-7

con

trol c

able

su

itabl

e fo

r the

inst

alla

tion.

An S16586-[LENGTH

] rem

ote

vo

ltage

sen

sing

wor

k le

ad m

ay b

e or

dere

d fo

r thi

s pu

rpos

e.

Co

nnec

t it d

irect

ly to

the

wor

k pi

ece

inde

pend

ent o

f the

wel

ding

w

ork

cabl

e co

nnec

tion.

For

con

veni

ence

, thi

s ex

tend

ed #21

lead

sh

ould

be

tape

d to

the

wel

ding

wor

k le

ad. (If

the

leng

th o

f

wel

ding

wor

k ca

ble

is sh

ort,

less

than

25

feet

, and

con

nect

ions

ca

n be

exp

ecte

d to

be

relia

ble,

then

con

trol c

able

lead

#21

doe

s

not n

eed

to b

e ex

tend

ed a

nd c

an b

e di

rect

ly co

nnec

ted

to

term

inal

#21

on

the

term

inal

stri

p. N

ote

that

this

is no

t the

pr

efer

red

conn

ectio

n be

caus

e it

adds

erro

r to

the LN-7

vol

tmet

er

Abo

ve d

iagra

m sh

ows e

lectro

de co

nnec

ted p

ositiv

e. T

o ch

ange

pola

rity,

turn

pow

er o

ff, re

verse

the e

lectro

de an

d wo

rk lea

ds at

the p

ower

414231

3275

7677

NEGATIVE

POSITI

VE

32 31 2 4 GND 21

N.A.

N.D.

ELECTRODE CABLE

TO WIRE FEED

UNIT

TO WORK

POWER

SOURCE

N.E.

N.F

.

re

adin

g.)

N.F

. If

lead

#21

is to

be

conn

ecte

d to

the

term

inal s

trip,

con

nect

to th

e #21

term

inal t

hat m

atch

eswo

rk p

olar

ity. Th

is c

onne

ctio

n m

ust b

e ch

ange

d wh

enev

er th

e ele

ctro

de p

olar

ity is

ch

ange

d.

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

LN-7

TO

INPUT

CABLE

PLUG

LN-7

CONTROL

CABLE

21-

21

FOR CONTROL CABLE

WITH 14

PIN

MS-TYPE

PLUG

CONNECTOR

OR

FOR CONTROL CABLE

WITH TERMINAL

STRIP

LEAD

CONNECTORS

CONTROL CABLE

S22976

sour

ce an

d po

sition

the s

witch

on w

ire fe

eder

(if eq

uippe

d )

to p

rope

r pola

rity. Als

o re

fer to

note N.F.

N.B.

& N

.C.

14-PIN

RECEPTACLE

lead

#21

from

con

trol c

able

with

term

inal

stri

p co

nnec

tors

or f

rom

14-

pin

rece

ptac

le u

sing

#14 AWG

or l

arge

r ins

ulat

ed w

ire p

hysic

ally

21+

REMOTE

VOLTAGE SENSING

LEAD

10-3

0-98F

N.G

.

N.G

. Illu

stra

tion

does

not

nec

essa

rily

repr

esen

t act

ual p

ositi

on o

f

fo

r mor

e inf

orm

atio

n.

CO

NN

EC

TIO

N O

F L

N-7

TO

TH

E C

V-6

55

, D

C-6

55

OR

DC

-60

0 P

OW

ER

SO

UR

CE

ap

prop

riate

out

put s

tuds

. Ref

er to

pow

er s

ourc

e op

erat

ing m

anua

l

For p

rope

r set

ting

of s

witc

hes

on p

ower

sou

rce,

see

pow

er s

ourc

e op

erat

ing

man

ual.

F-5DIAGRAMSF-5

DC-600 RED-D-ARC

N.C

. Ta

pe u

p bo

lted

conn

ectio

n if

lead

#21

is e

xten

ded.

N.D

. Co

nnec

t the

con

trol c

able

gro

und

lead

to th

e fra

me

term

inal

mar

ked

near

the

pow

er s

ourc

e te

rmin

al s

trip.

