RED-D-ARC DC-600 For use with machines having Code Numbers: IM669-D November, 2008 ( 10663, 11073, 11134, 11340, 11542 RETURN TO MAIN MENU OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You 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.
SAFETY i i WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
SAFETY ii ARC RAYS can burn. ELECTRIC SHOCK can kill. 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 bare skin 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 full area of physical contact with work and ground.
iii iii SAFETY WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to 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 hydraulic lines. Have a fire extinguisher readily available. 6.b.
SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: iv 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
v v Thank You for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products.
vi TABLE OF CONTENTS vi Page Installation .......................................................................................................Section A Technical Specifications ............................................................................................. A-1 Safety Precautions ..................................................................................................... A-2 Select Proper Location....................................................................................
vii TABLE OF CONTENTS vii Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine and Periodic Maintenance........................................................................D-1 Testing the GFCI Receptacle ................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – DC-600 INPUT - THREE PHASE ONLY Standard Voltage Input Current at Rated Output 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle 108/54/43 230/460/575/60 122/61/49 134/67/54 RATED OUTPUT Amps 600 680 750 Duty Cycle 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle Volts at Rated Amperes 44 44 44 OUTPUT Output Range 70A/13V-780A/44V (CV) 90A/24V-780A/44V (CC) Maximum Open Circuit Voltage 72V Auxiliary Power See the OPERATION section for Auxiliary Power inf
INSTALLATION A-2 Read entire Installation Section before installing the DC-600. SAFETY PRECAUTIONS A-2 STACKING Three DC-600 machines can be stacked. DO NOT stack more than three machines in one grouping. WARNING DO NOT stack the DC-600 on another type of machine. ELECTRIC SHOCK CAN KILL. • Only qualified personnel should install this machine. • Turn the input power OFF at the disconnect switch or fuse box before working on the equipment. Follow these guidelines when stacking: 1.
A-3 A-3 INSTALLATION ELECTRICAL INPUT CONNECTIONS INPUT POWER SUPPLY CONNECTIONS Before installing the machine check that the input supply voltage, phase, and frequency are the same as the voltage, phase, and frequency as specified on the welder Rating Plate located on the Case Back Assembly. Welder is rated for 230/460/575V input and is shipped from the factory connected for 460 input. Input power supply entry is through the hole in the Case Back Assembly. See Figure A.
A-4 INSTALLATION RECONNECT PROCEDURE Multiple voltage machines are shipped connected to the highest input voltage listed on the machineʼs rating plate. Before installing the machine, check that the Reconnect Panel in the Input Box Assembly is connected for the proper voltage. A-4 To reconnect a multiple voltage machine to a different voltage, remove input power and change the position of the reconnect board on the Reconnect Panel.
A-5 A-5 INSTALLATION OUTPUT CONNECTIONS See Table A.1 for recommended DC-600 cable sizes for combined lengths of electrode and work cables. TABLE A.1 DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable at 100% Duty Cycle ELECTRODE, WORK AND #21 LEAD Cable Length Parallel Cables Cable Size Lengths up to 150 ft. (46m) 2 1/0 (53mm2) 150 ft.(46m) to 200 ft (61m) 2 2/0 (85mm2) 200 ft.(61m) to 250 ft.(76m) 2 3/0 (107mm2) CONNECTIONS A.
A-6 A-6 INSTALLATION AUXILIARY POWER AND CONTROL CONNECTIONS FIGURE A.6 FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE K=42 Located at the left side of the front of the welder behind a hinged cover is a 115VAC GFCI receptacle for auxiliary power. On the right side of the case front is a 14 Pin MS type receptacle for connection of auxiliary equipment such as wire feeders.
INSTALLATION A-7 TERMINAL STRIPS Terminal strips are available behind the cover on the case front to connect wire feeder control cables that do not have a 14 Pin MS-type connector. These terminals supply the connections as shown in the following Terminal Strip charts. NOTE: There are two work sense lead connection points on the terminal strip.
OPERATION B-1 SAFETY PRECAUTIONS B-1 GENERAL DESCRIPTION Read and understand entire section before operating machine. WARNING The DC-600 is an SCR controlled three phase welding and cutting power source. It uses a single range potentiometer to control: • ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves.
B-2 OPERATION WELDING CAPABILITY DESIGN FEATURES AND ADVANTAGES • • • • • • • • • • • • • • • • • • • • • • • • B-2 Excellent arc characteristics for optimum constant voltage submerged arc and Innershield 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 control. Output Control Switch that provides simple switching from local to remote control.
B-3 OPERATION MEANING OF GRAPHICAL LOCAL/REMOTE Switch SYMBOLS ON SYMBOL MEANING RATING PLATE (LOCATED ON Control Of Output Voltage and CASE BACK) Current is Via DC-600's Control Dial B-3 Remote Control of Output Voltage and Current MODE Switch Designates welder complies with National Electrical Manufacturers NEMA EW 1 (100%) Association requirements EW 1 Class I with 100% duty cycle at 600Amps output.
