DC600 Operators Manual

IM657
RED-D-ARC December, 2000
DC-600
For use with machines having Code Numbers: 10650
OPERATOR’S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You

This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
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.
1-800-245-3660
North America’s Largest Fleet of Welding Equipment
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
DC-600
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
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,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.g. Never dip the electrode in water for cooling. ucts.
3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
DC-600
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
DC-600
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
a. Les circuits à l’électrode et à la piéce sont sous tension de la zone de travail qu’il est pratique de le faire. Si on place
quand la machine à souder est en marche. Eviter toujours la masse sur la charpente de la construction ou d’autres
tout contact entre les parties sous tension et la peau nue endroits éloignés de la zone de travail, on augmente le risque
ou les vétements mouillés. Porter des gants secs et sans de voir passer le courant de soudage par les chaines de lev-
trous pour isoler les mains. age, câbles de grue, ou autres circuits. Cela peut provoquer
b. Faire trés attention de bien s’isoler de la masse quand on des risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher câbles jusqu’à ce qu’ils se rompent.
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions voir le code “Code for safety in welding and cutting” CSA
pour le porte-électrode s’applicuent aussi au pistolet de Standard W 117.2-1974.
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 n’importe quelle partie
PRÉCAUTIONS DE SÛRETÉ POUR
du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. ‘93
DC-600
v v
for selecting this QUALITY product. We want you to take pride in
Thank You 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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for 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.
DC-600
TABLE OF CONTENTS vi
Page
Installation .......................................................................................................Section A
Technical Specifications ............................................................................................. A-1
Safety Precautions ..................................................................................................... A-2
Select Proper Location.................................................................................................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
Operation .........................................................................................................Section B
Safety Precautions ............................................................................................... B-1
General Description ............................................................................................. B-2
Recommended Processes and Equipment ...........................................................B-2
Design Features and Advantages ........................................................................B-2
Welding Capability ............................................................................................... B-3
Meaning of Graphical Symbols on Case Front ......................................................B-3
Meaning of Graphical Symbols on Rating Plate ....................................................B-4
Meaning of Graphical Symbol for Ground Connection ..........................................B-4
Controls and Settings ...........................................................................................B-5
Auxiliary Power in MS - Receptacle.......................................................................B-6
Overload, Overcurrent and Fault Protection ..........................................................B-6
Operating Steps ................................................................................................... B-7
Remote Control of Machine Operation ..................................................................B-7
Welding Procedure Recommendations ............................................................... B-7
Semi-Automatic and Automatic Wire Feeding
with a DC-600 and Wire Feeders ..........................................................................B-8
NA-3 Automatic Wire Feeder ..........................................................................B-8
NA-5 Automatic Wire Feeder ........................................................................B-10
LN-8 Semi-Automatic Wire Feeder ...............................................................B-10
LN-7 & LN-9 Semi-Automatic Wire Feeders .................................................B-10
Accessories .....................................................................................................Section C
Wire Feeders and Tractors....................................................................................C-1
Field Installed Options ...........................................................................................C-1
Remote Output Control (K775 or K857)..........................................................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
Multi-Process Switch (K804-1)........................................................................C-1
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-2
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F
Parts List ......................................................................................................P354 Series

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS – DC-600
INPUT - THREE PHASE ONLY
Standard Input Current at Rated Output Code
Volatge 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle Number
230/460/575/60 108/54/43 122/61/49 134/67/54 10650
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 600 44
OUTPUT
Output Range Maximum Open Circuit Voltage Auxiliary Power
70A/13V-780A/44V (CV) 72V See the OPERATION section
90A/24V-780A/44V (CC) for Auxiliary Power
information by model
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT HERTZ INPUT AMPERE TYPE 75°C TYPE 75°C TYPE 75°C
VOLTAGE / RATING ON COPPER WIRE GROUND WIRE (SUPER LAG)
FREQUENCY NAMEPLATE IN CONDUIT IN CONDUIT OR BREAKER
AWG(IEC-MM2) SIZES AWG(IEC-MM2) SIZES SIZE (AMPS)1
30°C (86°F) Ambient
230 60 108 2 (34) 6 (14) 175 Amp
460 60 54 6 (14) 8 (8.4) 90 Amp
575 60 43 8 (8.4) 8 (8.4) 70 Amp
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.75 in 22.25 in 39.0 in 522 lbs.
781 mm 567 mm 988 mm 237 kg.
1Also 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
Read entire Installation Section before installing SELECT PROPER LOCATION

the DC-600.
Place the welder where clean cooling air can freely
SAFETY PRECAUTIONS circulate in through the front louvers and out through
the rear louvers. Dirt, dust or any foreign material that
WARNING can be drawn into the welder should be kept at a mini-
mum. Failure to observe these precautions can result
ELECTRIC SHOCK CAN KILL. in excessive operating temperatures and nuisance
shut-downs.
• Only qualified personnel should
install this machine. TILTING
• Turn the input power OFF at the
disconnect switch or fuse box before
The DC-600 must be placed on a stable, level surface
working on the equipment. so it will not topple over.
• 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.
__________________
DC-600
ELECTRICAL INPUT CONNECTIONS INPUT POWER SUPPLYCONNECTIONS
Before installing the machine check that the input sup- A qualified electrician should connect the input power
ply voltage, phase, and frequency are the same as the supply leads.
voltage, phase, and frequency as specified on the
welder Rating Plate located on the Case Back 1. Follow all national and local electrical codes.
Assembly. Input power supply entry is through the
hole in the Case Back Assembly. See Figure A.1 for 2. Use a three-phase line.
the location of the machine’s input cable entry open-
ing, Input Contactor (CR1), and reconnect panel 3. Remove Input Access Door at upper rear of
assembly for dual voltage machines. machine.
INPUT SUPPLY 4. Follow Input Supply Connection Diagram located

CABLE ENTRY on the inside of the door.
INPUT
OPENING
CONTACTOR (CR1) 5. Connect the three phase AC power supply
leadsL1,L2,and L3 to the input contactor
RECONNECT terminals in the Input Box Assembly by passing
PANEL ASSEMBLY them thru the three aligned .50” diameter holes in
the baffle and tighten them in the terminal connec-
tors. Be sure to close the baffle by inserting the
tab into the slot in the baffle. See Figure A.2.
FIGURE A.1 - 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 ther-
mal/magnetic circuit breakers.
INPUT
CONTACTOR (CR1)
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in “nui- INPUT POWER SUPPLY
sance” tripping caused by inrush current even when CABLE WITH BUSHING
machine is not being used for welding at high output RECONNECT
OR BOX CONNECTOR
PANEL ASSEMBLY
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 contac-
FIGURE A.2 - Input Power Supply
tor. Access to the Input Box Assembly is at the upper Connections
rear of the machine. See your local and national elec-
trical codes for proper grounding methods.
DC-600
RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different

voltage, remove input power and change the position
Multiple voltage machines are shipped connected to of the reconnect board on the Reconnect Panel.
the highest input voltage listed on the machine’s rating Follow The Input Connection Diagram located on the
plate. Before installing the machine, check that the inside of Case Back Input Access Door. This connec-
Reconnect Panel in the Input Box Assembly is con- tion diagram for the following code is shown below.
nected for the proper voltage.
1. For 230/460/575, see Figure A.3. (M15666)
CAUTION
Failure to follow these instructions can cause immedi-
ate failure of components within the machine.
__________________
FIGURE A.3-Reconnect Panel Board Positions for 230/460/575 VAC Machines
DC-600
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
Cable Length Parallel Cables Cable Size
Lengths up to 150 ft. (46m) 2 1/0 (53mm2)
150 ft.(46m) to 200 ft (61m) 2 2/0 (85mm2)
200 ft.(61m) to 250 ft.(76m) 2 3/0 (107mm2)
ELECTRODE, WORK AND #21 LEAD

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.4.
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.
FIGURE A.4 - Output Terminals.
5. Connect electrode lead to the desired terminal B. Connect #21 Work Sense Lead to Proper
(positive/negative). Terminal
6. Tighten the output terminal nut with a wrench. There are two work sense lead connection points (+21
and -21) on terminal strip (T.S.2) located behind the
7. Connect the work lead to the other output hinged access panel on the right side of the case
terminal following steps 4-6. front. See 14 Pin MS Type Receptacle section or
Terminal Strip Section for connection procedure.
DC-600
AUXILIARY POWER AND PIN LEAD NO. FUNCTION

