Lincoln Electric IM669 User Manual
RED-D-ARC
RETURN TO MAIN MENU
DC-600
IM669-D
November, 2008
(
For use with machines having Code Numbers:
10663, 11073, 11134, 11340, 11542
OPERATOR’S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This
RED-D-ARC
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.
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.
The Global Leader in Welder Rentals
welder is built to
RED-D-ARC Extreme Duty
i
SAFETY
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
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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
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.
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
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
____________________________________________________
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.b. Operate engines in open, well-ventilated
areas
or vent the engine exhaust fumes
outdoors.
1.c. Do not add the fuel near an open flame
and in good repair.Keep hands, hair, clothing and
to perform required maintenance. Remove
1.f. Do not put your hands near the engine fan.
Do
idler by pushing on the throttle control rods
while the engine is running.
arc or when the engine is running.
welding
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
not attempt to override the governor or
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them 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 and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning
the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
DC-600 RED-D-ARC
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
ii
SAFETY
ii
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
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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the 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 semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should 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 and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for 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 welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
skin or wet clothing. Wear dry, hole-free
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
ventilation and/or exhaust at the arc to keep
vapors
to
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
DC-600 RED-D-ARC
iii
SAFETY
iii
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
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. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
DC-600 RED-D-ARC
Jan, 07
iv
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:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
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.
7. Quandonnesoude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du 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” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
DC-600 RED-D-ARC
Thank You
for selecting one of our QUALITY products. We want you to take
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. We respond to our customers based on the best information in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty 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 the
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the
results 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.
pride in operating this product ••• as much pride as we have in
bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
vv
Please record your equipment identification information below for future reference. This information can be
found 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 you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy 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:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ............................................................................................. A-1
Safety Precautions ..................................................................................................... A-2
Select Proper Location.................................................................................................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 ................................................................................................ A-4
Output Connections ................................................................................................... A-5
Electrode, Work and #21 Lead ..............................................................................A-5
Auxiliary Power and Control Connections .............................................................A-6
Terminal Strips.......................................................................................................A-7
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions ............................................................................................... B-1
General Description ............................................................................................. B-1
Recommended Processes and Equipment ...........................................................B-1
Design Features and Advantages ........................................................................B-2
Welding Capability ............................................................................................... B-2
Meaning of Graphical Symbols on Case Front......................................................B-2
Meaning of Graphical Symbols on Rating Plate ....................................................B-3
Meaning of Graphical Symbol for Ground Connection ..........................................B-3
Controls and Settings ...........................................................................................B-4
Auxiliary Power in MS - Receptacle.......................................................................B-5
Overload, Overcurrent and Fault Protection..........................................................B-5
Operating Steps ................................................................................................... B-6
Remote Control of Machine Operation ..................................................................B-6
Welding Procedure Recommendations ............................................................... B-6
Semi-Automatic and Automatic Wire Feeding
with a DC-600 and Wire Feeders ..........................................................................B-7
NA-3 Automatic Wire Feeder...................................................................B-7, B-8