The

pow

er

s

ourc

e gr

ound

ing

term

inal

(mar

ked

and

loca

ted

near

the

pow

er

s

ourc

e in

put p

ower

con

nect

ions) m

ust b

e pr

oper

ly co

nnec

ted

to

e

lect

rical

gro

und

per t

he p

ower

sou

rce

oper

atin

g m

anua

l.

N.A.

Wel

ding

cab

les

mus

t be

of p

rope

r cap

acity

for t

he c

urre

nt a

nd

Abo

ve d

iagra

m sh

ows e

lectro

de co

nnec

ted p

ositiv

e. T

o ch

ange

pola

rity,

turn

pow

er o

ff, re

verse

the e

lectro

de an

d wo

rk lea

ds at

the p

ower

NEGATIVE

POSITI

VE

32 31 2 4 GND 21

N.A.

N.D.

ELECTRODE CABLE

TO WIRE FEED

UNIT

TO WORK

POWER

SOURCE

N.E.

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

CABLE

21

FOR CONTROL CABLE

WITH 14

PIN

MS-TYPE

PLUG

CONNECTOR

OR

FOR CONTROL CABLE

WITH TERMINAL

STRIP

LEAD

CONNECTORS

CONTROL CABLE

S22977

sour

ce an

d po

sition

the s

witch

on w

ire fe

eder

(if eq

uippe

d )

to p

rope

r pola

rity. Als

o re

fer to

note N.F.

N.B.

& N

.C.

14-PIN

RECEPTACLE

ABC

N.E

. If

usin

g an

old

er LN-8

cont

rol c

able: c

onne

ct le

ad #75

to #75

on

term

inal

stri

p, c

onne

ct le

ad #76

to #76

on

term

inal

stri

p, c

onne

ctle

ad #77

to #77

on

the

term

inal

stri

p.

the

#21

term

inal t

hat m

atch

es w

ork

polar

ity. T

his c

onne

ctio

n m

ust b

e c

hang

ed w

hene

ver t

he e

lectro

de p

olar

ity is

cha

nged

.

N.G

. If

lead

#21

is to

be

conn

ecte

d to

the

term

inal s

trip,

con

nect

to

N.F.

The

LN-

9 vo

ltage

con

trol j

umpe

rs m

ust b

e co

nnec

ted

as fo

llow

s(re

fer t

o LN-9

Ope

ratin

g M

anua

l):W

hite

jum

per o

n vo

ltage

boa

rd to

pin

"S" .

Blue

jum

per o

n vo

ltage

boa

rd (l

ater

uni

ts o

nly)

,or

on

star

t boa

rd (e

arlie

r uni

ts),

to p

in "B

".

rem

ote

volta

ge s

ensin

g w

ork

lead

may

be

orde

red

for t

his

purp

ose.

N.B.

Ext

end

lead

#21

from

con

trol c

able

with

term

inal

stri

p co

nnec

tors

or

fro

m 14-

pin

rece

ptac

le u

sing

#14 AWG

or l

arge

r ins

ulat

ed w

ire

du

ty c

ycle

of i

mm

edia

te a

nd fu

ture

app

licat

ions

.

Con

nect

it d

irect

ly to

the

wor

k pi

ece

keep

ing

it el

ectri

cally

con

veni

ence

, thi

s ex

tend

ed #21

lead

sho

uld

be ta

ped

to th

e

w

eldi

ng w

ork

lead

. (If

the

leng

th o

f wor

k le

ad c

ircui

t is

sho

rt, a

nd c

onne

ctio

ns c

an b

e ex

pect

ed to

be

relia

ble,

then

con

trol c

able

lead

#21

doe

s no

t nee

d to

be

exte

nded

and

can

be

dire

ctly

conn

ecte

d to

term

inal

#21

on

the

term

inal

stri

p. N

ote

tha

t thi

s is

not t

he p

refe

rred

conn

ectio

n be

caus

e it

adds

erro

r

sep

arat

e fro

m th

e w

eldi

ng w

ork

lead

circ

uit a

nd c

onne

ctio

n. F

or

to

the

wire

feed

er v

oltm

eter

read

ing.)

phy

sical

ly su

itabl

e fo

r the

inst

alla

tion.

An S16586-[LENGTH

]

TO LN-8

OR

LN-9

CONTROL

N.F

.INPUT CABLE

PLUG

414231

3275

7677

N.E.

