Red-D-Arc DC-600 Operator'S Manual Download Page 43

F-4

DIAGRAMS

F-4

DC-600

  N.C.  Tape up bolted connection if lead #21 is extended.

  N.D.  Connect the control cable ground lead to the frame terminal

        marked       near the power source terminal strip.  The power

        source grounding terminal (marked       and located near the power

        source input power connections) must be properly connected to

        electrical ground per the power source operating manual.

   N.A.  Welding cables must be of proper capacity for the current and

 Above diagram shows electrode connected positive.  To change polarity,

 turn power off, reverse the electrode and work leads at the power

NEGATIVE

POSITIVE

32 31 2 4

GND

21

N.A.

N.D.

ELECTRODE CABLE

TO WIRE FEED UNIT

TO WORK

POWER SOURCE

N.E.

Only qualified persons should install, use or

service this machine.

Do not operate with covers removed.

Disconnect power source before

servicing.

Do not touch electrically live parts.

CABLE

21

FOR CONTROL CABLE

WITH 14 PIN

MS-TYPE

PLUG CONNECTOR

OR

FOR CONTROL CABLE

WITH TERMINAL STRIP

LEAD CONNECTORS

 CONTROL CABLE

  

   S22977   

source and position the switch on wire feeder (if equipped )

 to proper polarity. Also refer to note N.F.

N.B. & N.C.

14-PIN

RECEPTACLE

A

B

C

  N.E.  If using an older LN-8 control cable: connect lead #75 to #75 on

terminal strip, connect lead #76 to #76 on terminal strip, connect

lead #77 to #77 on the terminal strip.

the #21 terminal that matches work polarity. This connection must be  changed whenever 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):

White jumper on voltage board to pin "S" .

Blue jumper on voltage board (later units only),

or on start board (earlier units), to pin "B".

        remote voltage sensing work lead may be ordered for this purpose.

N.B.  Extend lead #21 from control cable with terminal strip connectors or  

         from 14-pin receptacle using #14 AWG or larger insulated wire 

         duty cycle of immediate and future applications.  

        Connect it directly to the work piece keeping it electrically

        convenience, this extended #21 lead should be taped to the

        welding work lead.  (If the length of work lead circuit is

        short, and connections can be expected to be reliable, then

        control cable lead #21 does not need to be extended and can be

        directly connected to terminal #21 on the terminal strip.  Note

        that this is not the preferred connection because it adds error

        separate from the welding work lead circuit and connection.  For

        to the wire feeder voltmeter reading.)

        physically suitable for the installation.  An S16586-[LENGTH] 

TO LN-8 OR  LN-9

 CONTROL

N.F.

INPUT CABLE PLUG

41

423

1

32

75

76

77

N.E.

N.G.

21

-

21

+

REMOTE VOLTAGE SENSING LEAD

10-30-98F  

  N.H.  Illustration does not necessarily represent actual position of appropriate

           output studs. Refer to power source instruction manual for more info.

N.H.

         CONNECTION OF LN-8 OR LN-9 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE       

For proper setting of switches on power source,

see power source operating manual.

Summary of Contents for DC-600

Page 1: ...safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AN...

Page 2: ...KER WEARERS 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...

Page 3: ...ctrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for...

Page 4: ...prevent 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 hydraul...

Page 5: ...opri s 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 pa...

Page 6: ...t be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser...

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

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: ...elay in tripping action that decreases as the magnitude of the current increases RECOMMENDED INPUT WIRE AND FUSE SIZES Standard Volatge 230 460 575 60 Code Number 10650 100 Duty Cycle 108 54 43 50 Dut...

Page 10: ...ical earth ground Set the DC 600 Power ON OFF PUSH BUTTON to the OFF position when connecting power cord to input power __________________ SELECT PROPER LOCATION Place the welder where clean cooling a...

Page 11: ...cal 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...

Page 12: ...ructions can cause immedi ate failure of components within the machine __________________ To reconnect a multiple voltage machine to a different voltage remove input power and change the position of t...

Page 13: ...rminals in the lower right and lower left corners of the Case Front Assembly See Figure A 4 3 Pull out the retractable strain relief loops 4 Insert the electrode lead through the loop directly below t...

Page 14: ...nt is a 14 Pin MS type recep tacle for connection of auxiliary equipment such as wire feeders Also terminal strips with 115VAC and connections for auxiliary equipment are located behind the hinged acc...

