Lincoln Electric SVM188-A User Manual
For use with machine code numbers: Above Code 10580
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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 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.
SVM188-A
October, 2008
DC-600
DC-600
View Safety Info View Safety Info View Safety Info View Safety Info
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i 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. PROTECTYOURSELF 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
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 posi-
tion
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 welding
arc or when the engine is running. 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.
and in good repair.Keep hands, hair, clothing and tools
to perform required maintenance. Remove
1.f. Do not put your hands near the engine fan. Do
not
attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.
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
tur
ning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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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 ‘95
ii ii
SAFETY
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.
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.
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
ventilation and/or exhaust at the arc to keep
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.
vapors
to
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5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug ‘06
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
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 par t 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 manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s 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.
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Jan ‘07
iv iv
SAFETY
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 L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode 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 s’isoler 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 l’eau 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 s’applicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres 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 d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils 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
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc 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.
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 n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, 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 l’on pique le laitier.
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
l’électricité 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, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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Mar ‘93
v v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
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h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
vi vi
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
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_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093 3-1-96H
I I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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Page
Safety ...........................................................................i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-349
DC-600
A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
TABLE OF CONTENTS - INSTALLATION SECTION
Limit on Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
FusesandWireSizes ..............................................................A-4
Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Input Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Electrode, Work and #21 Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Auxiliary Power and Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
DC-600
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – DC-600
INPUT - THREE PHASE ONLY
Standard
Volatge
230/460/60
230/460/575/60
460/60
575/60
220/380/440/50/60
380/500/50/60
440/50/60
200/400/50/60
415/50/60
Duty Cycle
100% Duty Cycle
60% Duty Cycle
50% Duty Cycle
100% Duty
108/54/43
116/67/58
RATED OUTPUT
Input Current at Rated Output
60% Duty Cycle
Cycle
122/61
108/54
54
43
67/51
58
128/64
61
Amps
600
680
750
122/61/49
61
49
128/74/64
74/56
64
140/70
68
50% Duty Cycle
134/67
134/67/54
67
54
138/80/69
80/61
69
152/76
73
Volts at Rated Amperes
44
44
44
Output Range
70A/13V-780A/44V (CV)
90A/24V-780A/44V (CC)
INPUT
VO LTAGE /
FREQUENCY
230
460
575
200
220
380
400
415
440
500
OUTPUT
Maximum Open Circuit Voltage
72V for 60 HZ models
69V for 50/60 HZ models
See the OPERATION section
RECOMMENDED INPUT WIRE AND FUSE SIZES
HERTZ
60
60
60
50/60
50/60
50/60
50/60
50/60
50/60
50/60
INPUT AMPERE
RATING ON
NAMEPLATE
108
54
43
128
116
67
64
61
58
51
TYPE 75°C
COPPER WIRE
IN CONDUIT
AWG(IEC-MM2)SIZES
30°C (86°F) Ambient
2(34)
6(14)
8 (8.4)
1(43)
2(34)
6(14)
6(14)
6(14)
6(14)
8 (8.4)
TYPE 75°C
GROUND WIRE
IN CONDUIT
AWG(IEC-MM2)SIZES
6 (14)
8 (8.4)
8 (8.4)
6 (14)
6 (14)
8 (8.4)
8 (8.4)
8 (8.4)
8 (8.4)
8 (8.4)
Auxiliary
for Auxiliary Power
information by model
Power
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
175 Amp
90 Amp
70 Amp
175 Amp
175 Amp
100 Amp
100 Amp
100 Amp
90 Amp
80 Amp
1
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PHYSICAL DIMENSIONS
HEIGHT
30.75 in
781 mm
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.
WIDTH
22.25 in
567 mm
DC-600
DEPTH
39.0 in
988 mm
WEIGHT
522 lbs.
237 kg.
A-3 A-3
SAFETY PRECAUTIONS
INSTALLATION
STACKING
Read entire Installation Section before installing
the DC-600.
