Lincoln Electric DC-600 series Operator'S Manual Download Page 8 | Manualshive

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TABLE OF CONTENTS

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Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-2

Troubleshooting ..............................................................................................Section E

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

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

Parts List ......................................................................................................P349 Series

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Summary of Contents for DC-600 series

Page 1: ...S MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful 1 2 3 4 5 6 7 8 9 10 DC 600 For use with machines having Code Numbers 10588 to 10701 1...

Page 2: ...RERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safe...

Page 3: ...or cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both weld...

Page 4: ...the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic line...

Page 5: ...et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talon...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...r Ground Connection B 4 Controls and Settings B 4 B 5 Auxiliary Power in MS Receptacle B 6 Overload Overcurrent and Fault Protection B 6 Operating Steps B 7 Remote Control of Machine Operation B 7 Wel...

Page 8: ...Precautions D 1 Routine and Periodic Maintenance D 2 Troubleshooting Section E Safety Precautions E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 Wiring Diagrams Connection Diagram...

Page 9: ...0 460 575 60 460 60 575 60 220 380 440 50 60 380 500 50 60 440 50 60 200 400 50 60 415 50 60 100 Duty Cycle 108 54 108 54 43 54 43 116 67 58 67 51 58 128 64 61 50 Duty Cycle 134 67 134 67 54 67 54 138...

Page 10: ...ree machines in one grouping DO NOT stack the DC 600 on another type of machine Follow these guidelines when stacking 1 Select a firm level surface capable of sup porting the total weight of up to thr...

Page 11: ...al electrical codes or see the Technical Specifications page in this manual GROUND CONNECTION Ground the frame of the machine A ground terminal marked with the symbol is located inside the Case Back o...

Page 12: ...m pasted on the inside of the Case Back Input Access Door L3 L2 L1 LINK LINES INPUT GND H2 H1 H3 L3 L2 L1 LINK LINES INPUT H3 H1 H2 GND W V U W V U CONTACTOR CRI CRI CONNECTION FOR HIGHEST RATING PLAT...

Page 13: ...TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 DISCONNECTAND INSULATE THE H3 H4 LEAD TERMINALS SEPARATELYWITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION 3 CONNECT L1 L2 L3 I...

Page 14: ...E FOR REQUIRED INPUT SUPPLY VOLTAGE 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 CONNECT TERMINALMARKED TO GROUND PER NATIONAL ELECTRIC CODES 3 CONNECT THE L1 L2 L3 INPUT S...

Page 15: ...minals in the lower right and lower left corners of the Case Front Assembly See Figure A 9 3 Pull out the retractable strain relief loops 4 Insert the electrode lead through the loop directly below th...

Page 16: ...DELS ONLY The 115VAC duplex receptacle is protected by a circuit breaker located on the nameplate The receptacle is a NEMA 5 15R AUXILIARY POWER TABLE Voltage and Circuit Breaker Ratings at Auxiliary...

Page 17: ...wire welder DC manual stick welder AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before ser vicing READ THIS WARNING PROTECT YOURSELF OTHERS FUMES A...

Page 18: ...ld welding performance A control circuit designed to provide good starting for a large variety of processes and procedures Output Control Potentiometer that provides easy single range continuous contr...

Page 19: ...ON REMOTE Switch OUTPUT TERMINALS ENERGIZED Remote Control of Output Terminals Energized or Non Energized LOCAL REMOTE Switch SYMBOL MEANING Control Of Output Voltage and Current is Via DC 600 s Cont...

Page 20: ...L SYMBOLS ON RATING PLATE LOCATED ON CASE BACK NEMA EW 1 100 Shielded Metal Arc Welding SMAW Submerged Arc Welding SAW MEANING OF GRAPHICAL SYMBOL FOR GROUND CON NECTION Signifies the equipment connec...

Page 21: ...this receptacle 11 Terminal Strip Cover Panel Rotate this panel to gain access to the circuits made available at the two terminal strips T S 1 and T S 2 These terminal strips contains the same circuit...

Page 22: ...c cutting it is recommended that the optional MULTI PROCESS SWITCH be used This switch permits you to easily change the polarity of the connected wire feeding equipment or switch to stick welding or a...

Page 23: ...E FEEDER 1 Set the DC 600 LOCAL REMOTE Switch to REMOTE Set the OUTPUT TERMINALS switch to REMOTE NOTE Later model NA 3 automatic wire feeders are capable of cold starts when the NA 3 Mode switch is i...

Page 24: ...t maximum For the best starting performance the NA 3 Open Circuit Voltage Control and Voltage Control set ting should be the same Set the Inch Speed Control for the slowest inch speed possible To adju...

Page 25: ...ong to connect a K857 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 the wire feeder connection is then not...

