Lincoln Electric DC-600 series Operator's Manual
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Lincoln Electric DC-600 series Operator's Manual

Lincoln Electric DC-600 series Operator's Manual

Multi-process welders
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For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN INDEX
DC-600
10588 to 10701,11071, 11072,11129,
11130, 11131, 11132, 11133 and 11140
11335, 11336, 11337, 11338, 11339
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2006 Lincoln Global Inc.
IM642-C
October, 2006

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Summary of Contents for Lincoln Electric DC-600 series

  • Page 1 RETURN TO MAIN INDEX IM642-C DC-600 October, 2006 10588 to 10701,11071, 11072,11129, For use with machines having Code Numbers: 11130, 11131, 11132, 11133 and 11140 11335, 11336, 11337, 11338, 11339 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 6 The code number is especially important when identifying the correct replacement parts. On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Page Installation .......................Section A Technical Specifications ..................... A-1 Safety Precautions ..................... A-2 Select Proper Location....................A-2 Limit on Stacking ....................A-2 Stacking .........................A-2 Tilting ........................A-2 Electrical Input Connections ..................A-3 Fuses and Wire Sizes....................A-3 Ground Connection ....................A-3 Input Power Supply Connections................A-3 Reconnect Procedure ....................
  • Page 8 TABLE OF CONTENTS Page 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...

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – DC-600 INPUT - THREE PHASE ONLY Input Current at Rated Output Standard 50% Duty Cycle 100% Duty Cycle 60% Duty Cycle Volatge 108/54 122/61 134/67 230/460/60 134/67/54 108/54/43 122/61/49 230/460/575/60 460/60 575/60 116/67/58 128/74/64 138/80/69 220/380/440/50/60 67/51 74/56 80/61...

  • Page 10: Safety Precautions

    INSTALLATION STACKING SAFETY PRECAUTIONS Three DC-600 machines can be stacked. Read entire Installation Section before installing the DC-600. DO NOT stack more than three machines in one grouping. ELECTRIC SHOCK CAN KILL. DO NOT stack the DC-600 on another type of WARNING machine.

  • Page 11: Electrical Input Connections

    INSTALLATION ELECTRICAL INPUT CONNECTIONS INPUT POWER SUPPLYCONNECTIONS A qualified electrician should connect the input power Before installing the machine check that the input sup- supply leads. ply voltage, phase, and frequency are the same as the voltage, phase, and frequency as specified on the 1.

  • Page 12: Reconnect Procedure

    INSTALLATION RECONNECT PROCEDURE 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. Multiple voltage machines are shipped connected to Follow The Input Connection Diagram located on the the highest input voltage listed on the machine’s rating inside of Case Back Input Access Door.
  • Page 13 INSTALLATION CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ) 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT LINES LEAST 600 VOLT INSULATION.
  • Page 14 INSTALLATION SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES. LINES 3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN. INPUT CONTACTOR FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines...

  • Page 15: Output Connections

    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...

  • Page 16: Auxiliary Power And Control Connections

    INSTALLATION AUXILIARY POWER AND LEAD NO. FUNCTION CONTROL CONNECTIONS 115 VAC Located at the left side of the front of the welder Chassis Connection behind a hinged cover is a 115VAC duplex receptacle Trigger Circuit for auxiliary power (60 Hertz Models only). On the right Trigger Circuit side of the case front is a 14 Pin MS type receptacle Output Control...

  • Page 17: Operation

    OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground.

  • Page 18: General Description

    OPERATION GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES The DC-600 is an SCR controlled three phase welding and cutting power source. It uses a single range • Excellent arc characteristics for optimum constant potentiometer to control: voltage submerged arc and Innershield welding performance.

  • Page 19: Welding Capability

    OPERATION WELDING CAPABILITY The DC-600 has the following Output and Duty Cycle based 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 SYMBOLS ON CASE FRONT Input POWER ON/OFF Switch LOCAL/REMOTE Switch SYMBOL...

  • Page 20: Meaning Of Graphical Symbols On Rating Plate

    OPERATION MEANING OF GRAPHICAL MEANING OF GRAPHICAL SYMBOLS ON RATING PLATE SYMBOL FOR GROUND CON- (LOCATED ON CASE BACK) NECTION Designates welder complies with Signifies the equipment connection National Electrical Manufacturers point for the protective earth ground NEMA EW 1 (100%) Association requirements EW 1 Class I with 100% duty cycle at 600Amps output.

  • Page 21: Auxiliary Power In Ms-Receptacle

    OPERATION 3. OUTPUT CONTROL 11.Terminal Strip Cover Panel This control provides continuous control of the Rotate this panel to gain access to the circuits machine’s output voltage and current from mini- made available at the two terminal strips (T.S.1 mum to maximum (typical full pot range between and T.S.2).

  • Page 22: Operating Steps

    OPERATION The power source circuitry is protected from faults on REMOTE CONTROL OF MACHINE leads 75, 76, or 77. If any of these leads are connect- OPERATION ed to either the positive or negative output leads, the DC-600 will either shut down completely (input con- The toggle switch on the control panel labeled tactor opens and white POWER light stays illuminat- “Remote - Panel”...