Page 15: ...ilation or exhaust to remove fumes from breathing zone WELDING CUTTING and GOUGING SPARKS can cause fire or explosion Keep flammable material away Do not weld cut or gouge on containers that have held...

Page 16: ...g for a large variety of processes and procedures Output Control Potentiometer that provides easy single range continuous control Output Control Switch that provides simple switch ing from local to re...

Page 17: ...itch 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 Control Dial Remo...

Page 18: ...der complies with both Underwriters Laboratories UL standards and Canadian Standards Association CSA standards 60 Hertz Models Gas Metal Arc Welding GMAW Flux Cored Arc Welding FCAW MEANING OF GRAPHIC...

Page 19: ...OUTPUT CONTROL This control provides continuous control of the machine s 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...

Page 20: ...Section AUXILIARY POWER IN MS RECEPTACLE 42 volt AC auxiliary power as required for some wire feeders is available through the wire feeder MS receptacle A 10 amp circuit breaker protects the 42 volt...

Page 21: ...toggle switch on the control panel labeled Remote Panel gives the operator the option of con trolling the machine output from a remote location If in the Remote position a wire feeder with remote con...

Page 22: ...should provide trouble free starting These pro cedures apply to single solid wires and Innershield wires 1 Cut the electrode to a sharp point 2 Set the NA 3 Open Circuit Voltage Control to the same d...

Page 23: ...performance the NA 3 Open Circuit Voltage Control and Voltage Control setting should be the same Set the Inch Speed Control for the slowest inch speed possible b To adjust the Open Circuit Voltage Co...

Page 24: ...ERGED ARC mode depending on the weld ing process being used 2 Set the DC 600 LOCAL REMOTE SWITCH to the REMOTE position 3 Set the DC 600 OUTPUT TERMINALS switch to REMOTE 4 Set the LN 8 Welding Mode S...

Page 25: ...10 Automatic Wire Feeders NA 3 NA 5R NA 5 Tractors LT 7 LT 56 FIELD INSTALLED OPTIONS Remote Output Control K775 or K857 with K864 Adapter An optional remote out control is available The K775 is the...

Page 26: ...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 specifie...

Page 27: ...n the 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 Wo...

Page 28: ...acket 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 transforme...

Page 29: ...CAUSE 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...

Page 30: ...g and place 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...

Page 31: ...REAS OF MISADJuSTMENT S Contact the Lincoln Electric Service Dept 216 383 2531 or 1 888 935 3877 1 Check for blown or missing fuses in input lines 2 Check the three phase input line voltage at the mac...

Page 32: ...orking 60HZ machines only POSSIBLE AREAS OF MISADJUSTMENT S 1 The input line voltage may be low Check all three phases 2 Make sure input line voltage matches machine rating and the reconnect panel is...

Page 33: ...manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine input contactor operates but machine has no weld output Fan runs and pilot light glows POSSIBLE AREAS OF MISADJUSTMENT S 1 Place OUTPUT TERMINAL...

Page 34: ...as of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Facility Observe Safety Guidelines detailed in the beginning of this manual TROUBLESHOOTING G...

Page 35: ...OF MISADJUSTMENT S 1 If a remote control unit is NOT connected to the 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...

Page 36: ...re at terminal strip or OUTPUT TERMINALS switch is in ON position The DC600 will NOT shut off when the Power Switch is turned to OFF POSSIBLE AREAS OF MISADJUSTMENT S 1 Remove all welding cables and c...

Page 37: ...Observe Safety Guidelines detailed in the beginning of this manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The weld output terminals are always electrically hot POSSIBLE AREAS OF MISADJUSTMENT S 1 Re...

Page 38: ...in the beginning of this manual TROUBLESHOOTING GUIDE 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...

Page 39: ...persists Contact your local Authorized Field Service Facility Observe Safety Guidelines detailed in the beginning of this manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Poor arc characteristics in al...

Page 40: ...SCR SCR SCR SCR SCR SCR 1 2 3 4 5 6 OUTPUT SNUBBER G6 G4 G2 OUTPUT RECTIFIER ASSEMBLY SCR SNUBBERS G1 G3 G5 NECESSARY TO HAVE SEPARATE GROUND A A A A A A C C C C C C N G 1 CR2 10 J7 1 2 3 4 5 6 7 8 10...

Page 41: ...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 42: ...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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 WITH K842...

Page 49: ...6 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to...

Page 50: ...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 51: ...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 52: ...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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