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Arco Sumergido Manual Cr10
Arco Sumergido Manual Cr10
Machinery LLC
W1222 Linden Road
Ixonia, Wisconsin 53036 USA
Phone: 800.248.8405 or 262.567.3993
Fax: 262.567.4307
www.wtcmachinery.com
Machinery, LLC CR-10 Idler/Roller Welder TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION 1: INTRODUCTION .....................................................………………………………… 1
SECTION 1 - INTRODUCTION
This Manual covers installing, using and maintaining the Model CR-10 Idler/Roller Welder.
Safety Statements
There are a number of safety statements throughout this manual, in three different categories -
It is in the interest of operator, but also of management and supervisors, to read and understand ways to
safely get the most from the CR-10 Idler/Roller Welder.
Cleanliness
Occasional cleaning is part of long term maintenance of the Idler/Roller Welder. A clean piece of equipment
is more pleasant to operate, safer and easier to maintain. Pay particular attention to removing flux dust,
which is an abrasive to mechanical parts, and traps heat in electrical parts, especially the Welding Power
Supplies
WARNING!
Altering any part of the CR-10 Idler/Roller Welder or its components, or using the Welder in a manner
other than intended is at the operator's own risk.
Such alterations or uses must necessarily void the warranty against the CR-10 Idler/Roller Welder.
WARNING!
The CR-10 Idler/Roller Welder contains dangerous moving parts and dangerous electrical voltages.
Never operate the CR-10 Idler/Roller Welder without all guards and covers in place and secured to the Welder.
1
Machinery, LLC CR-10 Idler/Roller Welder SPECIFICATIONS
WORKPIECE DIMENSIONS
Maximum Weight……………….. 2000 lbs (910 kg)
Maximum Diameter……………. 52 inches (1320 mm)
Maximum Width ……………….. 26 inches (660 mm)
MACHINE SUPPLY
Compressed Air Requirement - 80 to 120 p.s.i. (5,5 to 8,3 atm) 5.0 ft3/min (0,15 m3/min)
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Machinery, LLC CR-10 Idler/Roller Welder SPECIFICATIONS
Control Identification
Right Torch
Cylinder
Lock Pin
Air Clamp Right
Control Stop
Handle
Cylinder
Clamp
AIR CLAMP CONTROL - controls the air clamp to hold the idler or roller in place. Pressing down on the
control clamps the workpiece (idler or roller), pulling up releases the workpiece.
LEFT STOP HANDLE - sets the point at which the torches will stop traveling left, either in CIRC Mode step-
over, or in CROSS Mode travel
RIGHT STOP HANDLE - sets the point at which the torches will stop traveling right, either in CIRC Mode
step-over, or in CROSS Mode travel
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Machinery, LLC CR-10 Idler/Roller Welder SPECIFICATIONS
9 10 11 12 13
1) ARC STOP - Stops the welding cycle 8 14
7 OFF OFF
2
1 9
8
15
CROSS/FLANGE DOWN 0 10
16
6
3) LEFT VOLTAGE - Controls the voltage of the Left Torch WELD MODE
CROSS
OFF
Head CIRC 17
5 SPINDLE INDEX
LEFT ARC RIGHT ARC
VOLTAGE FEED RATE VOLTAGE FEED RATE
5 5 5 5
4 6 4 6 4 6 4 6
18
3 7 3 7 3 7 3 7
INCH
2 8 2 8 2 8 2 8
4 1 9 1 9 1 9 1 9
OFF
UP
10 0 10
ELECTRODE 0
OFF
UP
10
OFF
2 8 20
REV 1 9
DWELL ELECTRODE
TIME INCH
1 21
6) WELD MODE - selects the welding mode : 25 24 23 22
CROSS Mode moves the torch heads left and right over the roller or idler. At each end of the torch
travel, the idler or roller turns briefly, overlapping the previous weld bead.
9) MOVEUP DIRECTION - selects the direction the Beam moves, or turns the Moveup off.
10) LEFT WIRE FEED METER - shows the speed of the wire feeding through the Left Torch Head. This is
directly related to the Amps of the Left Torch
11) LEFT FEED RATE - sets the speed of the Left welding wire once the welding arc is established. This is
directly related to the Amps at the Left Torch Head.
12) MOVEUP SPEED - sets the speed the torches move up and down. It also controls how far the torches
move in the Automatic Modes; a higher speed will mean a larger automatic moveup.
13) RIGHT VOLTMETER - Displays the voltage of the Right Torch Head
14) MANUAL BEAM LIFT/LOWER -This moves the torches close to or away from an idler or roller. Pulling
out on the pushbutton starts the torches moving. Pushing in on the pushbutton stops the torches.
15) RIGHT FEED RATE - sets the speed of the Right welding wire once the welding arc is established. This
is directly related to the Amps at the Right Torch Head.
16) RIGHT VOLTAGE - Controls the voltage of the Right Torch Head
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Machinery, LLC CR-10 Idler/Roller Welder SPECIFICATIONS
17) RIGHT FEED RATE - sets the speed of the Right welding wire once the welding arc is established. This
is directly related to the Amps at the Right Torch Head.
18) RIGHT ELECTRODE UP/OFF/DOWN - selects the direction of the right welding wire. Welding happens
in the DOWN position
19) NOZZLE BEAM SPEED - sets how fast the left and right troches move from side-to-side
20) NOZZLE BEAM MOVE - manually moves the left and right troches from side-to-side
21) FLUX RECOVERY ON/OFF - starts and stops the flux recovery system
22) LEFT ELECTRODE UP/OFF/DOWN - selects the direction of the left welding wire. Welding happens
in the DOWN position
23) SPINDLE SPEED - sets the speed the idler or roller rotates
24) SPINDLE FWD/REV - selects whether the idler rotates forward (top away from the front) or reverse (top
towards the front)
26) DWELL TIME (on the control console's right side) - sets how long a period the idler or roller rotates a
each end of CROSS Mode travel
27) ELECTRODE INCH - sets how fast the left and right welding wire travel before an arc is struck. This is
set to a meter reading of 30 for welding, but increased to allow faster loading of new wire.
5
Machinery, LLC CR-10 Idler/Roller Welder INSTALLATION
SECTION 3 - INSTALLATION -
A) SETTING UP THE LOCATION
Use care in locating the CR-10 Idler - Roller Welder. It should be sited near electrical and compressed air
supplies. (Cooling water and a waste-water drain are also needed if the Welder is equipped with the
optional Water System)
Provide room for walkways on all sides of the welder – this is safer and simplifies maintenance.
See the drawing (below) for a recommended floor plan.
If an existing floor is used, make sure it will support the Welder, that it is made from a non-flammable
material (concrete, for example) and that the floor does not include metal bars that conduct electricity.
Site the Main Machine. While not necessary, it is recommended that the Main Machine is anchored to the
floor using eight ¾" (19 mm) or smaller anchor bolts.
Unpack the Control Console, and position it as shown in the Floor Plan drawing, below.
Control
)
,3 i n
m
Console
(0 14
55
89 1/2 in
Vertical Clearance
(2,27 m)
Required Over Machine:
130 in (3,30 m)
22 559
(0
,
in m)
Workpiece
Cooling
Area
Power Supplies
(2,03 m)
80 in
(2 Units Stacked)
(3,66 m)
144 in
Flux Pump
COMPRESSED AIR
CONNECTION
23 in
FLUX PUMP (0,58 m)
ELECTRICAL
CONNECTION
38 1/2 in
(0,98 m)
(1,02 m)
40 in
19 1/2 in
(0,50 m)
WELDER ELECTRICAL Wire Pay-Out Paks
CONNECTION (X 2)
134 in
(3,40 m)
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Machinery, LLC CR-10 Idler/Roller Welder INSTALLATION
Assemble the two Pay-out Paks, and locate them behind the Main Machine, as shown in the General Floor
Plan on page 5. Allow room between the Pay-out Paks and the Main Machine so the triangular Turntables
can move freely without hitting each other or any part of the Main Machine.