CONTROL CONNECTIONS
A 32 115 VAC
B GND Chassis Connection
Located at the left side of the front of the welder
C 2 Trigger Circuit
behind a hinged cover is a 115VAC duplex receptacle
D 4 Trigger Circuit
for auxiliary power (60 Hertz Models only). On the
E 77 Output Control
right side of the case front is a 14 Pin MS type recep-
F 76 Output Control
tacle for connection of auxiliary equipment such as
G 75 Output Control
wire feeders. Also, terminal strips with 115VAC and 2
connections for auxiliary equipment are located H 21 Work Sense Connection
behind the hinged access panel on the right side of I 41 42 VAC
1.
the case front. (see Auxiliary Power Table for details) J 31 115 VAC
AUXILIARY POWER TABLE K 42 42 VAC
Voltage and Circuit Breaker Ratings at Auxiliary Power L --- ---
Connections for Various Models M --- ---
Auxiliary 60 Hz N --- ---
Power Models
Connections TERMINAL STRIPS
At Duplex 115V 15A
Receptacle Terminal strips are available behind the cover on the
case front to connect wire feeder control cables that
Terminal strip 115V 15A
terminals 31 & 32 do not have a 14 Pin MS-type connector. These termi-
nals supply the connections as shown in the following
MS-Receptacle 115V 15A
pins A & J
Terminal Strip charts. NOTE: There are two work
sense lead connection points on the terminal strip.
MS-Receptacle 42V 10A Connect both the work sense lead #21 from the 14 pin
pins I & K
connector and #21 lead of the control cable to “-21”
when welding positive polarity or to “+21” when weld-
ing negative polarity.
115VAC DUPLEX RECEPTACLE (60 HERTZ
MODELS ONLY)
The 115VAC duplex receptacle is protected by a cir- TERMINAL STRIP 1 (T.S.1)

cuit breaker located on the nameplate. The receptacle Lead No. Function
is a NEMA 5-15R.
75 Output Control
14 PIN MS TYPE RECEPTACLE 76 Output Control
(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
77 Output Control
Refer to the figure A.5 for the available circuits in the
14 pin receptacle.
TERMINAL STRIP 2 (T.S.2)
Lead No. Function
42 VAC is available at receptacle pins I and K.
A 10 amp circuit breaker protects this circuit. +21 Work Connection (Electrode Negative)
-21 Work Connection (Electrode Positive)2
115 VAC is available at receptacle pins A and J (All 41 42 VAC
Models). A 15 amp circuit breaker protects this circuit. 4 Trigger Circuit
Note that the 42 VAC and 115 VAC circuits are electri- 2 Trigger Circuit
cally isolated from each other. 31 115 VAC1
FIGURE A.5 FRONT VIEW OF 14-PIN 32 115 VAC1
CONNECTOR RECEPTACLE 1.
115VAC circuit is on all models.
K=42
A=32 J=31 2.
As shipped from the factory Lead #21 from the 14 Pin connector is
B=GND I=41
connected to “-21” on the terminal strip (T.S.2). This is the config-
uration for positive welding. If welding negative polarity, connect
L N lead #21 to the “+21” connection point on the terminal strip
(T.S.2).
C=2
H=21
D=4
G=75
E=77 F=76
M
DC-600
B-1 OPERATION B-1
OPERATING INSTRUCTIONS
Read and understand entire section before operating machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts

or electrode with skin or wet
clothing.
• Insulate yourself from work and

ground.
• Always wear dry insulating

gloves.
FUMES AND GASES

can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to

remove fumes from breathing
zone.
WELDING, CUTTING and

GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge on

containers that have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body

protection.
Observe additional Safety Guidelines detailed in

the beginning of this manual.
DC-600
B-2 OPERATION B-2
GENERAL DESCRIPTION DESIGN FEATURES AND

ADVANTAGES
The DC-600 is an SCR controlled three phase welding
and cutting power source. It uses a single range • Excellent arc characteristics for optimum constant
potentiometer to control: voltage submerged arc and Innershield welding
performance.
• Submerged Arc Semi-Automatic or Automatic • A control circuit designed to provide good starting
Welding for a large variety of processes and procedures.
• Open Arc Semi-Automatic or Automatic Welding • Output Control Potentiometer that provides easy
• Stick Welding single range continuous control.
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to • Output Control Switch that provides simple switch-
3/8” Diameter) ing from local to remote control.
• Output Terminals Switch to energize output termi-
nals either local or remote.
The DC-600 has a three-position Welding Mode • Red neon pilot light to confirm that the Input
Switch to enable the user to operate in one of three Contactor is energized.
modes: • DC Ammeter and Voltmeter
• 42VAC 10 Amp auxiliary power available for the
• Constant Current (CC) Stick (also used for AAC) wire feeder, circuit breaker protected.
• Constant Voltage (CV) Submerged Arc • Single MS-type (14 pin) connector for wire feeder.
• Constant Voltage (CV) Innershield (also used for • 115VAC 15 Amp auxiliary power available for the
GMAW) wire feeder, circuit breaker protected.
• 115VAC 15 Amp duplex plug receptacle available
The optional Multi-Process Switch allows the user to on 60 Hertz models, circuit breaker protected.
switch between semi-automatic or automatic welding • Multi-functional terminal strip for easy connection
and stick welding or air/carbon arc cutting without dis- of wire feeding control cables.
connecting the wire feeder equipment control, elec- • Recessed output terminals to avoid any person or
trode,and work leads. object from accidentally coming into contact with
the output terminals and labeled " + " and " - " for
RECOMMENDED PROCESSES AND easy identification.
EQUIPMENT • Thermostatically protected power source.
• Electronic protection circuit to protect power
The DC-600 is designed for GMAW (MIG), FCAW, source against overloads.
and submerged arc (SAW) within the capacity of the • Input line voltage compensation to provide an
machine. It can also be used for stick welding essentially constant output.
(SMAW) and for air carbon arc (AAC) cutting with car- • SCR electronically controlled welder output pro-
bon rods up to 3/8" diameter. vides extra long life, especially for highly repetitive
welding applications.
The DC-600 is provided with a three position mode • Solid state 2 and 4 circuit for extra long life.
switch that selects CV Innershield, CV Submerged • Two circuit solid state control system provides
Arc, or CC Stick. maximum performance and circuit protection.
• Low profile case provides maximum use of space.
The DC-600 can be easily connected to wire feeding • Convenient access to all controls.
equipment, including: • Output lead strain relief loops to prevent terminal
and cable damage.
• Semi-automatic wire feeders LN-7, LN-7 GMA, • Easily removed case side.
LN-742, LN-8, LN-9, LN-9 GMA, LN- 10, LN-23P, • Outdoor operation because enclosure is designed
LN-25, and DH-10. with air intake louvers that keep dripping water
• Automatic wire feeders NA-3, NA-5, and NA-5R. from entering the unit. Transformer, SCR bridge,
• Tractors LT-56 and LT-7 and choke have special corrosion resistant paint
for added protection.
DC-600
B-3 OPERATION B-3
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%

MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT

Input POWER ON/OFF Switch LOCAL/REMOTE Switch
SYMBOL MEANING SYMBOL MEANING
Control Of Output Voltage and

ON Current is Via DC-600's Control Dial
Remote Control of Output Voltage

OFF and Current
MODE Switch
INPUT POWER CC STICK: Shielded Metal Arc
Welding (SMAW), this switch
position is also used for Air
Carbon Arc Cutting (AAC)
Pilot Light
CV SUBMERGED ARC:
Input power on when light is illuminated Constant Voltage Submerged
(except for abnormal conditions). Arc Welding (SAW)
Always indicates POWER ON/OFF
switch is in ON position.
CV INNERSHIELD: Flux Cored
Arc Welding (FCAW), this switch
position is also used for Gas
OUTPUT CONTROL Metal Arc Welding (GMAW).
OUTPUT VOLTAGE Output Terminal Connections

AND CURRENT
Positive Output Terminal
Clockwise Increase of Output

Voltage and Current Negative Output Terminal
WARNING Identification
TERMINALS ON/REMOTE Switch
Warning and Caution Identification
OUTPUT TERMINALS
ENERGIZED
Circuit Breaker
Remote Control of Output Terminals Circuit Breaker (two breakers: 15A
(Energized or Non-Energized) for 115V circuit and 10A for 42V
circuit)
DC-600
B-4 OPERATION B-4
MEANING OF GRAPHICAL SYMBOLS ON

RATING PLATE (LOCATED ON CASE BACK)
Designates welder complies with
National Electrical Manufacturers Shielded Metal Arc Welding (SMAW)
NEMA EW 1 (100%) Association requirements EW 1
Class I with 100% duty cycle at
600Amps output.
Submerged Arc Welding (SAW)
Three Phase Input Power

Designates welder complies with
R
both Underwriters Laboratories (UL)
3 Phase transformer with rectified standards and Canadian Standards
DC output NRTL/C
Association (CSA) standards. (60
Hertz Models)
Line Connection
Gas Metal Arc Welding (GMAW)
Flux Cored Arc Welding (FCAW)
MEANING OF GRAPHICAL SYMBOL FOR GROUND CONNECTION
Signifies the equipment connection

point for the protective earth ground
DC-600
B-5 OPERATION B-5
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.
3 6 8 9 4
5
5
1
7
6
4
7
3
8
2
9
1
10
DC-600
2
11
10
12
13
FIGURE B.1 - CONTROL PANEL KEYS
1. Input POWER ON/OFF Switch 15 to 44 volts and 90 to 750 amps) as it is rotated