ELECTRIC SHOCK CAN KILL.
WARNING
• 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.
__________________
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.
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SELECT PROPER LOCATION
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 shutdowns.
LIMIT ON STACKING
WARNING
• Lift only with equipment of adequate lifting capacity.
• Be sure machine is stable when
lifting.
• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
• Do not stack more than three high.
• Do not stack the DC-600 on top of any other machine.
------------------------------------------------------------------------
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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
A-4 A-4
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. Input power supply entry is through the hole
in the Case Back Assembly. See Figure A.2 for the
location of the machine’s input cable entry opening,
Input Contactor (CR1), and reconnect panel assembly
for dual voltage machines.
INPUT SUPPLY
CABLE ENTRY
OPENING
CONTACTOR (CR1)
INPUT
RECONNECT
PANEL ASSEMBLY
INSTALLATION
INPUT POWER SUPPLYCONNECTIONS
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
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DC-600
A-5 A-5
INSTALLATION
RECONNECT PROCEDURE
Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine’s 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 Dual Voltage except 380/500-460/575, see
Figure A.4. (M15009)
2. For 220/380/460, see Figure A.5. (M15010)
3. For 380/500-460/575, see Figure A.6. (M15011)
4. For 460 and 440 Single Voltage, see Figure A.7.
(S17894)
5. For 230/460/575, see Figure A.8. (M15666)
6. For Voltages not listed, see the Input Connection
Diagram pasted on the inside of the Case
Back Input Access Door.
LINK
LINES
INPUT
LINK
LINES
INPUT
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
L3
L2
L1
GND
H3
W
V
CONTACTOR
U
H1
PILOT
TRANSF.
CRI
H2
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
REMAINING HEX NUTS IN PLACE.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
L3
L2
L1
GND
H2
W
V
CTOR
U
H1
TRANSF.
CRI
PILOT
H3
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines
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DC-600
A-6 A-6
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
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE
POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUM
CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
LINES
INPUT
LINKS
L3
L2
L1
GND
H4
W
V
CONTACTOR
U
H1
CRI
PILOT
TRANSF.
H3
H2
CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.
CRI
LINES
INPUT
LINKS
L3
L2
L1
GND
H3
W
V
CONTACTOR
U
H1
PILOT
TRANSF.
H4
H2
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,
LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.
LINES
INPUT
LINKS
L3
L2
L1
GND
H2
W
V
CONTACTOR
U
H1
CRI
PILOT
TRANSF.
H4
H3
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines
CONNECTION FOR 380/460 VOLTAGES
H2
LINES
INPUT
GND
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN
ALL HEX NUTS
L3
L2
L1
H1
H3
W
V
CONTACTOR
U
CRI
TAPE
LINK
CONNECTION FOR 500/575 VOLTAGES
H3
GND
L3
L2
L1
H1
LINES
INPUT
H2
1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS
CRI
W
V
CONTACTOR
U
TAPE
LINK
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FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines
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DC-600
A-7 A-7
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.
3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
LINES
INPUT
L3
L2
L1
GND
W
V
CONTACTOR
U
CRI
FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines
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DC-600
A-8 A-8
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)
CONNECTIONS
1/0 (53mm
2
2
2/0 (67mm
3/0 (85mm
)2
2
)150 ft.(46m) to 200 ft (61m)
2
)200 ft.(61m) to 250 ft.(76m)
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.9.
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.9 - 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.
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DC-600
A-9 A-9
AUXILIARY POWER AND
INSTALLATION
PIN LEAD NO. FUNCTION
CONTROL CONNECTIONS
A 32 115 VAC
Located at the left side of the front of the welder behind
a hinged cover is a 115VAC duplex receptacle for auxiliary power (60 Hertz Models only). 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 50/60 Hz
Power Models Models
Connections
At Duplex 115V 15A No Duplex
Receptacle
Terminal strip 115V 15A 115V 15A
terminals31&32
MS-Receptacle 115V 15A 115V 15A
pinsA&J
MS-Receptacle 42V 10A 42V 10A
pinsI&K
115VAC DUPLEX RECEPTACLE (60 HERTZ
MODELS ONLY)
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
I41 42VAC
J 31 115 VAC
1.