Loosen the nuts locking the Wire Hold Bracket to the Wire Guide, and adjust them so the Wire Hold Bracket
is 1" -2" (25 - 50 mm) away from the edge of the wire barrel. Tighten the nuts.
Loosen the bolts locking the Top Hat Posts to the Top Hat. Slide the Top Hat Posts so they are centered,
and just fit inside the cardboard liner at the center of the wire barrel. Re-tighten the bolts, and place the Top
Hat on the wire barrel.
Turn the Turntable, wire barrel and Top Hat to make sure they spin freely, and that they don't touch the Wire
Hold Bracket or any parts of the other Pay-out Pak or Main Machine.
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Machinery, LLC CR-10 Idler/Roller Welder INSTALLATION
DANGER!
Electricity kills! All electrical work should be done by qualified personnel,
All electrical connections must be made in accordance with the U.S.A. National Electrical Codes.
Outside the U.S.A., local codes and ordinances must be followed and adhered to.
Position the two Welding Power Supply Units behind the Main Machine (see the Floor Plan drawing, page
5), facing the control end of the Units toward the Main Machine. The Power Supplies Units can be put side-
by-side, or stacked one atop the other. If placing the Units side-by-side, note that the right Unit is marked
with "R" tags ("R+", "R-" and "RC"), and the left Unit with "L" tags ("L+", "L-" and "LC") If stacking the Power
Supplies, make sure the bottom unit is level and firmly supported by the floor.
The electrical supply to the Welding Power Supply Units should have a lockable shutoff and over-current
protection. Two methods are a circuit breaker or a fused disconnect switch. Connect the electrical supply to
the end of the Power Supplies opposite the controls. Check the voltage connection instructions inside the
Power Supply to make sure the Power Supply is properly connected for the electrical supply voltage.
Unpack the Frame Ground cables ("L-" and "R-") and the Electrode Cables ("L+" and "R+") from the bottom
Flux Hopper to the back of the Main Machine. Route the cables to the Power Supply Units. Choose a path
to avoid the cables being tripped over, tangled in Pay-out Paks, run over or stepped on. Connect the cables
to the matching terminals on the Power Supply Units.
Unpack the Power Supply Control Cables ("LC" and "RC") from the Control Console. Again, route the
cables to the Power Supply Units choosing a path out of harm's way. Open the access covers at the front of
the Power Supply Units.
Loosen the cord grips to the right of the access covers, pass the ends of the Control Cables through the
cord grips, and then tighten the cord grips. Connect the Control Cable wires to the matching terminals on
the Power Supply Units.
Locate the Flux Pump at the back of the Main Machine (see the Floor Plan drawing, page 5.) Face the Inlet
Connector towards the Main Machine.
As before, the electrical supply to the Flux Pump should have a lockable shutoff and over-current protection
(either a circuit breaker or a fused disconnect switch.) See the Section 2 – Specifications (page Connect the
electrical supply to the Starter at the side of the Flux Pump. Check the voltage of the electrical supply
against the voltage specified on the face of the Starter.
Unpack the Flux Pump Control Cable ("FP") from the Bottom Flux Hopper to the back of the Main Machine.
Choose a safe path to the Flux Pump. Pass the cable through the cord grip on the bottom of the starter, and
tighten the cord grip. Connect the cable leads to the matching wires in the Flux Pump Starter.
Unpack the 1½" (37 mm) diameter Flux Hose from the Bottom Flux Hopper to the back of the Main Machine.
Route it, via a safe path, to the Flux Pump. Locate the Flux Pump outlet - hold open the spring-loaded cover
and push the metal coupling at the end of the flux hose into the outlet.
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Machinery, LLC CR-10 Idler/Roller Welder INSTALLATION
Unpack the Yoke-Tilt Power Cable ("115 VAC") from the Bottom Flux Hopper to the back of the Main
Machine. Route the cable safely, and connect it to the Left Welding Power Supply Unit ("LC") as follows -
Black wire to #32 Terminal
White wire to #31 Terminal
Green wire to GND Terminal
Unpack the Upper Flux Hopper. Remove one of the cotter pins from the Pivot Shaft, and remove the Pivot
Shaft from the Hopper.
Use a sturdy ladder or other stable platform to place the Upper Flux Hopper on top of the Beam Flux
Hopper, with the hose elbows on its top facing the back of the Main Machine.
Hose Clamps
Position the Upper Flux Hopper so the two metal angles
Flux Hoses Upper Flux Hopper
on its bottom are outside of the two metal angles on the
top of the Beam Flux Hopper. Pivot Shaft
Flux Limit Switch
Line up the holes at the back of the four angles, and Beam Flux Hopper
pass the Pivot Shaft through the holes, placing washers
in between the Upper Hopper angles and the Beam
Hopper angles. Re-install the cotter pin, and bend it so
it stays in place.
Bring the two 1½" (37 mm) flux hoses to the Upper Flux Hopper. Loosen the hose clamps at the ends of the
hoses, and push the hoses onto the elbows atop the Upper Flux Hopper. Re-tighten the hose clamps.
Re-position at the front of the Hopper. Remove the Die Spring and bolt from the under-side of the Upper
Flux Hopper. Place the Die Spring between the Beam Flux Hopper Frame and the Upper Flux Hopper.
Pass the bolt through the hole in the Beam Flux Hopper and the Die Spring, and tighten the bolt into the
threaded hole on the under-side of the Upper Hopper.
Focus on the Control Console. Make sure the "MODE" switch, the "LEFT ELECTRODE" switch, the
"RIGHT ELECTRODE" switch and the "FLUX RECOVERY" switch are all in the "OFF" position.
Start the right Welding Power Supply Unit. Position an assistant near the Flux Pump to watch the direction
the Pump Drive Belt turns. Turn the "FLUX RECOVERY" switch on for a second, and then off. If the Flux
Pump Drive Belt travels backwards, turn off power to the Flux Pump Starter, and swap two of the three
power leads to the flux pump. Turn power back on and check the belt travel direction again.
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
Techniques -
The goal in rebuilding idlers and rollers is returning the workpiece to its original dimensions while creating a
smooth, wear resistant surface. To do this, two techniques are used - "circumferential" (CIRC or "stringer")
welding, and "cross" welding. Stringer welding is easier to master and set-up and works on unevenly worn
tread surfaces and flanges. Cross welding is more difficult to master and only works level tread surfaces, but
can deposit metal faster.
Always consult the idler or roller manufacturer for guidance on the correct rebuild procedure.
Flange Face
Buildup Sequence - Flange Side Cupped Wear
No two idlers or rollers will be worn the same way. The operator Tread Surface
3rd Pass
must decide on the best sequence of beads to return the
2nd Pass
workpiece to its original dimensions.
1st Pass
Once the tread is level, weld across the entire tread surface, either
with a series of stringer beads or using cross weld, until the tread Sloping Wear Flange
is built back to the original diameter.
Rebuild flange sides with a series of stringer weld beads, stepping up the face of the flange.
It is important that both sides of the idler or roller are built up to the same diameter. If not, the larger side will
take more load and wear faster.
Step-over Correct
Step-over Distance -
The Step-over Distance sets the spacing between one weld bead and the next, and
affects the over-all smoothness of the welded surface. In circumferential, or
stringer, welding, the Step-over Distance is set by a combination of the Dwell Time Step-over Too Large
and the Nozzle Beam Speed. For cross welding, the Step-over Distance is set by a
combination of the Dwell Time and the Spindle Speed.
Step-over Too Small
A Step-over Distance set too large leaves gaps between weld beads. Too small a
Step-over distance cause the weld to "pile up" with the diameter getting larger as weld beads are added.
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
-out
Wire
Welding Wire
Stick
amperage of the weld. Flux and Slag
Flux Dam
The Wire Speed affects the width of the weld bead Lead
Lead - is the horizontal distance between the welding wire and the vertical center-line of the idler or roller.