This toggle switch turns the machine on or off. clock-wise. Voltage or current control is deter-
Putting the switch in the ON “ ” position ener- mined by setting of Mode Switch (CV or CC).
gizes the machine’s input contactor applying input
power to the machine. Switching the switch to the 4. OUTPUT TERMINALS ON/REMOTE Switch
OFF “ ” position de-energizes the input When this switch is in the REMOTE “ ” posi-
contactor. tion, the DC-600’s output terminals will be electri-
cally “cold” until a remote device such as a wire
2. POWER Light feeder closes the #2 and #4 circuit in the MS-
When the POWER switch is in the ON position the receptacle or terminal strip (T.S.2). When this
machine’s red POWER light will illuminate. If the switch is in the ON “ ” position the machine’s
input contactor de-energizes the machine in an output terminals will be electrically energized all
abnormal situation the pilot light will still illuminate. the time.
In this situation it may be necessary to reset the
machine by switching the POWER switch to the 5. LOCAL/REMOTE Switch
OFF and then to the ON position. (See Overload, When this switch is set to the LOCAL “ “ posi-
Overcurrent, and Fault Protection Section) tion, 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
3. OUTPUT CONTROL “ ” position, control is through a remote source
This control provides continuous control of the such as a wire feeder via the #75, #76, and #77
machine’s output voltage and current from mini- leads in the MS-receptacle or terminal strip
mum to maximum (typical full pot range between (T.S.1).
DC-600
B-6 OPERATION B-6
6. Mode Switch AUXILIARY POWER IN MS-RECEPTACLE

This switch allows for selecting the welding
process to be used: 42 volt AC auxiliary power, as required for some wire
CC STICK-for SMAW and AAC feeders, is available through the wire feeder MS-
CV SUBMERGED ARC- for SAW receptacle. A 10 amp circuit breaker protects the 42
CV INNERSHIELD- for FCAW and GMAW volt circuit from overloads.
7. 115VAC Duplex Receptacle (60 Hertz Models) DC-600 machines can also supply 115 volt AC auxil-
This receptacle provides up to 15 amps of 115 iary power through the wire feeder receptacle. A 15
VAC auxiliary power. amp circuit breaker protects the 115 volt circuit from
overloads.
8. 115VAC 15 Amp Circuit Breaker
This breaker protects the 115 VAC auxiliary cir-
cuits located in the duplex receptacle, terminal OVERLOAD, OVERCURRENT, AND
strip (T.S.2) and MS-receptacle. FAULT PROTECTION
9. 42VAC 10 Amp Circuit Breaker This welder has thermostatic protection from exces-
This breaker protects the 42VAC auxiliary circuits sive duty cycles, overloads, loss of cooling, and high
located in the terminal strip (T.S.2) and MS-recep- ambient temperatures. When the welder is subjected
tacle. to an overload or loss of cooling, a thermostat will
open. The input contactor will open and remain open
10.14 Pin MS-Receptacle until the machine cools; the red POWER light stays
This connector provides easy connection for a wire illuminated. No welding is possible during this cool
feeder control cable. It provides connections for down period. The machine will reset automatically
auxiliary power, output switching, remote output when the thermostat cools.
control, wire feeder voltmeter sense lead and
ground. Refer to 14 Pin MS Type Receptacle in the The power source is also protected against overcur-
Installation Section for information about the cir- rents in the SCR bridge assembly through an elec-
cuits made available at this receptacle. tronic protection circuit. This circuit senses currents
over 780 amps on the power source and opens the
11.Terminal Strip Cover Panel input contactor should the overcurrent remain for a
Rotate this panel to gain access to the circuits predetermined time (the red POWER light stays illumi-
made available at the two terminal strips (T.S.1 nated). The predetermined time varies with the
and T.S.2). These terminal strips contains the amount of overcurrent; the greater the overcurrent,
same circuits as the 14 pin MS-receptacle. There the shorter the time. The input contactor will remain
is a box connector adjacent to this cover for routing open until the power source is manually started by
leads to the terminal strips. resetting the POWER ON/OFF toggle switch.
12.Negative Output Terminal The power source circuitry is protected from faults on
This output terminal is for connecting a welding leads 75, 76, or 77. If any of these leads are connect-
cable. To change welding polarity and for proper ed to either the positive or negative output leads, the
welding cable size refer to Electrode and Work DC-600 will either shut down completely (input con-
Cables in the Installation Section. tactor opens and red POWER light stays illuminated),
or will operate at minimum output thus preventing any
13.Positive Output Terminal damage to the DC-600. If DC-600 shuts down, it must
This output terminal is for connecting a welding be manually started by resetting the POWER ON/OFF
cable. To change welding polarity and for proper toggle switch.
welding cable size refer to Electrode and Work
Cables in the Installation Section.
DC-600
B-7 OPERATION B-7
OPERATING STEPS REMOTE CONTROL OF MACHINE

OPERATION
The following procedures are for using the DC-600 in
the local control mode of operation. For remote con- The toggle switch on the control panel labeled
trol of the machine, see the Remote Control of “Remote - Panel” gives the operator the option of con-
Machine Operation section. trolling the machine output from a remote location. If
in the Remote position a wire feeder with remote con-
Before operating the machine, make sure you have all trol capabilities or a remote control device such as a
materials needed to complete the job. Be sure you K775 must be connected to terminals 75, 76, and 77.
are familiar with and have taken all possible safety Refer to Accessories Section for wire feeder remote
precautions before starting work. It is important that information.
you follow these operating steps each time you use
the machine.
1. Turn on the main AC power supply to the WELDING PROCEDURE

machine. RECOMMENDATIONS
2. Connect the #21 work lead to either + or - on ter- Select Welding Mode Switch position based on type of
minal strip (T.S.2). welding to be done.
3. Set the Welding Mode switch to welding process 1. Innershield Welding (FCAW)/MIG (GMAW)
being used: Welding: Use the CV INNERSHIELD mode.
• CC STICK (for SMAW and AAC) 2. Submerged Arc Welding (SAW): Use the CV
SUBMERGED ARC mode. If performing high
• CV SUBMERGED ARC (for SAW) speed welding, switch between the CV
Submerged Arc and the CV Innershield mode and
• CV INNERSHIELD (for FCAW and GMAW) use the mode that produces the best welding
results.
4. Turn the POWER ON/OFF Toggle Switch to the
“ON” position 3. Air/Carbon Arc Cutting (AAC) / Stick Welding
(SMAW) / High Current, Large Puddle Submerged
• The red pilot light glows. Arc Welding (SAW): Use the CC STICK mode.
When the DC-600 is used for Air/Carbon Arc cut-
• The fan starts. ting, the OUTPUT CONTROL potentiometer
should be set to "9" initially. Based on the size of
5. Set OUTPUT CONTROL Potentiometer to desired the carbon being used or the process, turn the
voltage or current. potentiometer to a lower setting as required by the
process. You can use carbon rods up to 3/8" in
6. Set the OUTPUT TERMINALS switch to either diameter at currents as high as 750 amps with
“ON” ( output terminals energized) or “REMOTE” excellent arc control. The welder protection circuit
(output terminals energized when #2 and #4 protects the machine from extremely high short
closed by remote device such as wire feeder) circuiting pulses.
7. Make the weld.
DC-600
B-8 OPERATION B-8
SEMI-AUTOMATIC AND AUTOMATIC 2. Set the NA-3 Open Circuit Voltage Control to the
same dial setting as the Arc Voltage Control. If
WIRE FEEDING WITH THE DC-600 this is a new welding procedure, a good starting
AND WIRE FEEDERS point is to set the Open Circuit Voltage Control to
# 6.
When using the DC-600 with semi-automatic or auto-
matic wire feeding equipment and for stick welding or NOTE: The open circuit voltage of the
air/carbon arc cutting, it is recommended that the DC-600 varies from approximately 16 volts to 56
optional MULTI-PROCESS SWITCH be used. This volts in the CV INNERSHIELD or CV
switch permits you to easily change the polarity of the SUBMERGED ARC modes. The open circuit volt-
connected wire feeding equipment or switch to stick age is constant in the CC STICK mode.
welding or air/carbon arc cutting.
3. Run a test weld. Set proper current, voltage, and
NA-3 AUTOMATIC WIRE FEEDER travel speed.
1. Set the DC-600 LOCAL/REMOTE Switch to a. For the best starting performance, the NA-
REMOTE. Set the OUTPUT TERMINALS switch 3 Open Circuit Voltage Control and Voltage
to REMOTE. NOTE: Later model NA-3 automatic Control setting should be the same. Set the
wire feeders are capable of cold starts when the Inch Speed Control for the slowest inch
NA-3 Mode switch is in the CV or CC mode posi- speed possible.
tion. Some earlier models are capable of cold
starting only in the CC mode position. Cold start- b. To adjust the Open Circuit Voltage Control to
ing enables you to inch the wire down to the work, get the best starting performance, make
automatically stop, and automatically energize the repeated starts observing the NA-3 voltmeter.
flux hopper valve.
When the voltmeter pointer swings smoothly up to
2. Set the DC-600 welding mode switch for the the desired arc voltage, without undershooting or
desired process: CV SUBMERGED ARC, CV overshooting the desired arc voltage, the Open
INNERSHIELD mode or CC STICK mode. Circuit Voltage Control is set properly.
3. Set the NA-3 mode Switch Position to either CV or If the voltmeter pointer overshoots the desired
CC to match the DC-600 mode selected in step 2. voltage and then returns back to the desired volt-
age, the Open Circuit Voltage Control is set too
4. Refer to the NA-3 operators manual for instruc- high. This can result in a bad start where the wire
tions on how to use the NA-3 in conjunction with tends to "Blast off."
the DC-600.
If the voltmeter pointer hesitates before coming up
5. Follow the following guidelines for good arc strik- to the desired voltage, the Open Circuit Voltage
ing detailed below for each welding mode. Control is set too low. This can cause the elec-
trode to stub.
GOOD ARC STRIKING GUIDELINES FOR THE NA-
3 WITH THE DC-600 IN THE CV INNERSHIELD, CV 4. Start and make the weld.
SUBMERGED ARC OR CC STICK WELDING
MODES. a. Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes posi-
Following are some basic arc striking techniques that tive contact with the work piece.
apply to all wire feed processes. Using these proce-
dures should provide trouble-free starting. These pro- b. Hot "On the Fly" starts. For hot starts, travel
cedures apply to single, solid wires and Innershield should begin before the wire contacts the
wires. work piece.
1. Cut the electrode to a sharp point.
DC-600
B-9 OPERATION B-9
ARC STRIKING WITH DC-600 AND THE NA-3 6. Establish the correct arc striking procedure with
START BOARD the NA-3 Start Board timer set at maximum.
When electrical strikeouts exceed 1 3/4” (44.4mm) an a. For the best starting performance, the NA-3
NA-3 Start Board may be required to improve arc Open Circuit Voltage Control and Voltage
striking. Control setting should be the same. Set the
Inch Speed Control for the slowest inch
When the NA-3 Start Board is used to improve arc speed possible.
striking, use the following procedures:
b. To adjust the Open Circuit Voltage Control to
1. Set start time at 0. get the best starting performance, make
repeated starts observing the NA-3 voltmeter.
2. Set NA-3 start current and start voltage at mid-
range. When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
3. Set the NA-3 output current and voltage to the overshooting the desired arc voltage, the Open
proper settings for the welding procedure to be Circuit Voltage Control is set properly.
used.
If the voltmeter pointer overshoots the desired
4. Turn the Start Board Timer to maximum. voltage and then returns back to the desired volt-
age, the Open Circuit Voltage Control is set too
5. Set Start Board current and voltage control. high. This can result in a bad start where the wire
tends to "Blast off."
a. Set the Start Board current control to 1 1/2
dial numbers below that set on the NA-3 cur- If the voltmeter pointer hesitates before coming up
rent control. to the desired voltage, the Open Circuit Voltage
Control is set too low. This can cause the elec-
b. Set the Start Board voltage control equal with trode to stub.
the NA-3 voltage control setting.
c. Set NA-3 Start Board current and voltage as
NOTE: These Start Board current and voltage close to the welding procedure current and
settings result in a start up current that is lower voltage as possible.
than the NA-3 current setting and approximately
equal with the NA-3 voltage setting for the desired NOTE: The Start Board current and voltage
welding procedure. should be as close as possible to the welding pro-
cedure current and voltage, while still getting sat-
isfactory starts.
d. Set the start time to as low a time as possible