N.G

.21-21+

REMOTE

VOLTAGE SENSING

LEAD

10-3

0-98F

N.H

. Ill

ustr

atio

n do

es n

ot n

eces

saril

y re

pres

ent a

ctua

l pos

ition

of a

ppro

pria

te

out

put s

tuds

. Ref

er to

pow

er s

ourc

e in

stru

ctio

n m

anua

l for

mor

e in

fo.

N.H.

CO

NN

EC

TIO

N O

F L

N-8

OR

LN

-9 T

O T

HE

CV

-65

5,

DC

-65

5 O

R D

C-6

00

PO

WE

R S

OU

RC

E

For p

rope

r set

ting

of s

witc

hes

on p

ower

sou

rce,

see

pow

er s

ourc

e op

erat

ing

man

ual.

F-6DIAGRAMSF-6

DC-600 RED-D-ARC

Abo

ve d

iagra

m sh

ows e

lectro

de co

nnec

ted p

ositiv

e. T

o ch

ange

pola

rity,

turn

pow

er o

ff, re

verse

the e

lectro

de an

d wo

rk lea

ds at

the p

ower

NEGATIVE

POSITI

VE

32 31 2 4 GND 21

N.A.

N.D.

ELECTRODE CABLE

TO WORK

POWER

SOURCE

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

CONTROL BO

X21

FOR CONTROL CABLE

WITH 14

PIN

MS-TYPE

PLUG

CONNECTOR

OR

FOR CONTROL CABLE

WITH TERMINAL

STRIP

LEAD

CONNECTORS

CONTROL CABLE

S22978

N.B.

& N

.C.

14-PIN

RECEPTACLE

757677

r

emot

e vo

ltage

sen

sing

wor

k le

ad m

ay b

e or

dere

d fo

r thi

s pu

rpos

e.

If le

ad #21

is to

be

conn

ecte

d to

the

term

inal

stri

p, c

onne

ct to

the

#21

term

inal

that

mat

ches

wor

k po

larit

y. T

his

con

nect

ion

mus

t be

chan

ged

whe

neve

r the

ele

ctro

de p

olar

ity is

ch

ange

d.

N.A

. W

eldi

ng c

able

s m

ust b

e of

pro

per c

apac

ity fo

r the

cur

rent

and

dut

y cy

cle

of im

med

iate

and

futu

re a

pplic

atio

ns.

Con

nect

it d

irect

ly to

the

wor

k pi

ece

keep

ing

it el

ectri

cally

sep

arat

e fo

rm th

e w

eldi

ng w

ork

lead

circ

uit a

nd c

onne

ctio

n. F

or

c

onve

nien

ce, t

his

exte

nded

#21

lead

sho

uld

be ta

ped

to th

e

w

eldi

ng w

ork

lead

. (If

the

leng

th o

f wor

k le

ad c

ircui

t is

sho

rt, a

nd c

onne

ctio

ns c

an b

e ex

pect

ed to

be

relia

ble,

then

con

trol c

able

lead

#21

doe

s no

t nee

d to

be

exte

nded

and

can

be

dire

ctly

conn

ecte

d to

term

inal

#21

on

the

term

inal

stri

p. N

ote

tha

t thi

s is

not t

he p

refe

rred

conn

ectio

n be

caus

e it

adds

erro

r

N.D

. Co

nnec

t the

con

trol c

able

gro

und

lead

to th

e fra

me

term

inal

mar

ked

ne

ar th

e po

wer

sou

rce

term

inal

stri

p. T

he p

ower

sou

rce

grou

ndin

g te

rmin

al (m

arke

d

and

loca

ted

near

the

pow

er

s

ourc

e in

put p

ower

con

nect

ions) m

ust b

e pr

oper

ly co

nnec

ted

to

e

lect

rical

gro

und

per t

he p

ower

sou

rce

oper

atin

g m

anua

l.

to

the

wire

feed

er v

oltm

eter

read

ing.)

N.F

.

sour

ce.

Reve

rse th

e lea

ds o

n the

bac

k of t

he am

meter

and

voltm

eter

in th

e aut

omati

c con

trol b

ox.

Also

refer

to no

te N.F.