The correct lead will vary from ½" (12 mm) for a small roller to about 2½" (64 mm) a large idler.
Travel Speed - is the speed of the welding tip related to the workpiece. In circumferential or stringer
welding, this is the Spindle Speed (the speed that the idler or roller turns.) In cross welding, this is
the Nozzle Beam Speed (the speed that the torches move across the tread surface.)
A general guide is to set the travel speed at 30 inches per minute (760 mm/min) Faster or slower
speeds will give wider or narrower weld bead profiles.
Peaked Concave
Common bead profiles are the peaked and concave bead profiles, Bead Bead Flat
Bead
which are not wanted, and the flat bead, which is.
The concave bead (hot weld) also leaves an uneven surface. Often the weld bead is hot enough to flow
away from the weld bead, leaving rivulets and drops of weld metal on the surface. This is caused by the
Voltage or Wire Speed set too high for the Travel Speed, or a Lead Distance that is too large.
The flat bead has an oval cross-section. This is the correct balance of Voltage, Wire Speed and Travel
Speed. The flat bead allows the maximum build-up per pass and results in the best surface finish, with weld
beads flowing into each other to leave a smooth surface.
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
REQUIRED TOOLS -
The preferred tools for rebuilding idlers and rollers will vary between operators. At minimum, have:
- a chipping hammer to remove weld slag,
- a wire cutters to trim the welding wire,
- a large caliper and a tape measure or scale to check the diameter
- a wear gauge to check the profile of the idler or roller
- a set of inch (imperial) hex keys ("Allen wrenches") and open-end wrenches for machine
adjustments
LOADING WIRE -
The Model CR-10 Idler / Roller Welder uses welding wire (supplied in barrels, also known as “pay-out paks”
or POP’s) and shielding flux in the rebuilding process. Please see the “Consumable Guide” on page 28 for
details on recommended types of wire and flux.
Load wire barrels on the two Pay-out Paks (see page 6.) Focus
Clamp Spring
on one of the wire barrels, and find the end of the welding wire. Tube Adapter
Straighten the first 12" to 18" (300 to 450 mm) of the wire, and Clamp
remove any burrs from its end. Feed the welding wire through Bolt
Pressure Roll
the Wire Hold Bracket and lower Wire Liner until it touches the
Wire Feed Drive and Pressure Rolls. Latch Side
Drive Roll
Plate
Focus on the Wire Feed. Loosen the hex nut on the Clamp
Bolt, and move the Clamp Bolt and Clamp Spring out of the
way. Swing the Latch Side Plate open. Pull the welding wire
past the Drive Roll and feed it into the upper Tube Adapter.
Tube Adapter
Swing the Latch Side Plate back up until the Pressure Roll
touches the Drive Roll. If needed, turn the Pressure Roll so it
meshes with the Drive Roll. Push the Clamp Bolt and Clamp Spring back their original position. Tighten the
hex nut until it begins to compress the Clamp Spring, and then tighten it five more turns.
Move to the front of the welder, to the proper Torch Head (left or
right.) Loosen the Flux Nozzle hose clamp, and slide the Flux Nozzle
off of the Torch Pipe. Loosen and remove the Welding Tip and
Welding Tip Adapter together.
Turn the right-side Welding Power Supply On. Find the proper
Torch Pipe
"ELECTRODE" switch (left or right) and switch it to the DOWN
position. Press and hold the "INCH" push button.
Welding Tip and
Welding Tip Adapter
Occasionally, the wire will snag on the Spring Liner inside the Torch
Pipe. If this happens, push the Spring Liner back into the Torch Flux Nozzle
Pipe. When the welding wire extends 2" to 3" (50 to 75 mm) past the
end of the Torch Pipe, release the "INCH" push Button.
Re-install and tighten the Welding Tip, Welding Tip Adapter and Flux Nozzle, and then load the welding wire
on the other Torch Head.
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
LOADING FLUX -
Pour clean, dry welding flux into the Bottom Flux Hopper. With the right Welding Power Supply On, turn the
"FLUX RECOVERY" switch ON. The Flux Pump starts drawing flux to the Upper Flux Hopper.
Vibrator Flow Control
Move to the left back of the Main Machine and locate the
Vibrator Flow Control. Turning this clock-wise increases the
shaking of the Bottom Flux Hopper.
More shaking speeds the flux flow through the Bottom Flux
Hopper screen, but increases the noise and compressed air
use. Generally, choose the lowest setting that allows flux to
pass easily through the flux screen.
To lower the Beam Carriage, set the "MOVEUP DIRECTION" switch to DOWN, and turn the "MOVEUP
SPEED" control fully clock-wise to the "10" setting. Pull out on the "MANUAL BEAM LIFT/LOWER" push
button. When the Beam carriage reaches the proper height, push in on the "MANUAL BEAM
LIFT/LOWER" push button.
WORKPIECE PREPARATION -
Thoroughly clean the idler or rollers. Remove all dirt, grease and rust by steam cleaning, washing and wire
brushing. A power wire brush is very helpful for the removal of rust, but take extreme care not to mix the dirt
or rust with the flux in the Bottom Flux Hopper. Dirt or rust mixed with the flux will cause porosity in the
welds.
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
WARNING!
Solid (drum style) idlers have an inside cavity which can contain moisture.
Heating these idlers creates steam, which can rupture the idler, destroying the idler and creating dangerous flying debris.
Always vent these idlers with a drill or cutting torch before rebuilding.
Disassembled idlers and rollers have the axle shaft removed - this common for idlers.
The first step in setting up is to measure the center bore diameter and bore length of the workpiece.
Choose and install the proper cones, based on the bore diameter. The smaller cones (B2712 Cylinder Cone
and B2713 Spindle Cone) are used on bores smaller than 7" (175 mm), generally small idlers and rollers.
The large cones (D1521 Cylinder Cone and D1522 Spindle Cone) are used on large idlers.
Retract the Air Cylinder, by pulling up on Disassembled Idler and Roller Clamping
D1521 Large Cylinder Cone
the Air Clamp Control. Adjust the Air D1522 Large Spindle Cone
Air Cylinder Clamp
Cylinder and the Spindle Shaft so the
Air Clamp Control
distance between the cones is slightly
Cylinder Spindle Shaft
larger than the bore length of the Lock Pin Lock Screw
workpiece and centered on the yoke.
Spindle Shaft
B2713 Cylinder Cone B2712 Spindle Cone
Adjust the Air Cylinder by removing the
Cylinder Lock Pin, sliding the Cylinder to
line up with a hole in the Yoke, and
reinstalling the Cylinder Lock Pin.
Lift the workpiece, using a safe lifting device (Locking Lifting Tongs, part number 532-
239A, are available from WTC Machinery Corporation) and a crane or forklift with Lifting Tongs
(WTC Part No. 532-239A)
enough lifting capacity for the weight of the idler or roller.
Place the workpiece between the cones, so the right side of bore touches the Spindle
Cone. Push down on the Air Clamp Control to clamp the workpiece. Slowly lower the
crane or forklift, while checking that the workpiece is tightly clamped.
If not, raise the crane or forklift to support the idler or roller again. Pull up on the Air
Clamp Control, and remove the Cylinder Lock Pin. Shift the Air Cylinder closer and re-
install the Lock Pin. Push down on the Air Clamp Control to again clamp the workpiece.
Once the workpiece is tightly clamped, loosen the bolt on the Air Cylinder Clamp, and slide the Clamp to the
left as far as possible. Tighten the Clamp bolt again.
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
WARNING!
Solid (drum style) idlers have a sealed cavity, which can contain moisture.
Heating these idlers creates steam, which can rupture the idler, destroying the idler and creating dangerous flying debris.
Always vent these idlers with a drill or cutting torch before rebuilding.
The first step in setting up assembled idlers is to measure the length of the idler axle shaft. The CR-10
Idler/Roller Welder can hold axles up to 26" (660 mm) long.