while still getting satisfactory starts.
7. Start and make the weld.
DC-600
B-10 OPERATION B-10
DC-600 POWER SOURCE SETTING WHEN LN-8 SEMI-AUTOMATIC WIRE FEEDER

CONNECTED TO NA-5 WIRE FEEDER
To use the LN-8 Semi-Automatic Wire Feeder with
When using the DC-600 with the NA-5 wire feeder, set DC-600
the controls on the DC-600 as follows for the best per-
formance: 1. Set the DC-600 WELDING MODE SWITCH to
either CV INNERSHIELD mode or CV
1. Turn OFF main AC input power supply to the DC- SUBMERGED ARC mode depending on the weld-
600. ing process being used.
2. Connect the electrode cables to terminal polarity 2. Set the DC-600 LOCAL/REMOTE SWITCH to the
to be used. REMOTE position.
3. Connect the #21 work lead (on T.S.2) to the 3. Set the DC-600 OUTPUT TERMINALS switch to
same polarity as the work cable connection. REMOTE.
4. Set the LN-8 Welding Mode Switch to the CV posi-

4. Set the DC-600 LOCAL/REMOTE Switch to
tion. The LN-8 Welding Mode Switch is located
REMOTE. on the variable voltage (CC) board.
5. Set the DC-600 OUTPUT TERMINALS switch to 5. Refer to the LN-8 Operator’s Manual for instruc-
REMOTE. tions on how to use the LN-8.
6. Set the DC-600 WELDING MODE SWITCH to the
position that matches the welding process being
used. LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
FEEDERS OR OTHER CONSTANT WIRE
a. For submerged arc welding, set WELDING FEEDERS
MODE SWITCH to CV SUBMERGED ARC
position. To use the LN-7, LN-9, or other constant wire feed
speed semi-automatic wire feeders with DC-600
b. For all open arc welding processes set
WELDING MODE SWITCH to CV INNER- 1. Set the DC-600 WELDING MODE SWITCH to
SHIELD position. either CV INNERSHIELD mode or CV
SUBMERGED ARC mode depending on the weld-
ing process being used.
NOTE: These semi-automatic wire feeders can-

not be used in the CC Stick mode.
2. Set the DC-600 LOCAL/REMOTE SWITCH.
a. LN-7: Use either an optional K775 Remote

Control Box Assembly or set the
DC-600 LOCAL/REMOTE SWITCH in the
Local position.
b. LN-9: Refer to the LN-9 Operator’s Manual for

instructions of how to use the LN-9.
c. Other Constant Wire Feeders: Refer to Wire

Feeders Operator’s Manual.
3. Set the DC-600 OUTPUT TERMINALS switch to

REMOTE.
DC-600
C-1 ACCESSORIES C-1
WIRE FEEDERS AND TRACTORS Undercarriages (K817P, K842)
The DC-600 can be used to power any of the follow- For easy moving of the machine, optional undercar-
ing Wire Feeders and Tractors: riages are available with polyolefin wheels (K817P) or
a platform undercarriage (K842) with mountings for
Semi-Automatic Wire Feeders: two gas cylinders at rear of welder.
DH-10 LN-9
LN-7 LN-9 GMA Paralleling Kit (K1611-1)
LN-7 GMA LN-23P
LN-742 LN-25 Permits paralleling of two DC-600's for welding cur-
LN-8 LN-10 rents of up to 1200 amps, 100% duty cycle.
Automatic Wire Feeders: Tig Module (K930-2)

NA-3 NA-5R
NA-5 Portable high frequency generator for AC/DC TIG
welding.
Tractors:
LT-7 LT-56
FACTORY OR FIELD INSTALLED
OPTIONS
FIELD INSTALLED OPTIONS
Multi-Process Switch (K804-1)
Remote Output Control (K775 or K857
with K864 Adapter) The MULTI-PROCESS SWITCH gives you the ability
to:
An optional “remote out control” is available. The • Switch between "stick welding or air/carbon arc
K775 is the same remote control that is used on other cutting" and using a semi-automatic or automatic
Lincoln power sources. The K775 consist of a control wire feeder.
box with 28 feet (8.5mm) of four conductor cable. This
connects to terminals 75,76, and 77 on the terminal • Change the polarity of a semi-automatic or auto-
strip (T.S.1) and the case grounding screw so marked matic wire feeder without changing any electrical
with the symbol “ ” on the machine. These termi- cable connections.
nals are located behind the hinged cover on the case
front. This control will give the same control as the See Figure C.1
output control on the machine.
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 con-
nector on the case front.
+
Remote Control Adapter Cable (K864) -
STICK OR
AIR
CARBON
ARC
STRAIGHT PLUG (14 PIN) CABLE RECEPTACLE (6 SOCKET)
TO POWER SOURCE
TO: K857 REMOTE CONTROL
CABLE RECEPTACLE (14 SOCKET)
TO: LN-7 WIRE FEEDERS

– +
A "V" cable 12" (.30 m) long to connect a K857
WIRE STICK OR
Remote Control (6-pin connector) with an LN-7 wire-
FEEDER AIR/CARBON
feeder (14-pin connector) and the machine (14-pin
CABLES ARC CABLES
connector). If a remote control is used alone the wire-
feeder connection is then not used.
FIGURE C.1 - MULTI-PROCESS SWITCH
DC-600
C-2 ACCESSORIES C-2
The MULTI-PROCESS SWITCH has two sets of out-
put terminals. You connect the wire feeder unit cables
TERMINAL
to the set of terminals on the left side of the box and STRIP COVER
the stick or air/carbon arc cables to the set of termi- BOX
nals on the right side (facing the front of the machine) CONNECTOR
as shown in Figure C.1. The output terminals are pro-

tected against accidental contact by hinged covers.
21+ 21- 41 4 2 31 32 75 76 77
When the MULTI-PROCESS SWITCH is in the "Stick
CONTROL
or Air/Carbon Arc" position, only those LEADS
terminals are energized. The wire feeder nozzle or
gun and electrode are not electrically "hot" when in NEGATIVE (–)
OUTPUT – +
POSITIVE (+)
OUTPUT
this mode. STUD STUD
Follow these steps to install the MULTI-PROCESS ELECTRODE ELECTRODE

CABLE CABLE
SWITCH:
WORK +
WIRE STICK AIR/CARBON
FEEDER ARC WELDING
1. Confirm that the DC-600 POWER ON/OFF switch ELECTRODES
EQUIPMENT
is in the OFF position.