TO AUTOMATIC

EQUIPMENT

TO AUTOMATIC

CONTROL CABLE

phy

sical

ly su

itabl

e fo

r the

inst

alla

tion.

An S16586-[LENGTH

]

414231

3275

7677

N.F

.21-21+

REMOTE

VOLTAGE SENSING

LEAD

N.C

. Ta

pe u

p bo

lted

conn

ectio

n if

lead

#21

is e

xten

ded.

N.E

. If

a va

riabl

e vo

ltage

boa

rd is

pre

sent

in th

e au

tom

atic

con

trols,

the

jum

per l

ead

on th

e VV

boa

rd m

ust b

e co

nnec

ted

to p

in "L

" to

perm

it th

e in

ch d

own

butto

n to

ope

rate

. Th

is ju

mpe

r, ho

wev

er,

will

disa

ble

the

cold

sta

rting

/aut

osto

p fe

atur

e of

the

auto

mat

icco

ntro

ls, p

erm

ittin

g on

ly ho

t sta

rting

tech

niqu

es to

be

used

.

or

from

14-

pin

rece

ptac

le u

sing

#14 AWG

or l

arge

r ins

ulat

ed w

ire

N.B.

Ext

end

lead

#21

from

con

trol c

able

with

term

inal

stri

p co

nnec

tors

10-3

0-98F

N.G

. Illu

stra

tion

does

not

nec

essa

rily

repr

esen

t act

ual p

ositi

on o

f

man

ual f

or m

ore

info

rmat

ion.

N.G

.

CO

NN

EC

TIO

N O

F N

A-3

, L

T-5

OR

LT

-7 T

O T

HE

CV

-65

5,

DC

-65

5 O

R D

C-6

00

PO

WE

R S

OU

RC

E

app

ropr

iate

out

put s

tuds

. Ref

er to

pow

er s

ourc

e op

erat

ing

For p

rope

r set

ting

of s

witc

hes

on p

ower

sou

rce,

see

pow

er s

ourc

e op

erat

ing

man

ual.

F-7DIAGRAMSF-7

DC-600 RED-D-ARC

NEGATIVE

POSITI

VE

32 31 2 4 GND 21

N.A.

N.D.

TO WORK

POWER

SOURCE

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

21

FOR CONTROL CABLE

WITH 14

PIN

MS-TYPE

PLUG

CONNECTOR

OR

FOR CONTROL CABLE

WITH TERMINAL

STRIP

LEAD

CONNECTORS

CONTROL CABLE

S22979

N.B.

& N

.C.

14-PIN

RECEPTACLE

ABC

rem

ote

volta

ge s

ensin

g w

ork

lead

may

be

orde

red

for t

his

purp

ose.

N.A

. W

eldi

ng c

able

s m

ust b

e of

pro

per c

apac

ity fo

r the

cur

rent

and

dut

y cy

cle

of im

med

iate

and

futu

re a

pplic

atio

ns.

Co

nnec

t red

jum

per t

o pi

n "S

".

Co

nnec

t whi

te ju

mpe

r to

pin

"B".

Abo

ve d

iagr

am s

how

s el

ectro

de c

onne

cted

pos

itive

. To

chan

ge p

olar

ity,

N.F.

If

lead

#21

is to

be

conn

ecte

d to

follo

ws:

N.D

. Co

nnec

t the

con

trol c

able

gro

und

lead

to th

e fra

me

term

inal

mar

ked

ne

ar th

e po

wer

sou

rce

term

inal

stri

p. T

he p

ower

sou

rce

grou

ndin

g te

rmin

al (m

arke

d

and

loca

ted

near

the

pow

er

s

ourc

e in

put p

ower

con

nect

ions) m

ust b

e pr

oper

ly co

nnec

ted

to

e

lect

rical

gro

und

per t

he p

ower

sou

rce

oper

atin

g m

anua

l.