K42 42VAC
L --- --M --- --N --- ---
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.
2
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The 115VAC duplex 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.10 for the available circuits in the
14 pin receptacle.
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.
FIGURE A.10 FRONT VIEW OF 14-PIN
CONNECTOR RECEPTACLE
K=42
A=32
B=GND
LN
C=2
D=4
E=77
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J=31
I=41
H=21
G=75
F=76
M
1.
2.
DC-600
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
+21
-21
41 42 VAC
4 Trigger Circuit
2 Trigger Circuit
31 115 VAC
32 115 VAC
115VAC circuit is on all models.
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).
Work Connection (Electrode Negative)
Work Connection (Electrode Positive)
1
1
2
A-10 A-10
NOTES
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DC-600
B-1 B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
GeneralDescription ...............................................................B-3
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Meaning of Graphical Symbols on Case Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Meaning of Graphical Symbols on Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Meaning of Graphical Symbol for Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
TABLE OF CONTENTS - OPERATION SECTION
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5, B-6
Auxiliary Power in MS - Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Overload, Overcurrent and Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
OperatingSteps ..................................................................B-7
Remote Control of Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Welding Procedure Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Semi-Automatic and Automatic Wire Feeding with a DC-600 and Wire Feeders . . . . . . . . . . . . . . . . . . . .B-7
NA-3 Automatic Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
NA-5 Automatic Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
LN-8 Semi-Automatic Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
LN-7 & LN-9 Semi-Automatic Wire Feeders .............................................B-9
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DC-600
B-2 B-2
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.
• Always wear dry insulating gloves.
• Do not use AC welder if your clothing, gloves or work area is damp or if
working on, under or inside workpiece.
Use the following equipment:
-Semiautomatic DC constant voltage
(wire) welder.
-DC manual (stick) welder.
-AC welder with reduced voltage control.
• Do not operate with panels removed.
• Disconnect input power before servicing.
-------------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF &
OTHERS.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc,
or both,to keep fumes and gases
from your breathing zone and general area.
WELDING, CUTTING and GOUGING SPARKS can cause fire or
explosion.
• Do not weld near flammable material.
• Do not weld, cut or gouge on containers which have held flammable mater-
ial.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
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DC-600
B-3 B-3
OPERATION
GENERAL DESCRIPTION
The DC-600 is an SCR controlled three phase welding
and cutting power source. It uses a single range potentiometer to control:
• Submerged Arc Semi-Automatic or Automatic
Welding
• Open Arc Semi-Automatic or Automatic Welding
• Stick Welding
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to
3/8” Diameter)
The DC-600 has a three-position Welding Mode Switch
to enable the user to operate in one of three modes:
• Constant Current (CC) Stick (also used for AAC)
• Constant Voltage (CV) Submerged Arc
• Constant Voltage (CV) Innershield (also used for
FCAW/GMAW)
Three models are available:
• Domestic - all 60 Hertz models except
230/460/575V.
• Canadian-230/460/575V 60 Hertz models
• Export-50/60 Hertz models
The optional Multi-Process Switch allows the user to
switch between semi-automatic or automatic welding
and stick welding or air/carbon arc cutting without disconnecting the wire feeder equipment control, electrode,and work leads.
RECOMMENDED PROCESSES AND
EQUIPMENT
The DC-600 is designed for GMAW (MIG), FCAW, and
submerged arc (SAW) within the capacity of the
machine. It can also be used for stick welding (SMAW)
and for air carbon arc (AAC) cutting with carbon rods
up to 3/8" diameter.