Loosen the Axle Lock Screw on the Air Cylinder. If a cone is mounted on the Air Cylinder, remove it and the
A2361 Center Shaft, and install the A2360 Axle Center onto the Air Cylinder. Tighten the Axle Lock Screw
until it just touches the Axle Center, and then loosen it ¼ turn. Tighten the Axle Lock Screw's lock nut.
Install these parts onto the Spindle Shaft. Axle Lock Screw
Lift the idler, using a safe lifting device (Locking Lifting Tongs, part number 532-239B, are available from
WTC Machinery Corporation) and a crane or forklift with enough lifting capacity for the idler's weight.
Place the idler between the Axle Center and the Spindle Shaft, touching the Spindle Shaft. Push down on
the Air Clamp Control to clamp the idler. Slowly lower the crane or forklift, checking that the idler is
supported. If not, raise the idler, unclamp the idler, adjust the Air Cylinder, clamp again.
Once the idler is supported, loosen the Air Cylinder Clamp, slide the Clamp to the left and tighten the Clamp
bolt again.
Adjust the Turning Arm and Connector Arm so the Weld-on Tab touches the side of the idler. Weld the
Weld-on Tab to the idler with a minimum 1/4" (6 mm) weld bead. Tighten the bolts holding the Weld-on Tab,
Connector Arm, Turning Arm and Drive Bar together.
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
Always use the Water Cooling System (WTC Machinery part number D1099) when welding assembled
rollers. Without water cooling, rollers heat beyond safe levels, warping the roller and damaging the roller's
bearings and seals.
The first step in setting up assembled rollers is to install the water cooling components (probe tip, adapter
and probe base) into the roller shaft. See the Water Cooling System manual for part numbers and details.
Measure the length of the roller axle shaft, including the probe base and adapter. The CR-10 Idler/Roller
Welder can hold axles up to 26" (660 mm) long.
Loosen the Axle Lock Screw on the Air Cylinder. If a cone is mounted on the Air Cylinder, remove it along
with the A2361 Center Shaft.
Assembled Roller Clamping
A1780 Drive Rod (X 2)
A2360 Axle Center
Install the A2360 Axle Center onto the Air 56-0114 Spring (X 2)
Air Cylinder Clamp A1725 Bushing (X 2)
Cylinder. Tighten the Axle Lock Screw until it
Air Clamp Control C0701 Drive Bar
just touches the Axle Center, and then loosen it
Cylinder
¼ turn. Tighten the Axle Lock Screw's lock nut. Lock Pin
Spindle Shaft
Lock Screw
loosen the locking set screw, and remove the Axle Lock Screw
cone.
890110 Probe Base
Pull up on the Air Clamp Control to retract the Air Cylinder. Adjust the Air Cylinder and the Spindle Shaft so
the distance between the Axle Center and the end of the Spindle Shaft is slightly larger than the length of
the roller axle and water adapter.
Lift the roller, using a safe lifting device (Locking Lifting Tongs, part number 532-239A, are available from
WTC Machinery Corporation) and a crane or forklift with enough lifting capacity.
Place the roller between the Axle Center and the Spindle Shaft, touching the Spindle Shaft. Push down on
the Air Clamp Control to clamp the idler. Slowly lower the crane or forklift, while checking that the idler is
tightly clamped.
If not, raise the crane or forklift to support the idler, unclamp the roller, adjust the Air Cylinder, clamp again.
Once the roller is tightly clamped, loosen the bolt on the Air Cylinder Clamp, and slide the Clamp to the left
as far as possible. Tighten the Clamp bolt again.
Adjust the Bushings so the two Drive Rods are even with the sides of the roller. Turn the hex nuts on the
Drive Rods until the Springs start to compress, and then turn the hex nuts to put tension on the Drive Rods
(generally 4 full turns for small rollers, and 6 turns for large rollers.)
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Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
FLUX DAMS -
Flux dams contain the flux around the welding wire. This makes sure that the weld is shielded, and keeps
the use of the Flux Recovery system to a minimum. The placement of flux dams depends on the size,
shape and wear pattern of the workpiece.
In general:
All Rollers and small idlers need flux dams in Dam Dam
front of the welding wire to keep the flux Dam
Dam
from spilling down the tread surface
Dam
PREHEATING -
Pre-heating the workpiece is necessary for good quality welding. It removes moisture from the workpiece,
and prevents cracking from too-rapid heating of welding on cold metal.
As a general rule, small disassembled rollers should be heated from 90° to 120°F (30° to 50°C) and large
rollers to 200°F (95°C) Idlers should be thoroughly to pre-heated to 300°F (150°C), starting at the hub and
working out to the rim. Always consult the manufacturer for pre-heating recommendations.
The most effective way to evenly pre-heat is to use large fuel-oxygen torches ("rosebuds") pointed at the
front of the workpiece, while the workpiece is turning.
To set the workpiece turning, make sure the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches are
in the OFF position. Move the "SPINDLE DIRECTION" switch up, press the "ARC START" push button, and
adjust the SPINDLE SPEED control to get a satisfactory speed.
17
Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
Before welding on an idler or roller, plan the sequence of beads, starting at the lowest (smallest diameter)
The Limit Stops are set to keep the Torch Heads confined within the part of the workpiece that needs
welding. With unevenly worn workpieces, the 1st series of weld beads are narrower than the 2nd series of
weld beads. The weld process can be stopped after the 1st series of welds to re-adjust the Limit Stops.
With practice and experience, the adjustment can be made while the welding continues.
Briefly using CROSS mode is the easiest way to set the Limit Stops.
Use the Beam Lift controls, or the Left and Torch Head Adjustments
Right Vertical Adjustments to raise the torch
heads clear of the highest part of the
workpiece. Left Limit Stop
Adjustment
Watch the right Torch Head relative to the weld area on the workpiece. Turn the Right Limit Switch
Adjustment to change where the torch stops at the right end of its travel, and the Left Limit Switch
Adjustment to change the left.
When the right Torch is set, move to the left Torch Head over its weld area using the Left Side Adjustment.
Press the "ARC STOP" push button to stop the Torch Heads moving.
18
Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
To set the step-over distance, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE"
switches are in the OFF position, and the right Welding Power Supply is ON. Turn the "WELD MODE"
switch to the CIRC position. Press the "ARC START" push button to start the workpiece turning. Turn the
"SPINDLE SPEED" control clockwise to shorten the time between step-overs.
The step-over happens once every revolution, shown by the "SPINDLE INDEX" light. The step-over is also
advertised by machined flat on the Spindle Shaft - the step-over happens when the flat is facing up.
The "NOZZLE BEAM SPEED" control sets how fast the Torch Heads move during the step-
over. Turning this clock-wise increases the step-over speed and the distance.
When the step-over distance is set, press the "ARC STOP" push button to stop the workpiece.
To set the spindle speed, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches
are in the OFF position. Turn the right Welding Power Supply ON, and set the "WELD MODE" switch to the
CIRC position. Press the "ARC START" push button to start the workpiece turning.
The correct spindle speed setting depends on the size of the workpiece, and the size of the weld wanted.
A good general guide is to set the spindle speed so the weld surface moves at 30 inches/minute
(760 mm/min) or 10" (255 mm) in 20 seconds.
To adjust the Spindle Speed, turn the "SPINDLE SPEED" control (clock-wise to move faster, anti-clock-wise
to move slower) until the idler or roller turns at the correct speed.
Once the Spindle Speed is set, press the "ARC STOP" push button to stop the workpiece turning.
19
Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
To set the voltage, make sure the welding wires of both the left and right Torch Heads are well away from
the workpiece. Focus on the "ELECTRODE INCH" control on the right side of the Control Console. Use a
flat screwdriver to turn the control fully anti-clock-wise (this prevents the welding arc from striking.)
Turn both the left and right Welding Power Supplies ON, and both the "LEFT ELECTRODE" and "RIGHT
ELECTRODE" switches to DOWN. Press the "ARC START" push button.