OPERATION B-4 B-4 CONTROLS AND SETTINGS All operator controls and adjustments are located on the Case Front Assembly of the DC-600. See Figure B.1 for the location of each control. 5 7 3 8 6 5 9 4 1 6 4 7 3 8 2 9 1 10 2 DC-600 11 10 12 13 FIGURE B.1 - CONTROL PANEL KEYS 1. Input POWER ON/OFF Switch This toggle switch turns the machine on or off. Putting the switch in the ON “ ” position energizes the machineʼs input contactor applying input power to the machine.
B-5 OPERATION B-5 6. Mode Switch This switch allows for selecting the welding process to be used: CC STICK-for SMAW and AAC CV SUBMERGED ARC- for SAW CV INNERSHIELD- for FCAW and GMAW AUXILIARY POWER IN MS-RECEPTACLE 7. 115VAC GFCI Receptacle (60 Hertz Models) This receptacle provides up to 15 amps of 115 VAC auxiliary power. DC-600 machines can also supply 115 volt AC auxiliary power through the wire feeder receptacle. A 15 amp circuit breaker protects the 115 volt circuit from overloads. 8.
B-6 OPERATION OPERATING STEPS The following procedures are for using the DC-600 in the local control mode of operation. For remote control of the machine, see the Remote Control of Machine Operation section. Before operating the machine, make sure you have all materials needed to complete the job. Be sure you are familiar with and have taken all possible safety precautions before starting work. It is important that you follow these operating steps each time you use the machine.
B-7 OPERATION SEMI-AUTOMATIC AND AUTOMATIC WIRE FEEDING WITH THE DC-600 AND WIRE FEEDERS When using the DC-600 with semi-automatic or automatic wire feeding equipment and for stick welding or air/carbon arc 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 air/carbon arc cutting. NA-3 AUTOMATIC WIRE FEEDER 1. Set the DC-600 LOCAL/REMOTE Switch to REMOTE.
B-8 OPERATION ARC STRIKING WITH DC-600 AND THE NA-3 START BOARD When electrical strikeouts exceed 1 3/4” (44.4mm) an NA-3 Start Board may be required to improve arc striking. When the NA-3 Start Board is used to improve arc striking, use the following procedures: B-8 If the voltmeter pointer overshoots the desired voltage and then returns back to the desired voltage, the Open Circuit Voltage Control is set too high. This can result in a bad start where the wire tends to "Blast off.
B-9 OPERATION DC-600 POWER SOURCE SETTING WHEN CONNECTED TO NA-5 WIRE FEEDER When using the DC-600 with the NA-5 wire feeder, set the controls on the DC-600 as follows for the best performance: 1. Turn OFF main AC input power supply to the DC600. 2. Connect the electrode cables to terminal polarity to be used. 3. Connect the #21 work lead (on T.S.2) to the same polarity as the work cable connection.
ACCESSORIES C-1 WIRE FEEDERS AND TRACTORS The DC-600 can be used to power any of the following Lincoln Wire Feeders and Tractors: Semi-Automatic Wire Feeders: DH-10 LN-9 GMA LN-7 LN-10 LN-7 GMA LN-15P LN-742 LN-23P LN-8 LN-25 LN-9 Automatic Wire Feeders: NA-3 NA-5R NA-5 Tractors: LT-7 C-1 Undercarriages (K817P, K842) For easy moving of the machine, an optional undercarriage (K842) is available with mountings for two gas cylinders at rear of welder.
C-2 ACCESSORIES C-2 The MULTI-PROCESS SWITCH has two sets of output terminals. You connect the wire feeder unit cables to the set of terminals on the left side of the box and the stick or air/carbon arc cables to the set of terminals on the right side (facing the front of the machine) as shown in Figure C.1. The output terminals are protected against accidental contact by hinged covers.
C-3 ACCESSORIES 12. Connect stick or air/carbon arc electrode and work cable. See Figure C.2. a. Insert the electrode and work cables through the strain relief loop on the right side (facing the front of the machine) of the DC-600. b. Connect the electrode cable to the "Positive" terminal on the right side of the MULTIPROCESS SWITCH. c. Connect the work cable to the "Negative" terminal on the right side of the MULTIPROCESS SWITCH.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 TESTING THE GFCI RECEPTACLE WARNING 1. Turn the welder ON. Press the reset button fully. Plug a lamp or radio into the GFCI (and leave it plugged in) to verify that the power is ON. If there is no power, go to Troubleshooting Section. ELECTRIC SHOCK CAN KILL. • Only qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. 2.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING E-2 E-2 PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. • Remove the P.C. Board from the static-shielding bag and place it directly into the equipment. Donʼt set the P.C. Board on or near paper, plastic or cloth which could have a static charge. If the P.C.
TROubLEShOOTING E-3 E-3 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAuSE RECOMMENDED COuRSE OF ACTION OuTPuT PRObLEMS Major Physical or Electrical Damage is Evident Contact the Service Dept. (216) 383-2531 or 1-888-935-3877 The Machine is dead. The Input contactor does not operate. 1. Check for blown or missing fuses in input lines. 2. Check the three phase input line voltage at the machine.