The DC-600 is provided with a three position mode
switch that selects CV Innershield, CV Submerged Arc,
or CC Stick.
The DC-600 can be easily connected to wire feeding
equipment, including:
• Semi-automatic wire feeders LN-7, LN-7 GMA, LN742, LN-8, LN-9, LN-9 GMA, LN- 10, LN-15 LN23P, LN-25, and DH-10.
• Automatic wire feeders NA-3, NA-5, and NA-5R.
• Tractors LT-56 and LT-7
DESIGN FEATURES AND
ADVANTAGES
• 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.
• Output Terminals Switch to energize output terminals either local or remote.
• White neon pilot light to confirm that the Input
Contactor is energized.
• DC Ammeter and Voltmeter
• 42VAC 10 Amp auxiliary power available for the
wire feeder, circuit breaker protected.
• Single MS-type (14 pin) connector for wire feeder.
• 115VAC 15 Amp auxiliary power available for the
wire feeder, circuit breaker protected.
• 115VAC 15 Amp duplex plug receptacle available
on 60 Hertz models, circuit breaker protected.
• Multi-functional terminal strip for easy connection
of wire feeding control cables.
• Recessed output terminals to avoid any person or
object from accidentally coming into contact with
the output terminals and labeled " + " and " - " for
easy identification.
• Thermostatically protected power source.
• Electronic protection circuit to protect power
source against overloads.
• Input line voltage compensation to provide an
essentially constant output.
• SCR electronically controlled welder output provides extra long life, especially for highly repetitive
welding applications.
• Solid state 2 and 4 circuit for extra long life.
• Two circuit solid state control system provides
maximum performance and circuit protection.
• Low profile case provides maximum use of space.
• Convenient access to all controls.
• Output lead strain relief loops to prevent terminal
and cable damage.
• Easily removed case side, even when stacked.
• Outdoor operation because enclosure is designed
with air intake louvers that keep dripping water
from entering the unit. Transformer, SCR bridge,
and choke have special corrosion resistant paint
for added protection.
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DC-600
B-4 B-4
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
SYMBOL
MEANING
INPUT POWER
Pilot Light
Input power on when light is illuminated
(except for abnormal conditions).
Always indicates POWER ON/OFF
switch is in ON position.
OUTPUT CONTROL
ON
OFF
LOCAL/REMOTE Switch
SYMBOL
Control Of Output Voltage and
Current is Via DC-600's Control Dial
Remote Control of Output Voltage
MODE Switch
CC STICK: Shielded Metal Arc
Welding (SMAW), this switch
position is also used for Air
Carbon Arc Cutting (AAC)
CV SUBMERGED ARC:
Constant Voltage Submerged
Arc Welding (SAW)
CV INNERSHIELD: Flux Cored
Arc Welding (FCAW), this switch
position is also used for Gas
Metal Arc Welding (GMAW).
MEANING
and Current
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OUTPUT VOLTAGE
Clockwise Increase of Output
TERMINALS ON/REMOTE Switch
OUTPUT TERMINALS
Remote Control of Output Terminals
(Energized or Non-Energized)
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AND CURRENT
Voltage and Current
ENERGIZED
Output Terminal Connections
Positive Output Terminal
Negative Output Terminal
WARNING Identification
Warning Identification
Circuit Breaker
Circuit Breaker (two breakers: 15A
for 115V circuit and 10A for 42V
circuit)
DC-600
B-5 B-5
OPERATION
MEANING OF GRAPHICAL
SYMBOLS ON RATING PLATE
(LOCATED ON CASE BACK)
Designates welder complies with
National Electrical Manufacturers
NEMA EW 1 (100%)
Association requirements EW 1
Class I with 100% duty cycle at
600Amps output.
Three Phase Input Power
3 Phase transformer with rectified DC output
Line Connection
Gas Metal Arc Welding (GMAW)
MEANING OF GRAPHICAL
SYMBOL FOR GROUND CONNECTION
Signifies the equipment connection
point for the protective earth ground
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.