Con

nect

it d

irect

ly to

the

wor

k pi

ece

keep

ing

it el

ectri

cally

con

veni

ence

, thi

s ex

tend

ed #21

lead

sho

uld

be ta

ped

to th

e

w

eldi

ng w

ork

lead

. (If

the

leng

th o

f wor

k le

ad c

ircui

t is

sho

rt, a

nd c

onne

ctio

ns c

an b

e ex

pect

ed to

be

relia

ble,

then

con

trol c

able

lead

#21

doe

s no

t nee

d to

be

exte

nded

and

can

be

dire

ctly

conn

ecte

d to

term

inal

#21

on

the

term

inal

stri

p. N

ote

that

this

is n

ot th

e pr

efer

red

conn

ectio

n be

caus

e it

adds

erro

r

tur

n po

wer

off,

reve

rse

the

elec

trode

and

wor

k le

ads

at th

e po

wer

sou

rce.

phy

sical

ly su

itabl

e fo

r the

inst

alla

tion.

An S16586-[LENGTH

]

N.D.

& N

.F.

INPUT CABLE

PLUG

CONTROL CABLE

414231

3275

7677

N.F

.21-21+

REMOTE

VOLTAGE SENSING

LEAD

TO NA-5/-5R

BOLT

TO

CABLES FROM

NA-5/-5R

WIRE CONTACT AS

'BLY

box

pol

arity

con

nect

ions

. Al

so re

fer t

o no

te N

.F.

Re

fer t

o NA-5

or NA-5R

Ope

ratin

g M

anua

l for

requ

ired NA-5

or NA-5R

con

trol

FOR ADDITIONAL INSTALLATION INSTRUCTIONS

, SEE

NA-5 OR NA-5R OPERATING

MANUAL.

or

from

14-

pin

rece

ptac

le u

sing

#14 AWG

or l

arge

r ins

ulat

ed w

ire

N.B.

Ext

end

lead

#21

from

con

trol c

able

with

term

inal

stri

p co

nnec

tors

sep

arat

e fro

m th

e w

eldi

ng w

ork

lead

circ

uit a

nd c

onne

ctio

n. F

or

to th

e NA-5

/-5R

vol

tmet

er re

adin

g.)

N.E

. Th

e ju

mpe

rs o

n th

e NA-5

/-5R

vol

tage

boa

rd m

ust b

e co

nnec

ted

as

NA-5

/-5R

cont

rol b

ox.

N.C

. Ta

pe u

p bo

lted

conn

ectio

n if

lead

#21

is e

xten

ded.

the

term

inal

strip

, con

nect

Whe

n us

ing NA-5

/-5R

con

trols

abo

ve C

ode 83

00, t

he NA-5/-5R In

ch D

own

but

ton

will

not o

pera

te u

nles

s a

jum

per i

s co

nnec

ted

betw

een

the

two

tab

term

inal

s, la

bele

d "AUTO

", lo

cate

d ab

ove

the

trans

form

er o

n th

e NA-5/-5R

Volta

ge P

.C. b

oard

. Th

is ju

mpe

r, ho

wev

er, w

ill di

sabl

e th

e

per

mitt

ing

only Ho

t Sta

rting

tech

niqu

es to

be

used

. C

old St

artin

g/Au

to-S

top/To

uchi

ng-W

ork

feat

ure

of th

e NA-5

/-5R

,

10-3

0-98F

N.H

. Illu

stra

tion

does

not

nec

essa

rily

repr

esen

t act

ual p

ositi

on o

f

fo

r mor

e inf

orm

ation

.

to th

e #21

term

inal

that

mat

ches

wor

k po

larity

. Thi

s co

nnec

tion

mus

t be

chan

ged

when

ever

the

elect

rode

pol

arity

is c

hang

ed.

N.G

. F

or p

rope

r NA-5/-5R

oper

atio

n, th

e ele

ctro

de c

ables

mus

t be

snu

gged

und

er

the

clam

p ba

r on

the

left s

ide

of th

e

N.H.

CO

NN

EC

TIO

N O

F N

A-5

/-5

R T

O T

HE

CV

-65

5,

DC

-65

5 O

R D

C-6

00

PO

WE

R S

OU

RC

E

ap

prop

riate

out

put s

tuds

. Ref

er to

pow

er s

ourc

e op

erat

ing m

anua

l F

or p

rope

r set

ting

of s

witc

hes

on p

ower

sou

rce,

see

pow

er s

ourc

e op

erat

ing

man

ual.