TROUBLESHOOTING E-4 E-4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine input contactor operates but machine has no weld output. Fan runs and pilot light glows. 1. Place OUTPUT TERMINAL Switch to “ON”, or install a jumper from #2 to #4 on machine terminal strip. If machine weld output is restored the problem is in the wire feeder or control cable. 2.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has minimum output and no control. 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" position. 2.
TROUBLESHOOTING E-6 E-6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine shuts off (input contactor drops out) when the welder output terminals are made electrically "hot". (#2 to #4 closure at terminal strip.) or OUTPUT TERMINALS switch is in ON position. 1. Remove all welding cables and control cables from the DC-600.
TROUBLESHOOTING E-7 E-7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Poor arc starting when the DC600 is in the CV Sub-Arc or CV Innershield Modes. 1. Make sure the proper welding procedures are being used. (wire feed speed, arc voltage and wire size). 2. Check weld cables for loose or faulty connections. Machine has output but trips off immediately when wire feed unit trigger is activated.
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 pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number. GFCI RECEPTACLE FOR CODE 10663 TO HAVE LEAD 31 CONNECTED TO THE WHITE LINE. LEAD 32 TO BE CONNECTED TO THE HOT LINE. DUPLEX RECEPTACLE TO BE WIRED AS SHOWN FOR ALL CODES EXCEPT 10663.
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 pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
DC-600 RED-D-ARC - OUTPUT CONTROL OUTPUT CONTROL OUTPUT CONTROL WORK 42V AC 42V AC 76 75 21 41 42 F G H I K TRIGGER CIRCUIT 4 77 E 2 C D TRIGGER CIRCUIT LEAD PIN FUNCTION (SEE APPROPRIATE WIRING DIAGRAM) N.D. E=77 AND 14-PIN CABLE PLUG, REAR VIEW service this machine. Only qualified persons should install, use or G=75 H=21 I=41 F=76 K=42 E=77 D=4 C=2 14-SOCKET BOX RECEPTACLE, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW G=75 H=21 I=41 TO "REMOTE" POSITION.
4 2 DC-600 RED-D-ARC POSITIVE 31 32 21 N.E. TO WIRE FEED UNIT TO WORK 32 31 2 4 CONTROL CABLE MS-TYPE service this machine. Only qualified persons should install, use or Do not touch electrically live parts. servicing. Disconnect power source before Do not operate with covers removed. for more information. see power source operating manual. For proper setting of switches on power source, appropriate output studs. Refer to power source operating manual to proper polarity.
4 2 DC-600 RED-D-ARC N.A. N.H. POSITIVE 31 32 21 TO WIRE FEED UNIT TO WORK For proper setting of switches on power source, see power source operating manual. to proper polarity. Also refer to note N.F. turn power off, reverse the electrode and work leads at the power source and position the switch on wire feeder (if equipped ) C B A 32 31 2 4 21 GND ELECTRODE CABLE N.D. N.E. REMOTE VOLTAGE SENSING LEAD 75 76 77 N.E. CONTROL CABLE INPUT CABLE PLUG TO LN-8 OR LN-9 CONTROL CABLE N.F.
4 2 DC-600 RED-D-ARC POSITIVE 31 32 TO WORK EQUIPMENT TO AUTOMATIC Also refer to note N.F. For proper setting of switches on power source, see power source operating manual. in the automatic control box. turn power off, reverse the electrode and work leads at the power source. Reverse the leads on the back of the ammeter and voltmeter 77 76 75 32 31 2 4 CONTROL CABLE 21 GND ELECTRODE CABLE N.D.
4 2 DC-600 RED-D-ARC POSITIVE 31 32 21 TO WORK N.D. & N.F. WIRE CONTACT AS'BLY turn power off, reverse the electrode and work leads at the power source. Refer to NA-5 or NA-5R Operating Manual for required NA-5 or NA-5R control For proper setting of switches on power source, see power source operating manual. FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OR NA-5R OPERATING MANUAL. box polarity connections. Also refer to note N.F.
+ TO WORK ELECTRODE CABLE 14 PIN AMPHENOL N.E.
4.75 17.75 38.00 29.93 * * .94 * DC-600 RED-D-ARC 39.95 LOCATION OF BASE MOUNTING HOLES 5.90 THIS DIMENSION WILL VARY WITH POSITION OF HANDLE 11.12 27.87 20.00 22.25 * DC-600 DIMENSION PRINT (WITH K817P UNDERCARRIAGE) DIAGRAMS M12244-6 1-20-89A 9.20 27.50 3.
17.76 49.89 54.91 36.12 38.00 DC-600 RED-D-ARC * 29.93 * * * .94 37.86 11.12 LOCATION OF BASE MOUNTING HOLES 5.19 27.65 20.00 22.25 23.28 DC-600 DIMENSION PRINT (WITH K842 UNDERCARRIAGE) * M15200-3 6-18-93C 7.11 27.50 3.
NOTES DC-600 RED-D-ARC
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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