7
5
3
6
8
5
6
4
7
3
8
2
9
1
10
DC-600
49
1
2
NRTL/C
Flux Cored Arc Welding (FCAW)
Shielded Metal Arc Welding (SMAW)
Submerged Arc Welding (SAW)
Designates welder complies with
R
both Underwriters Laboratories (UL)
standards and Canadian Standards
Association (CSA) standards. (60
Hertz Models)
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 machine’s input contactor applying input
power to the machine. Switching the switch to the
OFF “ ” position de-energizes the input contactor.
2. POWER Light
When the POWER switch is in the ON position the
machine’s white POWER light will illuminate. If the
input contactor de-energizes the machine in an
abnormal situation the pilot light will still illuminate.
In this situation it may be necessary to reset the
machine by switching the POWER switch to the
OFF and then to the ON position. (See Overload,
Overcurrent, and Fault Protection Section)
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DC-600
B-6 B-6
OPERATION
3. OUTPUT CONTROL
This control provides continuous control of the
machine’s output voltage and current from minimum
to maximum (typical full pot range between 15 to 44
volts and 90 to 750 amps) as it is rotated clock-wise.
Voltage or current control is determined by setting
of Mode Switch (CV or CC).
4. OUTPUT TERMINALS ON/REMOTE Switch
When this switch is in the REMOTE “ ” position, the DC-600’s output terminals will be electrically “cold” until a remote device such as a wire
feeder closes the #2 and #4 circuit in the MS-receptacle or terminal strip (T.S.2). When this switch is in
the ON “ ” position the machine’s output terminals will be electrically energized all the time.
5. LOCAL/REMOTE Switch
When this switch is set to the LOCAL “ “ position,
control of the output voltage and current is via the
OUTPUT CONTROL on the DC-600’s control panel.
When this switch is set to the REMOTE “ ”
position, control is through a remote source such as
a wire feeder via the #75, #76, and #77 leads in the
MS-receptacle or terminal strip (T.S.1).
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
11.Terminal Strip Cover Panel
Rotate this panel to gain access to the circuits made
available at the two terminal strips (T.S.1 and T.S.2).
These terminal strips contains the same circuits as
the 14 pin MS-receptacle. There is a box connector
adjacent to this cover for routing leads to the terminal strips.
12.Negative Output Terminal
This output terminal is for connecting a welding
cable. To change welding polarity and for proper
welding cable size refer to Electrode and Work
Cables in the Installation Section.
13.Positive Output Terminal
This output terminal is for connecting a welding
cable. To change welding polarity and for proper
welding cable size refer to Electrode and Work
Cables in the Installation 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 circuit from overloads.
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.
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7. 115VAC Duplex Receptacle (60 Hertz Models)
This receptacle provides up to 15 amps of 115 VAC
auxiliary power.
8. 115VAC 15 Amp Circuit Breaker
This breaker protects the 115 VAC auxiliary circuits
located in the duplex receptacle, terminal strip
(T.S.2) and MS-receptacle.
9. 42VAC 10 Amp Circuit Breaker
This breaker protects the 42VAC auxiliary circuits
located in the terminal strip (T.S.2) and MS-receptacle.
10.14 Pin MS-Receptacle
This connector provides easy connection for a wire
feeder control cable. It provides connections for
auxiliary power, output switching, remote output
control, wire feeder voltmeter sense lead and
ground. Refer to 14 Pin MS Type Receptacle in the
Installation Section for information about the circuits
made available at this receptacle.
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OVERLOAD, OVERCURRENT, AND
FAULT PROTECTION
This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and high ambient temperatures. When the welder is subjected to an
overload or loss of cooling, a thermostat will open. The
input contactor will open and remain open until the
machine cools; the white POWER light stays illuminated. No welding is possible during this cool down period. The machine will reset automatically when the thermostat cools.