Adjust the "LEFT VOLTAGE" control to get the correct voltage (shown on the "LEFT VOLTMETER"), and
adjust the "RIGHT VOLTAGE" control to for the correct voltage (shown on the "RIGHT VOLTMETER".)
Press the "ARC STOP" push button to shut off the process. Turn both the "LEFT ELECTRODE" and "RIGHT
ELECTRODE" switches to OFF. Press the "INCH" push button, and adjust the "ELECTRODE INCH" control
so a wire speed of 30 shows on the "LEFT WIRE FEED SPEED" and RIGHT WIRE FEED SPEED" meters.
The height is usually set so there is ½" to ¾" (12 to 19 mm) between the bottom of the Flux Nozzles and the
weld surface. The Welding Tip should recessed ¾" to 1" (19 to 25 mm) inside the Flux Nozzle. The total
wire stick-out is 1¼" to 1¾" (32 to 45 mm) Turn the left and right Vertical Adjustment knob to set the Torch
Head height.
Use the left and right "WIRE FEED SPEED" controls to change the wire feed speeds as needed.
Generally, a control setting of "6" is a good initial setting, but operator experience and the shape and
appearance of the weld bead are the best guides.
Press and hold the "SPINDLE JOG" push button until the workpiece comes to the step-over point (and the
"INDEX" light comes on.) Turn both the left and right Welding Power Supplies ON, and "WELD MODE"
switch to the CIRC position. Turn both the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches to
DOWN.
Open the left and right Flux Valves to cover the weld area with flux, and press the "ARC START" push
button to start welding.
20
Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
While Welding -
After the welding arc starts, the operator needs to do a number of things:
- Remove slag (solidified flux) from the weld bead, leaving clean metal for the next weld.
- Watch the weld bead shape and appearance, and adjusting the Voltage, Wire Feed Speed and
Lead Distance as need.
- Watch the step-over distance, and adjust the Nozzle Beam Speed as needed.
- On unevenly worn idlers and rollers, change the Limit Switch Stop positions as a wider weld
area is needed.
- Check the current diameter of the workpiece against the finished diameter.
- Occasionally, turn on the Flux Recovery, making sure enough flux is in the Beam Flux Hopper.
Experience is the best guide to how and when to do these. With practice, more of these can be done
without stopping the welding process.
As the welding arc stops, flux will coat the end of the welding wire. If left on, this coating prevents the
welding arc from starting again, so it is a good practice to trim ¼ " to ½" (6 to 12 mm) off of the end of the
electrode whenever welding ends.
Since welding is much easier on a horizontal surface, the Yoke and Watch For
workpiece are almost always tilted to rebuild flange sides. Clearance
Yoke Tilt
Watch For Switch
To tilt the Yoke anti-clock-wise, lift up on the switch. To tilt the Yoke Clearance
clock-wise push down on the switch. Watch that the Yoke and idler
or roller does not collide with the Torch Heads or the Beam Carriage.
If they get close, raise the Beam Carriage using the Beam Lift
Controls.
Welding begins at the tread face and works along the flange side. Weld set-up is similar to tread surface
welding, except that the only one Torch Head is used and the that a smaller step-over distance is probably
needed. If the Flange side is not completely horizontal, the Torch Head needs to move up slightly along with
the step-over each revolution.
21
Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
Setting the voltage and wire feed speed are also the same,
but cross welding beads are usually thicker and wider, with
higher settings for voltage and wire feed speed.
To set the travel speed, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches are
in the OFF position. Turn the right Welding Power Supply ON, and set the "WELD MODE" switch to the
CROSS position. Press the "ARC START" push button to start the cross mode pattern. Turn the "NOZZLE
BEAM SPEED" control to set the required travel speed.
To set the step-over distance, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE"
switches are in the OFF position, the right Welding Power Supply is ON, and set the "WELD MODE" switch
to the CROSS position. Press the "ARC START" push button to start the workpiece moving in the cross
welding pattern. Turn the "SPINDLE SPEED" control to set the step-over distance.
Welding -
Starting the welding arc, welding and stopping are all the same for cross welding as for circumferential
welding.
22
Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
WORKPIECE COOL-DOWN -
Slow cool-down after welding is important to avoid cracks and spalling in the weld surface. This is true both
when the rebuild is complete, and when welding is interrupted for more than a few minutes.
The best ways to slow cooling are to cover the idler or roller with a high-temperature blanket, or to bury it in
flux, sand or other high-temperature material. Avoid putting the idler or roller directly on a cool surface such
as a concrete floor.
ADVANCED TECHNIQUES -
Some "tricks of the trade” that make rebuilding faster and easier -
- Uneven wear on idler and roller treads can be leveled somewhat by changing the step-over
distance. Use a normal step-over setting on the high portions of the tread. Decrease the step-
over setting over the lower parts of the tread surface, increasing the build-up in these areas.
- Place one or more circumferential "Dam" beads near the outer edge of idler treads. This keeps
weld and flux from spilling off of the edge of the idler, especially when using the cross welding
technique.
- When welding flange sides which are not completely horizontal, use the "MOVEUP
AUTOMATIC" control to raise the torch every turn of the workpiece. Set this at the same time
as the step-over distance - put the "MOVEUP AUTOMATIC MODE" switch to the FLANGE
position, the "MOVEUP DIRECTION" switch to UP, and set the "MOVEUP SPEED" control to
get the correct amount of raise.
- For narrow flanges, it is sometimes faster to control the Torch Head position manually. Turn the
"NOZZLE BEAM SPEED" control full anti-clock-wise, and the "MOVEUP AUTOMATIC MODE"
OFF to stop automatic step-over. At the step-over point, (when the "INDEX" light come on) turn
the Vertical Adjustment Side Adjustment knobs to move the Torch head to the correct position
for the next weld bead.
- Standing upright, idler treads usually can not be welded to the edge, because the weld spills off
of the tread face. To "square off" the tread face, wait until the idler is still tilted to weld the flange
side, and then place a weld bead in the corner of the tread surface and the idler side.
23
Machinery, LLC CR-10 Idler/Roller Welder MAINTENANCE
Except for the places listed below, never grease parts of the Welder. Dry lubricants can be used
sparingly, but some of these (like graphite powder) are electrical conductors - keep them away from
the electrical insulators on the Welder Torch Heads and Wire Feed Assemblies.
Torch Heads -
Inspect the Torch Heads for burnt or worn components.
Especially important are the copper Welding Tips.
Torch Head
Worn Welding Tips allow the welding wire to move sideways, Replacement Parts
leading to a "wandering" weld bead. Badly worn Weld Tips
loose contact with the welding wire, stopping the weld.
Grease Fittings -
The CR-10 has the seven grease points, shown to the right. Regularly top these off with good
quality carriage grease.
Grease Points
Use high temperature grease (750°F or
400°C) for the Air Cylinder Axle.
Air Cylinder
Axle
Pay-out Pak
Turntable Axle
(X 2)
Gear Boxes -
Regularly inspect the oil level of the three gearboxes - the Yoke Tilt Gearbox, the Spindle
Drive Gearbox and the Spindle Drive Transmission.
See the attached gearbox manufacturer's manuals for recommended methods and oils.
Flux Hoses -
At least once every month, inspect the rubber flux hoses (connecting the Beam Flux Hopper to the
Flux Nozzles) Look for leaks, kinks, burnt spots or cracks. Replace damaged hoses.
Occasionally inspect the 1½" (37 mm) diameter hoses from the Bottom Flux Hopper to the Upper
Flux Hopper, and from the Upper Flux Hopper to the Flux Pump. Replace damaged hoses.
24
Machinery, LLC CR-10 Idler/Roller Welder MAINTENANCE
Every Week -
Use compressed air to clean the Welder, especially the Wire drive motors and gears and the wire liners
Every Month -
Check grease levels NOTE: Wipe excess grease off all exposed surfaces.
(If desired) Lubricate the Torch adjuster tubes lightly with a dry graphite or molybendium lubricant only
NOTE: Never grease the Ball Screw Assembly! Grease attracts abrasive dust, and will cause the Ball
Screw to fail.