WORK WORK
CABLE JUMPER (IF NEEDED CABLE
2. Disconnect main AC input power to the DC- SEE INSTRUCTIONS)
600.
FIGURE C.4 - MULTI-PROCESS SWITCH
3. Open the terminal strip hinged cover located on CABLE CONNECTIONS.
the Case Front Assembly.
8. Connect the left cable from the MULTI-PROCESS
4. The MULTI-PROCESS SWITCH is mounted to SWITCH (facing the front of the machine) to the
the case front with four 1/4” self-tapping screws. DC-600 negative (-) output terminal. See Figure
The screw holes are 13.8” apart side to side and C.2.
4.5” apart top to bottom, Run one of the 1/4”
screws part way in and out of the screw holes to 9. Connect the wire feeder electrode and work
open them up. Make sure that the two sleeved cables. See Figure C.2.
control leads do not get pinched when hanging
the switch; route them out the side to the right of a. Insert the wire feeder electrode and work
the switch. Support the switch in position and start cables through the strain relief loop on the left
the four screws, then tighten them. side of the DC-600 (facing the front of the
machine).
5. Route the MULTI-PROCESS SWITCH control
leads through the strain-relief box connectors and b. Connect the wire feeder electrode and work
into the terminal strip. Connect wire feeder control cables to the electrode and work
cable as specified in specific connection diagram terminals on the left side of the MULTI-
and make other terminal strip connections as PROCESS SWITCH.
specified on the connection diagram for the
Lincoln wire feeder being used. 10. Connect wire feeder control cable and make other
terminal strip connections as specified on the
6. Connect the control leads from the MULTI- connection diagram for the Lincoln wire feeder
PROCESS SWITCH to terminals #2 and #4 on being used.
the DC-600's terminal strip.
7. Connect the right cable from the MULTI- REMOTE.
PROCESS SWITCH (facing the front of the
machine) to the DC-600 positive (+) output termi-
nal. See Figure C.2.
DC-600
C-3 ACCESSORIES C-3
12. Connect stick or air/carbon arc electrode and work CONNECTIONS FOR SEMI-AUTO-
cable. See Figure C.2.
MATIC OR AUTOMATIC WIRE FEED-
ER CONTROL
a. Insert the electrode and work cables through
the strain relief loop on the right side (facing
the front of the machine) of the DC-600. 1. Set the DC-600 ON/OFF switch to OFF.
b. Connect the electrode cable to the "Positive" 2. Set the DC-600 LOCAL/REMOTE switch to
terminal on the right side of the MULTI- REMOTE.
PROCESS SWITCH.
c. Connect the work cable to the "Negative" ter- REMOTE.
minal on the right side of the MULTI-
PROCESS SWITCH. 4. Set the DC-600 MODE switch to the welding
process being used.
NOTE: The instructions above are for connecting
the stick polarity positive. To change the polarity, 5. Refer to the proper connection diagram in the DIA-
turn the DC-600 OFF, and reverse the cables. GRAMS section for more information.
NOTE: When it is not necessary to have separate

ground cables for stick and semi-automatic or
automatic welding, connect a jumper from the
MULTI-PROCESS SWITCH "Work" terminal to
the MULTI-PROCESS SWITCH "negative" termi-
nal. See Figure C.2.
To operate the MULTI-PROCESS SWITCH, refer to

the operating instructions on the switch nameplate.
DC-600
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
Only qualified personnel should
perform this maintenance.
Turn the input power OFF at the

disconnect switch or fuse box
before working on this equipment.
Do not touch electrically hot parts.

------------------------------------------------------------------------
ROUTINE AND PERIODIC
MAINTENANCE
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts.
Perform the following daily:
1. Check that no combustible materials are in the

welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that

could block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits or

punctures in the cable jacket, or any condition that
would affect the proper operation of the machine.
Perform Periodically:
Clean the inside of the machine with low pressure air

stream. Clean the following parts.
• Main transformer and choke.
• Electrode and work cable connections.
• SCR rectifier bridge and heat sink fins.
• Control board.
• Firing board.
• Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
DC-600
E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will
invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all
safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING d. Remove the P.C. Board from the static-shielding

bag and place it directly into the equipment. Don’t
set the P.C. Board on or near paper, plastic or
ELECTRIC SHOCK can cloth which could have a static charge. If the P.C.
kill. Board can’t be installed immediately, put it back in
Have an electrician install and
service this equipment. Turn the the static-shielding bag.
input power OFF at the fuse box
before working on equipment. Do e. If the P.C. Board uses protective shorting jumpers,
not touch electrically hot parts.
don’t remove them until installation is complete.
CAUTION: Sometimes machine failures appear to be f. If you return a P.C. Board for credit, it must be in
due to PC board failures. These problems can some- the static-shielding bag. This will prevent further
times be traced to poor electrical connections. To damage and allow proper failure analysis.
avoid problems when troubleshooting and replacing
PC boards, please use the following procedure: 4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
1. Determine to the best of your technical ability that board.
the PC board is the most likely component causing
the failure symptom. NOTE: It is desirable to have a spare (known good)
PC board available for PC board trou-
2. Check for loose connections at the PC board to bleshooting.
assure that the PC board is properly connected.
NOTE: Allow the machine to heat up so that all elec-
3. If the problem persists, replace the suspect PC trical components can reach their operating
board using standard practices to avoid static elec- temperature.
trical damage and electrical shock. Read the warn-
ing inside the static resistant bag and perform the 5. Remove the replacement PC board and substitute
following procedures: it with the original PC board to recreate the original
problem.
P.C. Board can be damaged by static electricity.
a. If the original problem does not reappear by sub-
a. Remove your body’s static stituting the original board,then the PC board was
charge before opening the not the problem. Continue to look for bad connec-
static-shielding bag. Wear an tions in the control wiring harness, junction
anti-static wrist strap. For blocks, and terminal strips.
safety, use a 1 Meg ohm
ATTENTION resistive cord connected to a b. If the original problem is recreated by the substi-
Static-Sensitive grounded part of the equip- tution of the original board, then the PC board
Devices ment frame. was the problem. Reinstall the replacement PC
Handle only at board and test the machine.
Static-Safe b. If you don’t have a wrist strap,
Workstations touch an unpainted, ground- 6. Always indicate that this procedure was followed
ed, part of the equipment when warranty reports are to be submitted.
Reusable frame. Keep touching the
Container frame to prevent static build- NOTE: Following this procedure and writing on the
Do Not Destroy up. Be sure not to touch any warranty report, “INSTAllED AND SWITCHED
electrically live parts at the PC BOARDS TO VERIFY PROBLEM,” will
same time. help avoid denial of legitimate PC board war-
ranty claims.
c. Tools which come in contact with the P.C. Board
must be either conductive, anti-static or static-dis-
sipative.
DC-600
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical Contact the Lincoln Electric Service
Damage is Evident Dept. (216) 383-2531 or 1-800-
833-9353 (WELD)
The Machine is dead- The Input 1. Check for blown or missing

contactor does not operate. fuses in input lines.
If all recommended possible areas
2. Check the three- phase input of misadjustment have been
line voltage at the machine. checked and the problem persists,
The input voltage must match Contact your local Authorized
the rating plate and reconnect Field Service Facility.
panel.
3. Power ON/OFF switch may be

defective
CAUTION
DC-600
TROUBLESHOOTING GUIDE Observe Safety Guidelines
OUTPUT PROBLEMS
Input contactor (CR1) chatters. 1. The input line voltage may be
low. Check all three phases.
2. Make sure input line voltage

matches machine rating and
the reconnect panel is connect-
ed correctly for the line voltage.

of misadjustment have been
checked and the problem persists,
Contact your local Authorized
Variable or sluggish welding arc. 1. Poor electrode or work lead con-
Field Service Facility.
nection
2. Welding cables too small.
3. Welding current or voltage too

low.
Output Control Pot. not functioning 1. LOCAL/REMOTE Switch (S3)

in “LOCAL” control. faulty or in wrong position.
2. Faulty OUTPUT CONTROL Pot.
No output control in “REMOTE” 1. LOCAL/REMOTE Switch (S3)

control. faulty or in wrong position.
2. Faulty Remote Control Unit.
115VAC duplex receptacle not 1. 115VAC Circuit Breaker tripped.