F-8DIAGRAMSF-8

DC-600 RED-D-ARC

S22980

ELECTRODE CABLE

-+

14 PIN

AMPHENOL

POWER

SOURCE TO

WORK

AND

14-PIN

CABLE

PLUG

, REAR

VIEW

AND

14-PIN

CABLE

PLUG

, FRONT

VIEW

K=42

I=41 H=21

D=4

C=2

PIN B C D E F

75767742

LEAD

42V AC

42V AC

TRIGGER

CIRCUIT

(SEE

APPROPRIATE

WIRING

DIAGRAM)

FUNCTION

FUNCTIONS ARE LISTED

FOR

REFERENCE

ONLY

AND

EACH

MAY

OR

MAY

NOT BE

PRESENT IN

YOUR

EQUIPMENT.

14-SOCKET

BO

X RECEPTACLE

, FRONT

VIEW

14-SOCKET

BO

X RECEPTACLE

, REAR

VIEW

N.C

. PINS NOT LISTED

ARE NOT CONNECTED

ON

CABLE

.

N.A

. WELDING

CABLE

MUST

BE SI

ZED

FOR

CURRENT

AND

DUTY

CYCLE

OF APPLICATION

.

G21

H41

I42

J

MF=76

E=77

G=75N

L

A

B=GND

K=42

I=41

H=21

D=4C=2

J

MF=76

E=77

G=75

NL

A

B=GND

9 PIN

AMPHENOL

K

GND

CHASSIS CONNECTION

WORK

OUTPUT CONTROL

OUTPUT CONTROL

OUTPUT CONTROL

TRIGGER

CIRCUIT

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

N.D

. IF

LEAD

#21

IS TO

BE CONNECTED

TO

THE

TERMINAL

STRIP

, CONNECT TO

THE

#21

TERMINAL

THAT

MATCHES

WORK

POLARIT

Y.

THIS

CONNECTION

MUST

BE CHANGED

WHENEVER

THE ELECTRODE POLARIT

Y IS

CHANGED

.

10-3

0-98F

N.E

.

N.E

. ILLUSTRATION

DOES

NOT NECESSARIL

Y REPRESENT

ACTUAL

POSITION

OF APPROPRIATE

OUTPUT STUDS.

MORE INFORMATION

.

CO

NN

EC

TIO

N O

F D

H-1

0 O

R L

N-1

0 T

O P

OW

ER

SO

UR

CE

WIT

H 1

4 P

IN A

MP

HE

NO

L

REFER

TO

POWER

SOURCE OPERATING

MANUAL

FOR

LINCOLN

WIRE

FEEDER

WIRE FEEDER

INPUT CABLE

ASSEMBLY

N.B

. DIAGRAM

SHOWS ELECTRODE POSITI

VE. TO

CHANGE POLARIT

Y, TURN

POWER

"OFF

",

REVERSE

ELECTRODE AND

WORK

CABLES AT

POWER

SOURCE.

FOR

PROPER

SETTINGS OF SWITCHES

ON

POWER

SOURCE,

SEE POWER

SOURCE OPERATING

MANUAL

.

F-9DIAGRAMSF-9

DC-600 RED-D-ARC

LOCATION

OF BASE MOUNTING

HOLES

.94

*

*

**

20.0

0

M12244-6

DC

-60

0

1-20-8

9A27

.87

9.20

27.5

0

3.25

39.95

22.25

29.93

THIS

DIMENSION

WILL

VAR

YWITH

POSITION

OF HANDLE

DIM

EN

SIO

N P

RIN

T (

WIT

H K

81

7P

UN

DE

RC

AR

RIA

GE

)

11.12

17.75

38.0

0

5.90

4.75

F-10DIAGRAMSF-10

DC-600 RED-D-ARC

6-18-93C

36.12

M1520

0-3

17.76

38.0

05.19

DIM

EN

SIO

N P

RIN

T (

WIT

H K

84

2 U

ND

ER

CA

RR

IAG

E)

20.0

0

27.65

*

37.86

LOCATION

OF BASE MOUNTING

HOLES

*

*29.93

.94

**

3.25

23.28

22.25

11.12

27.5

0

7.11

54.91

49.8

9

DIM

EN

SIO

N P

RIN

T (

WIT

H K

84

2 U

ND

ER

CA

RR

IAG

E)

DC

-60

0

NOTES

DC-600 RED-D-ARC

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

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