Replace the Ball Screw assembly (WTC Part number D1508-001) if the Ball Screw threads are worn, or if
parts of the Ball Screw Assembly are found.
25
Machinery, LLC CR-10 Idler / Roller Welder TROUBLE SHOOTING
Relocate the Pay-off Pak if the Turntable hits the Main Machine, the
other Pay-out Pak or any other object..
Inspect the Wire Liners for kinks or crushes, and replace if damaged.
Blockage or kinks in the
Wire Liners Remove the Liner, and blow through with compressed air. Replace
blocked Wire Liners.
Welding Wire does Check the alignment between the Wire Feed Drive Roll and Pressure
not Feed, or Feeds Roll, and adjust if necessary.
Unevenly Worn, misaligned or
Reset the tension of the Pressure Roll - loosen the Clamp Bolt hex
improperly tensioned nut. Re-tighten until the Clamp Spring begins to compress, and then
Wire Feed Rolls turn the hex nut five full turns.
26
Machinery, LLC CR-10 Idler/Roller Welder RECOMMENDED SPARE PARTS
The following is a list of factory recommended spare parts for the CR-10 Idler/Roller Welder.
27
Machinery, LLC CR-10 Idler/Roller Welder CONSUMABLE GUIDE
The recommended wire is suitable for hard-facing parts with metal-to-metal wear. Below are
hard-facing wire brands to use as a guide.
HARD-FACING WIRES
Maker Product Name Part Number Package Size
Thermadyne/Stoody 105B 11040100 500 lb (230 kg) Drum
Thermadyne/Stoody 105B 11902600 750 lb (340 kg) Drum
Lincoln Electric Lincore 40-S ED015945 300 lb (135 kg) Drum
Lincoln Electric Lincore 40-S ED015909 600 lb (270 kg) Drum
NOTE: hard-facing wires are limited to four passes (about ½ inch or 13 mm) of build-up
thickness. Badly worn idlers and rollers require the initial welding to be done in a low-alloy
welding wire and the final few welding passes done with hard-facing wire. Below are initial-pass
brands to use as a guide.
Granular Flux –
The recommended flux is a neutral flux with a slow chill time and a maximum grain size of 0.08”
(2.0 mm) or 10 Sieve Mesh. Below are granular flux brands to use as a guide.
GRANULAR FLUX
Maker Product Name Part Number Package Size
Thermadyne/Stoody Roll-Rite 11257000 50 lb (23 kg) Bag
Lincoln Electric Lincolnweld 801 ED019588 50 lb (23 kg) Bag
28
AMERICAN VACUUM COMPANY
Model # 7MH
OPERATING INSTRUCTIONS
INSTALLATION. THE ARCO WAND STATIONARY FLUX RECOVERY UNITS ARE MADE IN SINGLE
SEPARATOR MODELS (MH SERIES) AND DOUBLE SEPARATOR MODELS (DMH SERIES). IN THE
SINGLE (MH) SEPARATOR TYPE THE ENTIRE UNIT IS USUALLY MOUNTED OVERHEAD, WHILE IN
THE DOUBLE (DMH) SEPARATOR TYPE JUST THE, FIRST (PRIMARY) SEPARATOR IS OVERHEAD
AND THE POWER UNIT WITH SECOND SEPARATOR ATTACHED IS PLACED ON THE FLOOR. IN
EITHER CASE THE HOPPER BUCKET WITH DUMP VALVE SHOULD BE LOCATED OVER THE WELDER
SO THAT A VERTICAL FEEDOUT HOUSE CAN BE USED. THE FEED OUT ROSE SHOULD BE AS
LONG AND AS CLOSE TO VERTICAL AS POSSIBLE. IT SHOULD BE AT LEAST 4' LONG ON 1
1/2 H.P., 5' ON 2 H.P. AND 6' ON 3 H.P. AND LARGER MACHINES. IT SHOULD HAVE AT
LEAST A 2" I.D. AND NEVER BE MORE THAN 30" OFF VERTICAL.
LUBRICATION: WARNING: UNITS ARE SHIPPED WITHOUT LUBRICATING OIL. DO NOT ATTEMPT
TO OPERATE WITHOUT LUBRICATING AS BLOWER MAY BE DAMAGED AND GUARANTEE VOIDED.
FILL GEAR CASE BY REMOVING SQUARE HEAD OIL FILL PLUG AND ADD OIL UNTIL OIL DRIPS
OUT PET COCK. DO NOT OVER LUBRICATE. TOO MUCH OIL IN GEAR HOUSING WILL CAUSE
FLOODING AND EXCESS HEATING. USE NO. 40 SAE OIL. BEARINGS AT DRIVE END ARE
PACKED WITH GREASE BEFORE SHIPMENT BUT GREASE SHOULD BE ADDED AS OFTEN AS
NECESSARY. USE SPECIAL HIGH TEMPERATURE BALL BEARING GREASE. CHECK LUBRICATION
EVERY 250 WORKING HOURS.
AIR CLEANER: THE UNIT IS EQUIPPED WITH A VORTOX AIR CLEANER TO PREVENT DAMAGE TO
THE VACUUM PRODUCER IN THE EVENT OF SCREEN FAILURE. SEE INSTRUCTION CARD
ATTACHED TO AIR CLEANER FOR CARE AND OPERATION. BOTTOM CUP MUST BE FILLED WITH
OIL BEFORE USE. CHECK OIL CUP AND SMALL PRE-FILTER AT BOTTOM OF AIR CLEANER
FREQUENTLY AND CLEAN AS OFTEN AS NECESSARY. A RAPID CLOGGING OF THIS AIR CLEANER
MEANS SEPARATOR SCREENS (DUST BAGS) IN LARGE SEPARATOR SHOULD BE CHECKED.
PRIMARY TANK: ON TWO TANK (DMH) MODELS THE PRIMARY TANK IS EQUIPPED WITH A
BAFFLE INSIDE TOP OF TANK TO AGITATE FINES OF FLUX FLOUR WHICH IS CARRIED OVER
BY SUCTION TO SECONDARY TANK WHERE THEY CAN BE QUICKLY DISPOSED OF BY EMPTYING
THE FLAT BOTTOM BUCKET ON THIS TANK.
SECONDARY TANK: SECONDARY TANK ON POWER UNIT IS EQUIPPED WITH SEPARATOR SCREENS
(DUST BAGS) WHICH SEPARATE THE FINES FROM THE AIR, ALLOWING NOTHING BUT PURE AIR
TO PASS THROUGHT THE VACUUM PRODUCER. THESE BAGS SHOULD BE CLEANED FREQUENTLY TO
MAINTAIN HIGH EFFICIENCY AND LONG BAG LIFE.
PARTS LIST
RELIEF VALVE: RELIEF VALVE ON THE MACHINE IS SET AT THE FACTORY FOR THE MAXIUM
VACUUM THE MOTOR CAN CREATE WITHOUT OVER-LOADING AND THE ADJUSTMENTS ON THIS
VALVE SHOULD NOT BE CHANGED.
SLAG SCREEN: A WIRE SCREEN SEPARATING THE FUSED (SLAG) PIECES FROM THE USEABLE
FLUX IS LOCATED IN THE TOP OF THE OVERHEAD (PRIMARY) SEPARATOR. THIS SHOULD BE
REMOVED AS OFTEN AS NECESSARY AND THE FUSED FLUX DISPOSED OF SO THERE WILL NOT
BE AN ACCUMULATION AT THIS POINT WHICH COULD PREVENT THE USEABLE FLUX FROM
FLOWING INTO THE BOTTOM OF THE HOPPER. IT IS MOST ADVISABLE TO LOCATE THE PICK
UP TOOL IN A POSITION WHICH WILL PREVENT PICKING UP ANY QUANTITY OF THIS SLAG.