working. (60HZ machines only)
CAUTION
DC-600
OUTPUT PROBLEMS
Machine input contactor operates 1. Place OUTPUT TERMINAL
but machine has no weld Switch to “ON”, or install a
output.Fan runs and pilot light jumper from #2 to #4 on
glows. machine terminal strip. If
machine weld output is
restored the problem is in the
wire feeder or control cable.
2. If remote control is not being of misadjustment have been
used make certain the checked and the problem persists,
LOCAL/REMOTE SWITCH Contact your local Authorized
(SW3) is in the "Local" position. Field Service Facility.
3. Check 42V Circuit Breaker in

the front panel.Reset if neces-
sary.
4. Check for loose or faulty weld

cable connections.
5. Trigger circuit not working.
CAUTION
DC-600
OUTPUT PROBLEMS
Machine has maximum weld out- 1. LOCAL/REMOTE Switch (S3)
put and no control. in wrong position.
2. LOCAL/REMOTE Switch (S3) If all recommended possible areas

is faulty, or an open lead going of misadjustment have been
to the LOCAL/REMOTE Switch checked and the problem persists,
(S3). Contact your local Authorized
CAUTION
DC-600
OUTPUT PROBLEMS
Machine has minimum output and 1. If a remote control unit is NOT
no control. connected to the terminal strip
#75, #76, and #77 terminals, or
is not connected to the 14 pin
MS receptacle the
LOCAL/REMOTE SWITCH
must be in the "Local" position.
2. If a remote control cable is con-

nected to terminals #75, #76
and #77 or is connected to the
14 pin MS receptacle the leads
may be "shorted" to the posi-
tive weld output.
3. Make certain the Three Phase

input voltage is correct and
matches the machine rating
and the reconnect panel. If all recommended possible areas
The machine does not have maxi- Contact your local Authorized
mum weld output. Field Service Facility.
1. Check all Three-Phase input
lines at the DC600. Make
sure input voltages match
machine rating and recon-
nect panel.
2. Put LOCAL/REMOTE
SWITCH (SW3) in "LOCAL"
position. If problem is
solved then check remote
control unit or wire feeder.
3. Check for loose welding

cable connections.
CAUTION
DC-600
OUTPUT PROBLEMS
Machine shuts off (input contactor 1. Remove all welding cables and
drops out) when the welder output control cables from the DC
terminals are made electrically 600. Jumper #2 to #4 at the
"hot". terminal strip or set OUTPUT
(#2 to #4 closure at terminal strip.) TERMINALS switch to ON
or OUTPUT TERMINALS switch position. If the machine does
is in ON position. NOT shut off and normal open
circuit voltage is present at the
welder output terminals the
problem is external to the
DC600. Either the remote
leads #75, #76 or #77 are
grounded to the negative out-
put cable or there is a short on
the welding output terminals.
2. If the machine still shuts off

when all control and welding
cables are removed then the
problem is internal to the If all recommended possible areas
DC600. of misadjustment have been
The DC600 will NOT shut off when 1. Contact your local Lincoln
the Power Switch is turned to
Authorized Field Ser vice
OFF.
Facility.
CAUTION
DC-600
OUTPUT PROBLEMS
The weld output terminals are 1. Remove any external leads
always electrically "hot". hooked to #2 and #4 on the ter-
minal strip or any connections
to the 14 pin MS connector. If all recommended possible areas
Set OUTPUT TERMINALS of misadjustment have been
switch to the OFF position. If checked and the problem persists,
the problem disappears the Contact your local Authorized
fault is in the control cable or Field Service Facility.
wire feeder.
2. If some open circuit voltage is

present (over 3VDC.) after per-
forming Step #1. then the prob-
lem is within the DC600.
CAUTION
DC-600
WELDING PROBLEMS
Poor arc starting when the DC600 1. Make sure the proper welding
is in the CV Sub-Arc or CV procedures are being used. If all recommended possible areas
Innershield Modes. (wire feed speed , arc voltage of misadjustment have been
and wire size) checked and the problem persists,
2. Check weld cables for loose or Field Service Facility.
faulty connections.
Machine has output but trips off 1. Remove output cables from
immediately when wire feed unit DC-600. If problem is resolved
trigger is activated check for external short
between weldiong cables. Also
check control cable (#75, #76,
& #77) for grounds or shorts.
CAUTION
DC-600
WELDING PROBLEMS
Poor arc characteristics in all 1. Check for the correct input volt-
processes. ages on the three- phase input
lines at the DC600. If all recommended possible areas
2. Make sure the proper welding checked and the problem persists,
procedures are being Contact your local Authorized
used.(wire feed speed, arc volt- Field Service Facility.
age and wire size).
3. Check the welding cables for

loose or faulty connections.
CAUTION
DC-600
DC-600 WIRING DIAGRAM-230/260/575 V 60HZ ONLY
F-1
H4 230/460/575V DUPLEX (ON 60 HZ MACHINES ONLY)

N.G. (SHOWN CONNECTED 42
H3 32 31
TO FOR LOW VOLTAGE)
GND
H2
H1 SUPPLY
LINES 41 CIRCUIT
272 15A OUTPUT
A J 31 BREAKER
32 TERM.
B I 32A T.S.2 WELDING MODE
9 TO GROUND SWITCH
K 32 236 SWITCH S4
3 PER NATIONAL 2 21 S2
L3
8 6 ELECTRICAL R1 (SHOWN IN CC
C L N H 31
5 CODE
2 4 75 STICK POSITION)
L2 4 10K 2W
7 M R.F.
RECONNECT 4 D G OUTPUT 237
L1 1 CHOKE 2
PANEL E F 42
AS'BLY 2 CONTROL
CR1 N.C. 2
INPUT TO PRIMARY COILS 42
271 14 PIN 75
77 76 4 81
CONTACTOR 4
RECEPT. LOCAL/
76 77
(FRONT 41 41 REMOTE
18,17,16 15,14,13 41 80
226 SWITCH 232
VIEW) -
222 21 S3
N.G. N.G.
- 222 +
VM 210 21
H1 H2 H3
+
210
CONTROL 237 236 280 215
T2 TRANSFORMER
229 224
X1 238
255 X2
FAULT
S1
INPUT PROTECTION 75 76 77
255 POWER R.F.
RELAY
SWITCH CR2 CHOKE
7 5 AS'BLY
T.S.1
271 255
A B
PILOT
W 235
LIGHT
CIRCUIT 233 1 1 229
10A BREAKER 233 256 2 2 75
256
T1 MAIN TRANSFORMER 42 3 3 232
4 4 80
PRIMARY 256
THERMOSTAT 231 5 J2 5 226
272
255 6 6 81
273 J1
16 S 17 42A 18 32A 290 7 7
S SEC. LEAD 291
31 S 8 8 280
N.G. 1 AUX.2 2 31 THERMOSTAT 238 9
F 41 3 F TWISTED 9
F
PRI. TOGETHER 235 10 10 215
207
F F F R.F. 11 224
203 205 210 1
ALL PRIMARY 4 S 5 S 6 S CHOKE J3 12 222
FAN 215 2
LEADS TO AS'BLY
13 204 AUX. 1 15 MOTOR
RECONNECT 206 208 32A CONTROL
14 R.F.
PANEL
7 P.C. BOARD CHOKE
8 9
AS'BLY
PRI.
R2 214
222 222 30 100W G1 1 1 41
222
G2 2 2
G3 3 3
J4
G4 4 4 2
SEC. (-) G5 5 208
222 5
G6 6 6 207
J5
7 206
A 1 8 205
.05 B 2 9 4
mFd
3 10 290
SEC. B' 291
.05 4 11
OUTPUT J7
mFd C 5 12 215
CHOKE
OUTPUT
C7 C' 6 13 231
NOTES:
7 14 214
N.C. LOCATION OF THIS LEAD ON T.S.2 TERMINAL STRIP N.D. A' 8 15 203
DIAGRAMS
MAY VARY. SEE IM MANUAL FOR LOCATION. 16 204

210
N.D. WELDING CABLE MUST BE OF THE PROPER P22
CAPACITY FOR THE CURRENT AND DUTY CYCLE
J6 1 261 1
DC-600
AM
OF IMMEDIATE AND FUTURE APPLICATIONS. 210 (+)
+ - 2 262 2
G1 G3 G5 SCR
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY A A A 3 263 3
FIRING CIRCUIT
SNUBBERS 4 4
"POSITIVE". TO CHANGE THE POLARITY, TURN P.C. BOARD 342
215 210
THE DC-600 OFF, AND REVERSE THE LEADS AT SCR 2
SCR SCR + - J23
THE MULTI-PROCESS SWITCH. 1 3 5 FOR OPTIONAL
320V 4
N.F. USING A WIRE FEEDER, K-317 OR K-318 PARALLELING
210 160J
TP1 KIT
CONNECTION DIAGRAM, CONNECT ELECTRODE 215
OUTPUT SHUNT
AND WORK LEADS TO THESE TERMINALS
(50MV @800 AMPS) C1
INSTEAD OF THE POWER SOURCE C C C
OUTPUT TERMINALS. .05mFD
OUTPUT 600 V
N.G. TAPE UP SEPARATELY TO PROVIDE AT
SNUBBER C C C
LEAST 600V INSULATION. 215
THESE NOTES APPLY ONLY TO DC-600 WITH A