Page 26: ...s through the strain relief box connectors and into the terminal strip Connect wire feeder control cable as specified in specific connection diagram and make other terminal strip connections as specif...

Page 27: ...he DC 600 OFF and reverse the cables NOTE When it is not necessary to have separate ground cables for stick and semi automatic or automatic welding connect a jumper from the MULTI PROCESS SWITCH Work...

Page 28: ...cket or any condition that would affect the proper operation of the machine Perform Periodically Clean the inside of the machine with low pressure air stream Clean the following parts Main transformer...

Page 29: ...AUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it...

Page 30: ...ace it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a static charge If the P C Board can t be installed immediately put it back in the static...

Page 31: ...1 800 833 9353 WELD 1 Check for blown or missing fuses in input lines 2 Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel 3 Pow...

Page 32: ...oltage may be low Check all three phases 2 Make sure input line voltage matches machine rating and the reconnect panel is connect ed correctly for the line voltage 1 Poor electrode or work lead con ne...

Page 33: ...hine input contactor operates but machine has no weld output Fan runs and pilot light glows POSSIBLE CAUSE 1 Place OUTPUT TERMINAL Switch to ON or install a jumper from 2 to 4 on machine terminal stri...

Page 34: ...f all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility PROBLEMS SYMPTOMS Machine has maximum weld out...

Page 35: ...terminal strip 75 76 and 77 terminals or is not connected to the 14 pin MS receptacle the LOCAL REMOTE SWITCH must be in the Local position 2 If a remote control cable is con nected to terminals 75 76...

Page 36: ...n ON position The DC600 will NOT shut off when the Power Switch is turned to OFF POSSIBLE CAUSE 1 Remove all welding cables and control cables from the DC 600 Jumper 2 to 4 at the terminal strip or se...

Page 37: ...coln Authorized Field Service Facility PROBLEMS SYMPTOMS The weld output terminals are always electrically hot POSSIBLE CAUSE 1 Remove any external leads hooked to 2 and 4 on the ter minal strip or an...

Page 38: ...ity PROBLEMS SYMPTOMS Poor arc starting when the DC600 is in the CV Sub Arc or CV Innershield Modes Machine has output but trips off immediately when wire feed unit trigger is activated POSSIBLE CAUSE...

Page 39: ...e been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility PROBLEMS SYMPTOMS Poor arc characteristics in all processes POSSIBLE CAUSE 1 Check for the correct...

Page 40: ...dary winding of the control transformer T2 which supplies leads 255 and 256 Measure 16VDC from TEST POINTS A to C and 10VDC from TEST POINTS A to J on Control board 2 LED 2 indicates welder output vol...

Page 41: ...damaging rheostat tabs 6 Rotate the OUTPUT voltage control rheostat The resistance reading should be from around zero to 10K ohms Check the resistance reading between the two outer tabs on the rheosta...

Page 42: ...e only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible...

Page 43: ...E LEAD 32 TO BE CONNECTED TO THE HOT LINE 11338 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pas...

Page 44: ...2V 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 PRESE...

Page 45: ...adds error to the LN 7 voltmeter Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power 41 4 2 31 32 75 76 77 NEGATIVE PO...

Page 46: ...r the electrode polarity is changed N G If lead 21 is to be connected to the terminal strip connect to N F The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual...

Page 47: ...al 21 on the terminal strip Note that this is not the preferred connection because it adds error N D Connect the control cable ground lead to the frame terminal marked near the power source terminal s...

Page 48: ...t the power source physically suitable for the installation An S16586 LENGTH N D N F INPUT CABLE PLUG CONTROL CABLE 41 4 2 31 32 75 76 77 N F 21 21 REMOTE VOLTAGE SENSING LEAD TO NA 5 5R BOLT TO CABLE...

Page 49: ...UT CONTROL OUTPUT CONTROL OUTPUT CONTROL TRIGGER CIRCUIT Only qualified persons should install use or service this machine Do not operate with covers removed Disconnect power source before servicing D...

Page 50: ...LOCATION OF BASE MOUNTING HOLES 94 20 00 M12244 6 DC 600 1 20 89A 27 87 9 20 27 50 3 25 39 95 22 25 29 93 THIS DIMENSION WILL VARY WITH POSITION OF HANDLE DIMENSION PRINT WITH K817P UNDERCARRIAGE 11 1...

Page 51: ...8 93C 36 12 M15200 3 17 76 38 00 5 19 DIMENSION PRINT WITH K842 UNDERCARRIAGE 20 00 27 65 37 86 LOCATION OF BASE MOUNTING HOLES 29 93 94 3 25 23 28 22 25 11 12 27 50 7 11 54 91 49 89 DIMENSION PRINT W...

Page 52: ...NOTES DC 600...

Page 53: ...NOTES DC 600...

Page 54: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 55: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 56: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

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