WHERE PICKUP IS MADE FROM A PAN OR TROUGH UNDER THE WELDING ARC THIS CONTAINER
SHOULD BE COVERED WITH A 1/8" TO 1/4" MESH SCREEN. THIS ALLOWS A VERY EASY AND
CONVENIENT REMOVAL OF SLAG FROM THE SYSTEM.
PICK UP HOSE: PICKUP HOSE SHOULD BE AS SHORT AS POSSIBLE TO AVOID ANY LOOPS OR
TRAPS IN THE HOSE THAT MIGHT TEND TO CREATE A POCKET. THE FLUX IS VERY HEAVY AND
WILL CLOG EASILY IN A POCKET.
BELT: BELT SHOULD BE REASONABLY TIGHT. NOT TOO TIGHT. TO ADJUST BELT TENSION,
LOOSEN LOCKING NUTS ON PLATFORM ADJUSTING STUDS. THEN LOOSEN MOTOR PLATFORM
BOLTS. TURN BOTH STUDS MOVING MOTOR PLATFORM AWAY FROM VACUUM PRODUCER UNTIL
PROPER BELT TENSION IS OBTAINED. MAKE CERTAIN BOTH SHEAVES REMAIN IN ALIGNMENT.
TIGHTEN LOCKING NUTS ON ADJUSTING STUDS.
Installation,
Lubrication
and
Maintenance
Instructions
CONGRATULATIONS!
Your decision to purchase an American Crafted Speed Reducer from Grove Gear
will provide you with many years of trouble free service if the following
installation and maintenance instructions are adhered to.
Instruction Manual
Selection Information
Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation,
maintenance or operation.
Written authorization from Grove Gear is required to operate or use reducers in man lift or people moving devices.
Check to make certain application does not exceed the allowable load capacities published in the current catalog.
Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply the
product. The application by Buyer shall not be subject to any implied warranty of fitness for a particular purpose.
Safety Alert
WARNING • For safety, Buyer or User should provide protective guards over all shaft extensions and any moving
apparatus mounted thereon. The User is responsible for checking all applicable safety codes in his area
and providing suitable guards. Failure to do so may result in bodily injury and/or damage to equipment.
• Hot oil and reducers can cause severe burns. Use extreme care when removing lubrication plugs and vents.
• Make certain that the power supply is disconnected before attempting to service or remove any
components. Lock out the power supply and tag it to prevent unexpected application of power.
• Reducers are not to be considered fail safe or self-locking devices. If these features are required, a
properly sized, independent holding device should be utilized. Reducers should not be used as a brake.
• Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way so as to
not subject the reducer to loads beyond the catalog rating.
• Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other
associated attachments or motors.
• Use of an oil with an EP additive on units with backstops may prevent proper operation of the backstop.
Injury to personnel, damage to the reducer or other equipment may result.
• Overhung loads subject shaft bearings and shafts to stress which may cause premature bearing failure
and/or shaft breakage from bending fatigue, if not sized properly.
CAUTION • Test run unit to verify operation. If the unit tested is a prototype, that unit must be of current production.
• If the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply,
then precautions must be taken to avoid the ingestion of contaminants such as water and the reduction in
cooling ability due to exterior contaminants.
• Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for
proper operation.
Important Information
In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a
conspicuous place and in a conspicuous manner in a written agreement covering such sale:
The manufacturer makes no warranties or representations, express or implied, by operation of law or otherwise,
as to the merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges
that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their
intended use. In no event will the manufacturer be liable for consequential, incidental or other damages. Even
if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section
2-719 of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for consequential
damages.
Resellers/Buyers agree to also include this entire document including the warnings above in a conspicuous place and in a
conspicuous manner in writing to instruct users on the safe usage of the product.
This instructions manual should be read together with all other printed information such as catalogs, supplied by Grove Gear.
Installation
1. Mount the unit to a rigid flat surface using grade 5 or higher fasteners. The mounting fasteners should be the largest standard size
that will fit in the base mounting hole. Shim as required under flange or base feet which do not lie flat against the mounting surface.
2. For shipment, pipe plugs are installed in the unit and a vent plug is packed separately. After mounting the unit in position, remove
the appropriate pipe plug and install the vent plug in the location shown on page 5. On double reduction units both the primary
and the secondary must be vented. Failure to vent the unit can cause premature seal wear or loss of seal and oil. These conditions
are not covered by warranty. Check for correct oil level. Contact the factory for level and vent recommendations on non-standard
mounting positions. Grove Gold units with optional internal pressure compensating system do not use vents. See (internal pressure
compensating system) under Lubrication for further information.
3. Grove Gold units include synthetic oil and an internal pressure compensation system pre-installed at the factory. It is not necessary
to vent these units, and they can be used as supplied from the factory. Do not loosen the nut holding the stem of the pressure
compensator, and do not block the hole in the stem. Do not blow pressurized air into the hole, and avoid spraying washdown
chemicals directly into the hole.
4. Connect motor to speed reducer.
WARNING Depending upon gear geometry and operating conditions worm gear reducers may or may not backdrive.
Special consideration should be given to high inertia loads connected to the output shaft. Consult the
factory for further details.
CAUTION DO NOT CHANGE MOUNTING POSITIONS WITHOUT CONTACTING FACTORY.
Altering the mounting position may require special lubrication provisions which must be factory installed.
CAUTION Do not operate the reducer without making sure it contains the correct amount of oil. Do not overfill or
underfill with oil, or injury to personnel, reducer or other equipment may result. Grove Gold units are
lubed and sealed for life, so in most applications it will not be necessary to drain or re-fill the unit.
CAUTION A unit cannot be used as an integral part of a machine superstructure which would impose additional
loads on the unit other than those imposed by the torque being transmitted either through a shaft-
mounted arrangement, and any shaft mounted power transmitting device. (e.g., sprockets, pulleys,
couplings)
CAUTION For safe operation and to maintain the unit warranty, when changing a factory installed fastener for any
reason, it becomes the responsibility of the person making the change to properly account for fastener
grade, thread engagement, load, tightening torque and the means of torque retention.
Change Intervals: Standard compounded lubricants should be changed every six months or 2500 operating hours, whichever comes first.
Factory installed synthetic lubricants should be changed every two years or 6000 hours, whichever comes first.
Internal pressure compensating system: Grove Gold and stainless steel reducers come standard with an internal pressure
compensating system and synthetic oil pre-installed at the factory. It is not necessary to vent these reducers, and they can be used as
supplied from the factory.
CAUTION In the Food and Drug Industry (including animal food), consult the lubrication supplier for
recommendation of lubricants which are acceptable to the Food and Drug Administration and/or other
authoritative bodies having jurisdiction. Factory supplied oil is not suitable for these applications or this
industry.
CAUTION Do not mix different oils in the reducer. Oils should be compatible with Viton® seal material.
The precision-made gears and bearings in Grove Gear Speed Reducers require high-grade lubricants of the proper viscosity to maintain
trouble-free performance. For best results, use lubricants on the following chart for worm gear reducers:
Some gear lubricants contain E.P. additives that can be corrosive to gear bronze. Avoid lubricants that are compounded with sulfur and/or chlorine.
For lubrication requirements of Grove Gold or helical reducers (primaries of helical/worm reducers, ratio multipliers, and styles BAMCQ,
BAMC, and BA), contact factory.
CAUTION Always check for proper oil level after filling. Capacities vary somewhat with model and mounting position.
Oil should rise to bottom edge of level hole. Do not overfill.
Synthetic Lubricants
Synthetic lubricants provide the potential for numerous benefits including wider temperature range and increased interval between
changes. Use of synthetics can cause problems if they are not compatible with the seals or the conventional lubricants they replace. For
continuous duty at normal ambient temperatures (-10°F to 105°F) we recommend the use of Mobil SHC 634 which is compatible with the
standard compounded oil shipped in our product and the Viton® seal material used through size 252. For other temperatures, or for
intermittent operation below 20° F, contact the factory for a recommendation.