MULTI-PROCESS SWITCH INSTALLED.
SCR SCR SCR
TO STICK ELECTRODE HOLDER OR
2 4 6 WORK +
J3 J6 J4 J7 AIR-CARBON ARC TORCH
1 1 2 1 3 1 4
N.D., N.F. N.D. N.E.
A G2 A G4 A G6 ELECTRODE
TO "WORK" USED WITH STICK
3 4 4 6 5 8
2 - OR AIR-CARBON ARC
J2 J1 J5 OUTPUT RECTIFIER
1 5 1 7 1 8 ASSEMBLY
OPTIONAL USER SUPPLIED JUMPER FOR
STICK WORK LEAD NOT
THOSE SITUATIONS WHERE IT IS NOT
OPTIONAL USED WHEN JUMPER IS
6 10 8 14 8 16 NECESSARY TO HAVE SEPARATE GROUND
MULTI-PROCESS USED.
CABLES FOR STICK AND SEMI-AUTOMATIC
CONNECTOR CAVITY NUMBERING SEQUENCE SWITCH WELDING.
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537

8-2000J
G3506-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-1
CONNECTION OF LN-742 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-2
Turn off (0) the power switch on the Welding
Power Source before connecting the wire feeder.
LINCOLN
Only qualified persons should install, use or
POWER SOURCE
N.D. service this machine.
14 PIN
AMPHENOL
LN-742
WIRE
FEEDER N.A. WELDING CABLE MUST BE SIZED FOR CURRENT
+ AND DUTY CYCLE OF APPLICATION.
-
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO
CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLES AT
POWER SOURCE AND SET WIRE FEEDER
VOLTMETER POLARITY SWITCH ON POWER
TO WORK SOURCE TO PROPER POLARITY.
LN-742
INPUT CABLE N.C. PINS NOT LISTED ARE NOT CONNECTED
ELECTRODE CABLE
ASSEMBLY ON CABLE.
DIAGRAMS
N.D. IF USING K589-1, REMOTE CONTROL KIT,

SET POWER SOURCE CONTROL SWITCH
DC-600
TO "REMOTE" POSITION.
FUNCTIONS ARE LISTED FOR REFERENCE K=42

K=42
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQUIPMENT.
I=41
(SEE APPROPRIATE WIRING DIAGRAM)
I=41
PIN LEAD FUNCTION
H=21 C=2
C 2 TRIGGER CIRCUIT
D 4 TRIGGER CIRCUIT C=2 H=21

E 77 OUTPUT CONTROL
F 76 OUTPUT CONTROL G=75 D=4
D=4 G=75
G 75 OUTPUT CONTROL
E=77 F=76 F=76 E=77
H 21 WORK
14-SOCKET BOX RECEPTACLE, FRONT VIEW 14-SOCKET BOX RECEPTACLE, REAR VIEW
I 41 42V AC
AND 14-PIN CABLE PLUG, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW
K 42 42V AC 1-28-94
F-2
S20409
CONNECTION OF LN-7 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-3
14-PIN
RECEPTACLE
POWER SOURCE CONTROL CABLE
Do not operate with covers removed.
FOR CONTROL CABLE
WITH 14 PIN MS-TYPE Disconnect power source before
PLUG CONNECTOR servicing.
LN-7 TO INPUT
Do not touch electrically live parts.
CABLE PLUG
21
OR Only qualified persons should install, use or
LN-7 CONTROL
FOR CONTROL CABLE service this machine.
CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
N.A. Welding cables must be of proper capacity for the current and
duty cycle of immediate and future applications. See LN-7
Operating Manual for proper sizes.
+21 - 21 41 4 2 31 32 75 76 77
N.E. N.B. If LN-7 is equipped with a meter kit, extend LN-7 control cable
lead #21 from control cable with terminal strip connectors or from
14-pin receptacle using #14 AWG or larger insulated wire physically
N.F. suitable for the installation. An S16586-[LENGTH] remote
voltage sensing work lead may be ordered for this purpose.
32
Connect it directly to the work piece independent of the welding
31
2 work cable connection. For convenience, this extended #21 lead
4 should be taped to the welding work lead. (If the length of
welding work cable is short, less than 25 feet, and connections
N.B. & N.C. GND
can be expected to be reliable, then control cable lead #21 does
N.D. not need to be extended and can be directly connected to
NEGATIVE POSITIVE
terminal #21 on the terminal strip. Note that this is not the
21
preferred connection because it adds error to the LN-7 voltmeter
DIAGRAMS
reading.)
DC-600
N.G. N.C. Tape up bolted connection if lead #21 is extended.
ELECTRODE CABLE N.D. Connect the control cable ground lead to the frame terminal
TO WIRE FEED UNIT marked near the power source terminal strip. The power
source grounding terminal (marked and located near the power
N.A. source input power connections) must be properly connected to
electrical ground per the power source operating manual.
N.E. If an optional remote voltage control is used, connect it to

TO WORK this terminal strip.
N.F. If lead #21 is to be connected to the terminal strip,

connect to the #21 terminal that matches work polarity. This
REMOTE VOLTAGE SENSING LEAD
connection must be changed whenever the electrode polarity is
changed.
Above diagram shows electrode connected positive. To change polarity,
turn power off, reverse the electrode and work leads at the power N.G. Illustration does not necessarily represent actual position of
source and position the switch on wire feeder (if equipped ) appropriate output studs. Refer to power source operating manual
to proper polarity. Also refer to note N.F. for more information.
For proper setting of switches on power source,

see power source operating manual.
10-30-98F
F-3
S22976
CONNECTION OF LN-8 OR LN-9 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-4
14-PIN
RECEPTACLE
FOR CONTROL CABLE
21 Do not touch electrically live parts.

TO LN-8 OR LN-9
INPUT CABLE PLUG OR
N.F. Only qualified persons should install, use or
FOR CONTROL CABLE service this machine.
CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
duty cycle of immediate and future applications.
N.B. Extend lead #21 from control cable with terminal strip connectors or
+21 - 21 41 4 2 31 32 75 76 77 from 14-pin receptacle using #14 AWG or larger insulated wire
N.E.
physically suitable for the installation. An S16586-[LENGTH]
remote voltage sensing work lead may be ordered for this purpose.
N.G. C Connect it directly to the work piece keeping it electrically

B N.E. separate from the welding work lead circuit and connection. For
A convenience, this extended #21 lead should be taped to the
32
31 welding work lead. (If the length of work lead circuit is
2 short, and connections can be expected to be reliable, then
4
control cable lead #21 does not need to be extended and can be
N.B. & N.C. GND directly connected to terminal #21 on the terminal strip. Note
that this is not the preferred connection because it adds error
NEGATIVE POSITIVE N.D. to the wire feeder voltmeter reading.)
21
N.C. Tape up bolted connection if lead #21 is extended.
DIAGRAMS
N.D. Connect the control cable ground lead to the frame terminal
N.H.
DC-600
marked near the power source terminal strip. The power
ELECTRODE CABLE
source input power connections) must be properly connected to
TO WIRE FEED UNIT
electrical ground per the power source operating manual.
N.A. N.E. If using an older LN-8 control cable: connect lead #75 to #75 on
terminal strip, connect lead #76 to #76 on terminal strip, connect
lead #77 to #77 on the terminal strip.
TO WORK
N.F. The LN-9 voltage control jumpers must be connected as follows
(refer to LN-9 Operating Manual):
White jumper on voltage board to pin "S" .
Blue jumper on voltage board (later units only),
or on start board (earlier units), to pin "B".
Above diagram shows electrode connected positive. To change polarity, N.G. If lead #21 is to be connected to the terminal strip, connect to
turn power off, reverse the electrode and work leads at the power the #21 terminal that matches work polarity. This connection must be
source and position the switch on wire feeder (if equipped ) changed whenever the electrode polarity is changed.
to proper polarity. Also refer to note N.F. N.H. Illustration does not necessarily represent actual position of appropriate
output studs. Refer to power source instruction manual for more info.
10-30-98F
F-4
S22977
CONNECTION OF NA-3, LT-5 OR LT-7 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-5
14-PIN
RECEPTACLE
FOR CONTROL CABLE

21 TO AUTOMATIC
CONTROL BOX OR Only qualified persons should install, use or
service this machine.
CONTROL CABLE FOR CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
+21 - 21 41 4 2 31 32 75 76 77
N.B. Extend lead #21 from control cable with terminal strip connectors
or from 14-pin receptacle using #14 AWG or larger insulated wire
77 remote voltage sensing work lead may be ordered for this purpose.
N.F. 76
Connect it directly to the work piece keeping it electrically
75
32
separate form the welding work lead circuit and connection. For
31 convenience, this extended #21 lead should be taped to the
4
short, and connections can be expected to be reliable, then
N.B. & N.C. GND control cable lead #21 does not need to be extended and can be
directly connected to terminal #21 on the terminal strip. Note
NEGATIVE POSITIVE N.D. that this is not the preferred connection because it adds error
21 to the wire feeder voltmeter reading.)
DIAGRAMS
N.C. Tape up bolted connection if lead #21 is extended.