The power source is also protected against overcurrents in the SCR bridge assembly through an electronic protection circuit. This circuit senses currents over
780 amps on the power source and opens the input
contactor should the overcurrent remain for a predetermined time (the white POWER light stays illuminated).
The predetermined time varies with the amount of
overcurrent; the greater the overcurrent, the shorter
the time. The input contactor will remain open until the
power source is manually started by resetting the
POWER ON/OFF toggle switch.
DC-600
B-7 B-7
The power source circuitry is protected from faults on
leads 75, 76, or 77. If any of these leads are connected to either the positive or negative output leads, the
DC-600 will either shut down completely (input contactor opens and white POWER light stays illuminated), or
will operate at minimum output thus preventing any
damage to the DC-600. If DC-600 shuts down, it must
be manually started by resetting the POWER ON/OFF
toggle switch.
OPERATING STEPS
OPERATION
REMOTE CONTROL OF MACHINE
OPERATION
The toggle switch on the control panel labeled “Remote
- Panel” gives the operator the option of controlling the
machine output from a remote location. If in the
Remote position a wire feeder with remote control
capabilities or a remote control device such as a K775
must be connected to terminals 75, 76, and 77. Refer
to Accessories Section for wire feeder remote information.
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.
1. Turn on the main AC power supply to the machine.
2. Connect the #21 work lead to either + or - on terminal strip (T.S.2).
3. Set the Welding Mode switch to welding process
being used:
• CC STICK (for SMAW and AAC)
• CV SUBMERGED ARC (for SAW)
• CV INNERSHIELD (for FCAW and GMAW)
4. Turn the POWER ON/OFF Toggle Switch to the
“ON” position
• The white pilot light glows.
WELDING PROCEDURE
RECOMMENDATIONS
Select Welding Mode Switch position based on type of
welding to be done.
1. Innershield Welding (FCAW)/MIG (GMAW)
Welding: Use the CV INNERSHIELD mode.
2. Submerged Arc Welding (SAW): Use the CV SUB-
MERGED ARC mode. If performing high speed
welding, switch between the CV Submerged Arc
and the CV Innershield mode and use the mode
that produces the best welding results.
3. Air/Carbon Arc Cutting (AAC) / Stick Welding
(SMAW) / High Current, Large Puddle Submerged
Arc Welding (SAW): Use the CC STICK mode.
When the DC-600 is used for Air/Carbon Arc cutting, the OUTPUT CONTROL potentiometer
should be set to "9" initially. Based on the size of
the carbon being used or the process, turn the
potentiometer to a lower setting as required by the
process. You can use carbon rods up to 3/8" in
diameter at currents as high as 750 amps with
excellent arc control. The welder protection circuit
protects the machine from extremely high short circuiting pulses.
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• The fan starts.
5. Set OUTPUT CONTROL Potentiometer to desired
voltage or current.
6. Set the OUTPUT TERMINALS switch to either
“ON” ( output terminals energized) or “REMOTE”
(output terminals energized when #2 and #4
closed by remote device such as wire feeder)
7. Make the weld.
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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.
DC-600
B-8 B-8
OPERATION
NA-3 AUTOMATIC WIRE FEEDER
4. Connect the electrode cables to terminal polarity to
1. Set the DC-600 LOCAL/REMOTE Switch to
REMOTE. Set the OUTPUT TERMINALS switch to
REMOTE. NOTE: Later model NA-3 automatic wire
feeders are capable of cold starts when the NA-3
Mode switch is in the CV or CC mode position.
Some earlier models are capable of cold starting
only in the CC mode position. Cold starting
enables you to inch the wire down to the work,
automatically stop, and automatically energize the
flux hopper valve.
be used.
5. Connect the #21 work lead (on T.S.2) to the
same polarity as the work cable connection.
6. Set the DC-600 LOCAL/REMOTE Switch to
REMOTE.