  • Page 23: Na-3 Automatic Wire Feeder

    OPERATION NA-3 AUTOMATIC WIRE FEEDER • To adjust the Open Circuit Voltage Control to get the best starting performance, make repeated starts observing the NA-3 voltmeter. 1. Set the DC-600 LOCAL/REMOTE Switch to REMOTE. Set the OUTPUT TERMINALS switch When the voltmeter pointer swings smoothly up to to REMOTE.
  • Page 24 OPERATION NOTE: These Start Board current and voltage set- DC-600 POWER SOURCE SETTING WHEN tings result in a start up current that is lower than CONNECTED TO NA-5 WIRE FEEDER the NA-3 current setting and approximately equal with the NA-3 voltage setting for the desired weld- When using the DC-600 with the NA-5 wire feeder, set ing procedure.

  • Page 25: Automatic Wire Feeder

    ACCESSORIES WIRE FEEDERS AND TRACTORS Undercarriages (K817P, K842) For easy moving of the machine, optional undercar- The DC-600 can be used to power any of the follow- riages are available with polyolefin wheels (K817P) or ing Lincoln Wire Feeders and Tractors: a platform undercarriage (K842) with mountings for two gas cylinders at rear of welder.
  • Page 26 ACCESSORIES The MULTI-PROCESS SWITCH has two sets of out- put terminals. You connect the wire feeder unit cables to the set of terminals on the left side of the box and TERMINAL STRIP COVER the stick or air/carbon arc cables to the set of termi- nals on the right side (facing the front of the machine) CONNECTOR as shown in Figure C.1.

  • Page 27: Connections For Semi-Automatic Or Automatic Wire Feeder Control

    ACCESSORIES 12. Connect stick or air/carbon arc electrode and work CONNECTIONS FOR SEMI-AUTO- cable. See Figure C.2. MATIC OR AUTOMATIC WIRE FEED- ER CONTROL • Insert the electrode and work cables through the strain relief loop on the right side (facing the front 1.

  • Page 28: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS WARNING 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 equip- ment. Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE 1.

  • Page 29: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric 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.

  • Page 30: Pc Board Troubleshooting Procedures

    WARNING don’t remove them until installation is complete. ELECTRIC SHOCK can kill. • If you return a P.C. Board to The Lincoln Electric Have an electrician install and ser- Company for credit, it must be in the static-shield- vice this equipment. Turn the input ing bag.
  • Page 31 RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Major Physical or Electrical Contact the Lincoln Electric Service Damage is Evident Dept. (216) 383-2531 or 1-800- 833-9353 (WELD) The Machine is dead- The Input 1. Check for blown or missing contactor does not operate.
  • Page 32 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Input contactor (CR1) chatters. 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 connect- ed correctly for the line voltage.
  • Page 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine input contactor operates 1. Place OUTPUT TERMINAL machine weld Switch to “ON”, or install a output.Fan runs and pilot light jumper from #2 to #4 on glows.
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine has maximum weld out- 1. LOCAL/REMOTE Switch (S3) put and no control. in wrong position. 2. LOCAL/REMOTE Switch (S3) is faulty, or an open lead going to the LOCAL/REMOTE Switch (S3).
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine has minimum output and 1. If a remote control unit is NOT no control. connected to the terminal strip #75, #76, and #77 terminals, or is not connected to the 14 pin receptacle LOCAL/REMOTE SWITCH...
  • Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine shuts off (input contactor 1. Remove all welding cables and drops out) when the welder output control cables from the DC terminals are made electrically 600.
  • Page 37 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS The weld output terminals are 1. Remove any external leads always electrically "hot". hooked to #2 and #4 on the ter- minal strip or any connections to the 14 pin MS connector.
  • Page 38 E-10 E-10 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PROBLEMS Poor arc starting when the DC600 1. Make sure the proper welding is in the CV Sub-Arc or CV procedures are being used.
  • Page 39 E-11 E-11 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PROBLEMS Poor arc characteristics in all 1. Check for the correct input volt- processes. ages on the three- phase input lines at the DC-600.

  • Page 40: Troubleshooting Guide

    E-12 E-12 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Voltage across leads 255 and 256 should be PC BOARD TROUBLESHOOTING GUIDE approximately 115VAC. Check voltage across sec- FIRING P.C. BOARD ondary winding of the control transformer (T2) which supplies leads 255 and 256.
  • Page 41 E-13 E-13 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual CHECKING POWER ON/OFF SWITCH (S1) CONNECTING REMOTE OUTPUT CONTROL RHEOSTAT TO THE MACHINE 1. Turn off the machine input power (" "position). Extreme caution must be observed when installing or SW1 has 115 volts across it when the input power extending the wiring of a remote control.
  • Page 42 DIAGRAMS DC-600...
  • Page 43 DIAGRAMS DC-600...
  • Page 44 DIAGRAMS DC-600...
  • Page 45 DIAGRAMS DC-600...
  • Page 46 DIAGRAMS DC-600...
  • Page 47 DIAGRAMS DC-600...
  • Page 48 DIAGRAMS DC-600...
  • Page 49 DIAGRAMS DC-600...
  • Page 50 DIAGRAMS DC-600...
  • Page 51 F-10 F-10 DIAGRAMS DC-600...
  • Page 52 NOTES DC-600...
  • Page 53 NOTES DC-600...
  • Page 54 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 55 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 56 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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