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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.
3. Set the DC-600 OUTPUT TERMINALS switch toREMOTE.
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.
3. Set the DC-600 OUTPUT TERMINALS switch toREMOTE.
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.
11. Set the DC-600 OUTPUT TERMINALS switch toREMOTE.
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.
3. Set the DC-600 OUTPUT TERMINALS 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
E-2TROUBLESHOOTINGE-2
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
E-4TROUBLESHOOTINGE-4
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
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
Observe all Safety Guidelines detailed throughout this manual
DC-600 RED-D-ARC
E-5TROUBLESHOOTINGE-5
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
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.
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
DC-600 RED-D-ARC
E-6TROUBLESHOOTINGE-6
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
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local AuthorizedField Service Facility.
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.
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
DC-600 RED-D-ARC
E-7TROUBLESHOOTINGE-7
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
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local AuthorizedField Service Facility.
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.
RECOMMENDEDCOURSE OF ACTION
WELDING PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
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 •
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