7. Set the DC-600 OUTPUT TERMINALS switch to
REMOTE.
2. Connect the NA-3 Control Cable to the 14 pin
Amphenol of the DC-600.
Connect the #21 work lead (on T.S.2) to the
3.
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22978) for remote connection (recommended) of the #21 lead.
4. Connect the electrode cables to terminal polarity to
be used.
5. Set the DC-600 welding mode switch for the
desired process: CV SUBMERGED ARC, CV
INNERSHIELD mode or CC STICK mode.
6. Set the NA-3 mode Switch Position to either CV or
CC to match the DC-600 mode selected in step 2.
7. Refer to the NA-3 operators manual for instructions
on how to use the NA-3 in conjunction with the DC-
600.
8 Follow the following guidelines for good arc striking
detailed below for each welding mode.
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:
8. Set the DC-600 WELDING MODE SWITCH to the
position that matches the welding process being
used.
• For submerged arc welding, set WELDING MODE
SWITCH to CV SUBMERGED ARC position.
• For all open arc welding processes set WELDING
MODE SWITCH to CV INNERSHIELD position.
GOOD ARC STRIKING GUIDELINES FOR THE DC600 IN THE CV INNERSHIELD, CV SUBMERGED
ARC MODES
Following are some basic arc striking techniques that
apply to all wire feed processes. Using these procedures should provide trouble-free starting. \These procedures 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 (NA-5
STRIKE VOLTS Control) to the same dial setting
as the Arc Voltage Control. For the NA-3, If this is
a new welding procedure, a good starting
set the Open Circuit Voltage Control to # 6.
NOTE: The open circuit voltage of the
DC-600 varies from approximately 16 volts to 56
volts in the CV INNERSHIELD or CV
SUBMERGED ARC modes. The open circuit voltage is constant in the CC STICK mode.
point is to
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1. Turn OFF main AC input power supply to the DC-
600.
2. Connect the NA-5 Control Cable to the 14 pin
Amphenol of the DC-600.
Connect the #21 work lead (on T.S.2) to the
3.
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22979) for remote connection (recommend-
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ed) of the #21 lead.
DC-600
B-9 B-9
3. Run a test weld. Set proper current, voltage, and
travel speed.
OPERATION
2. Connect the LN-8 or LN-9 Control Cable to the 14
pin Amphenol of the DC-600.
• For the best starting 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.
• To adjust the Open Circuit Voltage Control to get
the best starting performance, make repeated
starts observing the NA-3 voltmeter.
When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
overshooting the desired arc voltage, the Open
Circuit Voltage Control is set properly.
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."
If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit Voltage
Control is set too low.This can cause the electrode
to stub.
4. Start and make the weld.
• Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes positive
contact with the work piece.
Connect the #21 work lead (on T.S.2) to the
3.
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22977) for remote connection (recommended) of the #21 lead.
4. Connect the electrode cables to terminal polarity to
be used.
2. Set the IDEALARC DC-600 OUTPUT
CONTROL SWITCH to the REMOTE position.
3. Set the LN-8 Welding Mode Switch to the CV or
VV position. The LN-8 Welding Mode Switch is
located on the variable voltage (CC) board.
4. Refer to the LN-8 Operator’s Manual for instructions on how to use the LN-8 in the CC (VV) mode.
LN-7 AND OTHER CONSTANT WIRE
FEEDERS
To use the LN-7 or other constant wire feed speed
semi-automatic wire feeders with IDEALARC DC-600
1. Set the IDEALARC DC-600 WELDING MODE
SWITCH to either CV Innershield mode or CV
Submerged Arc mode depending on the welding
process being used.
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• Hot "On the Fly" starts. For hot starts, travel should
begin before the wire contacts the work piece.
ARC STRIKING WITH DC-600 AND THE NA-3 OR
NA-5 START BOARD
When electrical stickout exceeds 1 3/4” (44.4mm) the
optional Start Board (K221 for the NA-3 and K334 for
the NA-5) may be required to improve arc striking.