NA-5 Automatic Wire Feeder ..........................................................................B-9
LN-8 Semi-Automatic Wire Feeder .................................................................B-9
LN-7 & LN-9 Semi-Automatic Wire Feeders ...................................................B-9
________________________________________________________________________
vi vi
Accessories.....................................................................................................Section C
Wire Feeders and Tractors....................................................................................C-1
Field Installed Options...........................................................................................C-1
Remote Output Control (K857 or K857-1) ......................................................C-1
Remote Control Adapter Cable (K864) ...........................................................C-1
Undercarriages (K817P, K842).......................................................................C-1
Paralleling Kit (K1611-1) .................................................................................C-1
TIG Module (K930-2) ......................................................................................C-1
Factory or Field Installed Options..................................................................C-1, C-2
Multi-Process Switch (K804-1)........................................................................C-2
Connections for Semi-Automatic or Automatic Wire Feeder Control ....................C-3
________________________________________________________________________
vii
TABLE OF CONTENTS
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Testing the GFCI Receptacle ................................................................................D-1
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-7
________________________________________________________________________
Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F
________________________________________________________________________
PARTS PAGES .......................................................................................................P-362
________________________________________________________________________
vii
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – DC-600
INPUT - THREE PHASE ONLY
Standard
Voltage
100% Duty Cycle
Input Current at Rated Output
60% Duty Cycle
A-1
50% Duty Cycle
230/460/575/60
Duty Cycle
100% Duty Cycle
60% Duty Cycle
50% Duty Cycle
Output Range
70A/13V-780A/44V (CV)
90A/24V-780A/44V (CC)
INPUT
VOLTAGE /
FREQUENCY
230
460
575
HEIGHT
30.75 in
781 mm
108/54/43
122/61/49
RATED OUTPUT
Amps
600
680
750
Volts at Rated Amperes
OUTPUT
Maximum Open Circuit Voltage
72V
See the OPERATION section
RECOMMENDED INPUT WIRE AND FUSE SIZES
HERTZ
60
60
60
INPUT AMPERE
RATING ON
NAMEPLATE
108
54
43
TYPE 75°C
COPPER WIRE
IN CONDUIT
AWG(IEC-MM2) SIZES
30°C (86°F) Ambient
2 (34)
6 (14)
8 (8.4)
TYPE 75°C
GROUND WIRE
IN CONDUIT
AWG(IEC-MM2) SIZES
8 (8.4)
8 (8.4)
PHYSICAL DIMENSIONS
WIDTH
22.25 in
567 mm
DEPTH
39.0 in
988 mm
134/67/54
44
44
44
Auxiliary Power
for Auxiliary Power
information by model
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
6 (14)
WEIGHT
522 lbs.
237 kg.
1
175 Amp
90 Amp
70 Amp
1
Also 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.
DC-600 RED-D-ARC
A-2
INSTALLATION
A-2
Read entire Installation Section before installing
the DC-600.
SAFETY PRECAUTIONS
WARNING
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.
• Do not touch electrically hot parts.
• Always connect the IDEALARC DC-600 grounding
terminal to a good electrical 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
STACKING
Three DC-600 machines can be stacked.
DO NOT stack more than three 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 supporting 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 Case
Front of each machine flush with each other. See
Figure A.1.
Place the welder where clean cooling air can freely
circulate in through the front louvers and out through
the rear louvers. Dirt, dust or any foreign material that
can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
shut-downs.
WARNING
FALLING EQUIPMENT can cause
injury.
• Do not lift this machine using lift bale if
it is equipped with a heavy accessory
such 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.
---------------------------------------------------------------------
STACKING HOLE
STACKING PINS
FIGURE A.1 - Stacking DC-600 machines
TILTING
The DC-600 must be placed on a stable, level surface
so it will not topple over.
DC-600 RED-D-ARC
A-3
INSTALLATION
A-3
ELECTRICAL INPUT 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.2 for the location
of the machineʼs input cable entry opening, Input
Contactor (CR1), and reconnect panel assembly for
dual voltage machines.
INPUT SUPPLY
CABLE ENTRY
OPENING
INPUT
CONTACTOR (CR1)
RECONNECT
PANEL ASSEMBLY
INPUT POWER SUPPLY CONNECTIONS
A qualified electrician should connect the input power
supply leads.
1. Follow all national and local electrical codes.
2. Use a three-phase line.
3. Remove Input Access Door at upper rear of
machine.
4. Follow Input Supply Connection Diagram located
on the inside of the door.
5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
terminals in the Input Box Assembly by passing
them thru the three aligned .50” diameter holes in
the baffle and tighten them in the terminal connectors. Be sure to close the baffle by inserting the
tab into the slot in the baffle. See Figure A.3.
FIGURE A.2 - Rear Panel
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or thermal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in “nuisance” tripping caused by inrush current even when
machine is not being used for welding at high output
currents.
Use input and grounding wire sizes that meet local
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 of the machine near the input contactor. Access to the Input Box Assembly is at the upper
rear of the machine. See your local and national electrical codes for proper grounding methods.
INPUT
CONTACTOR (CR1)
INPUT POWER SUPPLY
CABLE WITH BUSHING
OR BOX CONNECTOR
RECONNECT
PANEL ASSEMBLY
FIGURE A.3 - Input Power Supply
Connections
DC-600 RED-D-ARC
A-4
INSTALLATION
A-4
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.
CAUTION
Failure to follow these instructions can cause
immediate failure of components within the
machine.
When powering welder from a generator be sure
to turn off welder first, before generator is shut
down, in order to prevent damage to the welder.