DC-600
N.G.
marked near the power source terminal strip. The power
ELECTRODE CABLE source grounding terminal (marked and located near the power
TO AUTOMATIC source input power connections) must be properly connected to
EQUIPMENT electrical ground per the power source operating manual.
N.A. N.E. If a variable voltage board is present in the automatic controls,

the jumper lead on the VV board must be connected to pin "L" to
permit the inch down button to operate. This jumper, however,
TO WORK will disable the cold starting/autostop feature of the automatic
controls, permitting only hot starting techniques to be used.
N.F. If lead #21 is to be connected to the terminal strip,

REMOTE VOLTAGE SENSING LEAD connect to the #21 terminal that matches work polarity. This
connection must be changed whenever the electrode polarity is
changed.
Above diagram shows electrode connected positive. To change polarity,
turn power off, reverse the electrode and work leads at the power N.G. Illustration does not necessarily represent actual position of
source. Reverse the leads on the back of the ammeter and voltmeter appropriate output studs. Refer to power source operating
in the automatic control box. Also refer to note N.F. manual for more information.

10-30-98F
S22978
F-5
CONNECTION OF NA-5/-5R TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-6
14-PIN
RECEPTACLE
POWER SOURCE CONTROL CABLE Do not operate with covers removed.
FOR CONTROL CABLE Disconnect power source before

WITH 14 PIN MS-TYPE servicing.
PLUG CONNECTOR
21
TO NA-5/-5R
INPUT CABLE PLUG OR
CONTROL CABLE FOR CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
N.B. Extend lead #21 from control cable with terminal strip connectors
or from 14-pin receptacle using #14 AWG or larger insulated wire
+21 - 21 41 4 2 31 32 75 76 77
remote voltage sensing work lead may be ordered for this purpose.
Connect it directly to the work piece keeping it electrically
C
N.F. separate from the welding work lead circuit and connection. For
B
A convenience, this extended #21 lead should be taped to the
31
2 short, and connections can be expected to be reliable, then
4 control cable lead #21 does not need to be extended and can be
N.B. & N.C. GND directly connected to terminal #21 on the terminal strip. Note
that this is not the preferred connection because it adds error
NEGATIVE POSITIVE N.D. to the NA-5/-5R voltmeter reading.)
21 N.C. Tape up bolted connection if lead #21 is extended.
DIAGRAMS
DC-600
N.H. marked near the power source terminal strip. The power
BOLT TO CABLES FROM NA-5/-5R source input power connections) must be properly connected to
WIRE CONTACT AS'BLY electrical ground per the power source operating manual.
N.E. The jumpers on the NA-5/-5R voltage board must be connected as follows:
N.A. Connect red jumper to pin "S".
N.D. & N.F.
Connect white jumper to pin "B".
When using NA-5/-5R controls above Code 8300, the NA-5/-5R Inch Down
TO WORK button will not operate unless a jumper is connected between the two
tab terminals, labeled "AUTO", located above the transformer on the
NA-5/-5R Voltage P.C. board. This jumper, however, will disable the
Cold Starting/Auto-Stop/Touching-Work feature of the NA-5/-5R,
permitting only Hot Starting techniques to be used.
Above diagram shows electrode connected positive. To change polarity, N.F. If lead #21 is to be connected to the terminal strip, connect to the #21
turn power off, reverse the electrode and work leads at the power source. terminal that matches work polarity. This connection must be changed
Refer to NA-5 or NA-5R Operating Manual for required NA-5 or NA-5R control
whenever the electrode polarity is changed.
box polarity connections. Also refer to note N.F. N.G. For proper NA-5/-5R operation, the electrode cables must be snugged under
the clamp bar on the left side of the NA-5/-5R control box.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OR NA-5R OPERATING MANUAL.
N.H. Illustration does not necessarily represent actual position of
For proper setting of switches on power source, appropriate output studs. Refer to power source operating manual
see power source operating manual. for more information.
10-30-98F
S22979
F-6
CONNECTION OF DH-10 OR LN-10 TO POWER SOURCE WITH 14 PIN AMPHENOL
F-7
Disconnect power source before
LINCOLN servicing.
WIRE
POWER SOURCE Do not touch electrically live parts.
FEEDER
N.E.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT
AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO
- + CHANGE POLARITY, TURN POWER "OFF",
14 PIN 9 PIN
REVERSE ELECTRODE AND WORK CABLES AT
AMPHENOL AMPHENOL POWER SOURCE.
N.C. PINS NOT LISTED ARE NOT CONNECTED

ON CABLE.
N.D. IF LEAD #21 IS TO BE CONNECTED TO THE
TERMINAL STRIP, CONNECT TO THE #21
ELECTRODE CABLE WIRE FEEDER TERMINAL THAT MATCHES WORK POLARITY.
INPUT CABLE THIS CONNECTION MUST BE CHANGED WHENEVER
TO WORK THE ELECTRODE POLARITY IS CHANGED.
ASSEMBLY
N.E. ILLUSTRATION DOES NOT NECESSARILY REPRESENT
ACTUAL POSITION OF APPROPRIATE OUTPUT STUDS.
FOR PROPER SETTINGS OF SWITCHES ON POWER SOURCE,
REFER TO POWER SOURCE OPERATING MANUAL FOR
SEE POWER SOURCE OPERATING MANUAL.
MORE INFORMATION.
DIAGRAMS
DC-600
FUNCTIONS ARE LISTED FOR REFERENCE K=42 K=42
A J J A
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQUIPMENT.
(SEE APPROPRIATE WIRING DIAGRAM) B=GND I=41 I=41 B=GND
PIN LEAD FUNCTION

C=2 H=21 H=21 C=2
B GND CHASSIS CONNECTION
C 2 TRIGGER CIRCUIT L N N L
D 4 TRIGGER CIRCUIT G=75 D=4

E 77 OUTPUT CONTROL D=4 G=75
F 76 OUTPUT CONTROL E=77 M F=76 F=76 M E=77
G 75 OUTPUT CONTROL 14-SOCKET BOX RECEPTACLE, FRONT VIEW 14-SOCKET BOX RECEPTACLE, REAR VIEW
H 21 WORK AND 14-PIN CABLE PLUG, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW
I 41 42V AC
K 42 42V AC 10-30-98F
F-7
S22980
F-8
DC-600 DIMENSION PRINT (WITH K817P UNDERCARRIAGE)
THIS DIMENSION WILL VARY

WITH POSITION OF HANDLE
38.00 22.25
17.75 11.12
5.90
3.25
27.50
39.95
DIAGRAMS
DC-600
9.20
4.75 * .94 20.00

*
*
29.93
27.87
1-20-89A
* LOCATION OF BASE MOUNTING HOLES M12244-6

F-8
F-9
DC-600 DIMENSION PRINT (WITH K842 UNDERCARRIAGE)

23.28
54.91
22.25
38.00 5.19
11.12
17.76
3.25
27.50
37.86
DIAGRAMS
DC-600
7.11
29.93
*
* .94 *
* 20.00
36.12
49.89 27.65
LOCATION OF BASE MOUNTING HOLES 6-18-93C

* M15200-3
F-9
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● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION ● Aislese del trabajo y de la tierra.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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IM657

RED-D-ARC December, 2000

Safety Depends on You

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

5.e. Also see item 1.b.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

5. Toujours porter des lunettes de sécurité dans la zone de

for selecting this QUALITY product. We want you to take pride in

Please Examine Carton and Equipment For Damage Immediately

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F

Parts List ......................................................................................................P354 Series

230/460/575/60 108/54/43 122/61/49 134/67/54 10650

Read entire Installation Section before installing SELECT PROPER LOCATION

• Do not touch electrically hot parts.

• Always connect the IDEALARC

• Set the DC-600 Power ON/OFF PUSH BUTTON to the OFF

INPUT SUPPLY 4. Follow Input Supply Connection Diagram located

FIGURE A.1 - Rear Panel

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses or

Use input and grounding wire sizes that meet local

Ground the frame of the machine. A ground

RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different

FIGURE A.3-Reconnect Panel Board Positions for 230/460/575 VAC Machines

Cable Length Parallel Cables Cable Size

Lengths up to 150 ft. (46m) 2 1/0 (53mm2)

150 ft.(46m) to 200 ft (61m) 2 2/0 (85mm2)

200 ft.(61m) to 250 ft.(76m) 2 3/0 (107mm2)

ELECTRODE, WORK AND #21 LEAD

A. Connect Electrode and Work Leads to

1. Set the ON/OFF toggle switch to OFF.

2. Locate the retractable strain relief loops directly

3. Pull out the retractable strain relief loops.

4. Insert the electrode lead through the loop directly

AUXILIARY POWER AND PIN LEAD NO. FUNCTION

The 115VAC duplex receptacle is protected by a cir- TERMINAL STRIP 1 (T.S.1)

• Do not touch electrically live parts

• Insulate yourself from work and

• Always wear dry insulating

FUMES AND GASES

• Keep your head out of fumes.

• Use ventilation or exhaust to

WELDING, CUTTING and

• Keep flammable material away.

• Do not weld, cut or gouge on

• Wear eye, ear and body

Observe additional Safety Guidelines detailed in

GENERAL DESCRIPTION DESIGN FEATURES AND

600 Amps, 44 Volts at 100%

MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT

Control Of Output Voltage and

Remote Control of Output Voltage

OUTPUT VOLTAGE Output Terminal Connections

Clockwise Increase of Output

MEANING OF GRAPHICAL SYMBOLS ON

Three Phase Input Power

Gas Metal Arc Welding (GMAW)