See the NA-3 or NA-5 Operator’s Manual for detailed
instructions on setting the Start Circuit controls.
LN-8 OR LN-9 SEMI-AUTOMATIC WIRE
FEEDER
To use the LN-8 or LN-9 Semi-Automatic Wire Feeder
with the IDEALARC DC-600
1. Set the IDEALARC DC-600 WELDING MODE
SWITCH to either CV Innershield mode or CV
Submerged Arc mode depending on the welding
process being used.
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2. Connect the Wire Feeder Control Cable to the 14
pin Amphenol of the DC-600.
Connect the #21 work lead (on T.S.2) to the
3.
same polarity as the work cable connection or
follow instructions on the Connection Diagram
(S22978) for remote connection (recommended) of the #21 lead.
4. Connect the electrode cables to terminal polarity to
be used.
5. Set the IDEALARC DC-600 OUTPUT
CONTROL SWITCH per the Connection Diagram
for the feeder being used
NOTE: Older Lincoln control cables that do not have an
Amphenol connector on the Power Source end
can be connected to the T.S.1 & T.S.2 terminal
strips behind the DC-600 nameplate. See the
Installation section of this manual and the
appropriate Connection Diagram.
DC-600
B-10 B-10
NOTES
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DC-600
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3/C-4
TABLE OF CONTENTS - ACCESSORIES SECTION
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DC-600
C-2 C-2
T
WIRE FEEDERS AND TRACTORS
ACCESSORIES
Undercarriages (K817P, K842)
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
LN-7 LN-9 GMA
LN-7 GMA LN-23P
LN-742 LN-25
LN-8 LN-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 same remote control that is used on other
Lincoln power sources. The K775 consist of a control
box with 28 feet (8.5mm) of four conductor cable. This
connects to terminals 75,76, and 77 on the terminal
strip (T.S.1) and the case grounding screw so marked
with the symbol “ ” on the machine. These terminals are located behind the hinged cover on the case
front. This control will give the same control as the output control on the machine.
For easy moving of the machine, optional undercarriages are available with polyolefin wheels (K817P) or
a platform undercarriage (K842) with mountings for
two gas cylinders at rear of welder.
Paralleling Kit (K1611-1)
Permits paralleling of two DC-600's for welding currents of up to 1200 amps, 100% duty cycle.
Tig Module (K930-2)
Portable high frequency generator for AC/DC TIG
welding.
FACTORY OR FIELD INSTALLED
OPTIONS
Multi-Process Switch (K804-1)
The MULTI-PROCESS SWITCH gives you the ability
to:
• Switch between "stick welding or air/carbon arc cutting" and using a semi-automatic or automatic wire
feeder.
• Change the polarity of a semi-automatic or automatic wire feeder without changing any electrical
cable connections.
See Figure C.1
The K857 is similar to the K775, except the K857 has
a 6-pin MS-style connector. The K857 requires a K864
adapter cable which connects to the 14-pin connector
on the case front.
+
Remote Control Adapter Cable (K864)
STRAIGHT PLUG (14 PIN)
O POWER SOURCE
A "V" cable 12" (.30 m) long to connect a K857 Remote
Control (6-pin connector) with an LN-7 wire-feeder (14pin connector) and the machine (14-pin connector). If
a remote control is used alone the wire-feeder connection is then not used.
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CABLE RECEPTACLE (6 SOCKET)
TO: K857 REMOTE CONTROL
CABLE RECEPTACLE (14 SOCKET)
TO: LN-7 WIRE FEEDERS
WIRE
FEEDER
CABLES
FIGURE C.1 - MULTI-PROCESS SWITCH
DC-600
-
–
STICK OR
AIR
CARBON
ARC
+
STICK OR
AIR/CARBON
ARC CABLES
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