------------------------------------------------------------------------
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.
Follow The Input Connection Diagram located on the
inside of Case Back Input Access Door. These connection diagrams for the following codes are listed
below.
1. For 230/460/575, see Figure A.4. (M15666)
2. For Voltages not listed, see the Input Connection
Diagram pasted on the inside of the Case
Back Input Access Door.
FIGURE A.4-Reconnect Panel Board Positions for 230/460/575 VAC Machines
DC-600 RED-D-ARC
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 SizeParallel CablesCable Length
2
Lengths up to 150 ft. (46m)
1/0 (53mm
2
2
2/0 (85mm
3/0 (107mm
)2
2
)150 ft.(46m) to 200 ft (61m)
2
)200 ft.(61m) to 250 ft.(76m)
A-5
CONNECTIONS
A. Connect Electrode and Work Leads to
Output Terminals.
1. Set the ON/OFF toggle switch to OFF.
2. Locate the retractable strain relief loops directly
below the output terminals in the lower right and
lower 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 directly
below 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 Proper
Terminal
There are two work sense lead connection points (+21
and -21) on terminal strip (T.S.2) located behind the
hinged access panel on the right side of the case
front. See 14 Pin MS Type Receptacle section or
Terminal Strip Section for connection procedure.
DC-600 RED-D-ARC
A-6
INSTALLATION
AUXILIARY POWER AND
CONTROL CONNECTIONS
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. Also, terminal
strips with 115VAC and connections for auxiliary
equipment are located behind the hinged access
panel on the right side of the case front. (see Auxiliary
Power Table for details)
AUXILIARY POWER TABLE
Voltage and Circuit Breaker Ratings at Auxiliary Power
Connections for Various Models
Auxiliary 60 Hz
Power Models
Connections
At GFCI 115V 15A
Receptacle
Terminal strip 115V 15A
terminals 31 & 32
MS-Receptacle 115V 15A
pins A & J
MS-Receptacle 42V 10A
pins I & K
115VAC GFCI RECEPTACLE (60 HERTZ MODELS
ONLY)
The 115VAC GFCI receptacle is protected by a circuit
breaker located on the nameplate. The receptacle is a
NEMA 5-15R.
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 the
14 pin receptacle.
FIGURE A.6 FRONT VIEW OF 14-PIN
CONNECTOR RECEPTACLE
K=42
A=32
B=GND
LN
C=2
D=4
E=77
J=31
I=41
H=21
G=75
F=76
M
PIN LEAD NO. FUNCTION
A 32 115 VAC
B GND Chassis Connection
C 2 Trigger Circuit
D 4 Trigger Circuit
E 77 Output Control
F 76 Output Control
G 75 Output Control
H 21 Work Sense Connection
I 41 42 VAC
J 31 115 VAC
1.
K 42 42 VAC
L --- --M --- --N--- ---
1.
115VAC circuit is on all models.
2.
As shipped from the factory Lead #21 from the 14 Pin connector is
connected to “-21” on the terminal strip (T.S.2). This is the configuration for positive welding. If welding negative polarity, connect
lead #21 to the “+21” connection point on the terminal strip
(T.S.2).
A-6
2
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 (All
Models). A 15 amp circuit breaker protects this circuit.
Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other.
DC-600 RED-D-ARC
A-7
INSTALLATION
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.
Connect both the work sense lead #21 from the 14 pin
connector and #21 lead of the control cable to “-21”
when welding positive polarity or to “+21” when welding negative polarity.
TERMINAL STRIP 1 (T.S.1)
Lead No. Function
75 Output Control
76 Output Control
77 Output Control
TERMINAL STRIP 2 (T.S.2)
Lead No. Function
A-7
+21
-21
Work Connection (Electrode Negative)
Work Connection (Electrode Positive)
41 42 VAC
4 Trigger Circuit
2 Trigger Circuit
31 115 VAC
32 115 VAC
1.
115VAC circuit is on all models.
2.
As shipped from the factory Lead #21 from the 14 Pin connector is
connected to “-21” on the terminal strip (T.S.2). This is the configuration for positive welding. If welding negative polarity, connect
lead #21 to the “+21” connection point on the terminal strip
(T.S.2).
1
1
2
DC-600 RED-D-ARC
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