For synthetic lubrication to be used in helical reducers (primaries of helical/worm reducers, ratio multipliers, and styles BAMCQ, BAMC,
and BA), contact factory.
CAUTION In the Food and Drug Industry (including animal food), consult the lubrication supplier for recommenda-
tion of lubricants which are acceptable to the Food and Drug Administration and/or other authoritative
bodies having jurisdiction. Factory supplied oil is not suitable for these applications or this industry.
Standard Speed Reducer Mounting Positions & Vent Plug, Level and Drain Locations
VENT VENT VENT VENT VENT
DIPSTICK**
LEVEL*
LEVEL LEVEL
LEVEL
LEVEL
DRAIN
DRAIN
DRAIN
VENT VENT DRAIN
(All primary units have
LEVEL their own oil level.)
LEVEL DRAIN
DRAIN *For 4 1/4” through 6” center distance units (far side plug).
DRAIN
**For 7” center distance & larger units.
Note: High oil level applies to all 4 1/4” center distance & larger secondary & tertiary units
regardless of primary unit type.
~22°
CAUTION Always check for proper oil level after filling. Do not overfill or underfill with oil, or injury to personnel, reducer, or
other equipment may result.
CAUTION Do not mix different oils in the reducer.
Class of Service
All capacity ratings are based on American Gear Manufacturers Association (AGMA) Standards. Load conditions must be within cataloged
ratings published in the current Grove Gear Catalog (available upon request).
Warranty From Grove Gear - See catalog pages 192-195 for warranty terms and conditions.
A Division of REGAL-BELOIT
1524 15th Avenue • Union Grove, WI 53182
Phone: 262-878-1221 • Fax: 262-878-1968 • www.grovegear.com 6-02/BH
RETURN TO MAIN INDEX
IM642-B
DC-600 May, 2004
For use with machines having Code Numbers: 10558 to 10701,11071, 11072,11129,
11130, 11131, 11132, 11133 and 11140
OPERATOR’S MANUAL
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.
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.
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
3.g. Never dip the electrode in water for cooling. products.
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.
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
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique: 8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains. des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on câbles jusqu’à ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans 9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse. galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement. 10. Ne pas souder en présence de vapeurs de chlore provenant
d. Ne jamais plonger le porte-électrode dans l’eau pour le d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir. chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines. 11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de voir le code “Code for safety in welding and cutting” CSA
courant pour soudage semi-automatique, ces precautions Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I’installation et l’entretien du poste seront
l‘arc. effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l’huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.
DC-600
v v
Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
TABLE OF CONTENTS vi
Page
Installation .......................................................................................................Section A
Technical Specifications ............................................................................................. A-1
Safety Precautions ..................................................................................................... A-2
Select Proper Location.................................................................................................A-2
Limit on Stacking ...................................................................................................A-2
Stacking .................................................................................................................A-2
Tilting .....................................................................................................................A-2
Electrical Input Connections ....................................................................................... A-3
Fuses and Wire Sizes............................................................................................A-3
Ground Connection .............................................................................................. A-3
Input Power Supply Connections...........................................................................A-3
Reconnect Procedure ................................................................................................ A-4
Output Connections ................................................................................................... A-7
Electrode, Work and #21 Lead ..............................................................................A-7
Auxiliary Power and Control Connections .............................................................A-8
________________________________________________________________________
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-4, 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
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 600 44
60% Duty Cycle 680 44
50% Duty Cycle 750 44
OUTPUT
Output Range Maximum Open Circuit Voltage Auxiliary Power
70A/13V-780A/44V (CV) 72V for 60 HZ models See the OPERATION section
90A/24V-780A/44V (CC) 69V for 50/60 HZ models 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
200 50/60 128 1 (43) 6 (14) 175 Amp
220 50/60 116 2 (34) 6 (14) 175 Amp
380 50/60 67 6 (14) 8 (8.4) 100 Amp
400 50/60 64 6 (14) 8 (8.4) 100 Amp
415 50/60 61 6 (14) 8 (8.4) 100 Amp
440 50/60 58 6 (14) 8 (8.4) 90 Amp
500 50/60 51 8 (8.4) 8 (8.4) 80 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
A-2 INSTALLATION A-2
SAFETY PRECAUTIONS STACKING
Read entire Installation Section before installing Three DC-600 machines can be stacked.
the DC-600.
DO NOT stack more than three machines in one
grouping.
ELECTRIC SHOCK CAN KILL.
DO NOT stack the DC-600 on another type of
WARNING machine.
• Do not touch electrically hot parts. 3. Stack the second machine on top of it by
aligning the two holes in the base rails of the
• Always connect the IDEALARC second machine with the two pins on top front
DC-600 grounding terminal to a good electrical of the bottom machine.
earth ground.
4. Repeat process for third machine.
• Set the DC-600 Power ON/OFF PUSH BUTTON to
the OFF position when connecting power cord to NOTE: The machines must be stacked with the Case
input power. Front of each machine flush with each other. See
Figure A.1.
__________________
SELECT PROPER LOCATION
STACKING HOLE
Place the welder where clean cooling air can freely
circulate in through the front louvers and out through
the rear louvers. Dirt, dust or any foreign material that
can be drawn into the welder should be kept at a mini-
mum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
shut-downs.
DC-600
A-3 INSTALLATION A-3
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.2 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.
GROUND CONNECTION
DC-600
A-4 INSTALLATION A-4
Failure to follow these instructions can cause 3. For 380/500-460/575, see Figure A.6. (M15011)
immediate failure of components within the
machine. 4. For 460 and 440 Single Voltage, see Figure A.7.
(S17894)
When powering welder from a generator be sure
to turn off welder first, before generator is shut 5. For 230/460/575, see Figure A.8. (M15666)
down, in order to prevent damage to the welder
6. For Voltages not listed, see the Input Connection
------------------------------ Diagram pasted on the inside of the Case
Back Input Access Door.
U 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.
GND H1 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H2 H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT
TRANSF.
DC-600
A-5 INSTALLATION A-5
L1 U L1 U
GND H1 GND H1
H3 LINK H2 LINK
TAPE TAPE
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT 1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION. LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR. 2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN. AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES. 4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN 5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS ALL HEX NUTS
FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines
DC-600
A-6 INSTALLATION A-6
L1 U
GND
DC-600
A-7 INSTALLATION A-7
OUTPUT CONNECTIONS
See Table A.1 for recommended DC-600 cable sizes for combined lengths of electrode and work cables.
TABLE A.1
DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable
at 100% Duty Cycle
ELECTRODE, WORK AND #21 LEAD
CONNECTIONS
5. Connect electrode lead to the desired terminal FIGURE A.9 - Output Terminals.
(positive/negative).
B. Connect #21 Work Sense Lead to Proper
6. Tighten the output terminal nut with a wrench. Terminal
7. Connect the work lead to the other output There are two work sense lead connection points (+21
terminal following steps 4-6. and -21) on terminal strip (T.S.2) located behind the
hinged access panel on the right side of the case
front. See 14 Pin MS Type Receptacle section or
Terminal Strip Section for connection procedure.
DC-600
A-8 INSTALLATION A-8
AUXILIARY POWER AND PIN LEAD NO. FUNCTION
CONTROL CONNECTIONS
A 32 115 VAC
Located at the left side of the front of the welder B GND Chassis Connection
behind a hinged cover is a 115VAC duplex receptacle C 2 Trigger Circuit
for auxiliary power (60 Hertz Models only). On the right D 4 Trigger Circuit
side of the case front is a 14 Pin MS type receptacle E 77 Output Control
for connection of auxiliary equipment such as wire F 76 Output Control
feeders. Also, terminal strips with 115VAC and con- G 75 Output Control
nections for auxiliary equipment are located behind the 2
H 21 Work Sense Connection
hinged access panel on the right side of the case front.
I 41 42 VAC
(see Auxiliary Power Table for details) 1.
J 31 115 VAC
K 42 42 VAC
AUXILIARY POWER TABLE
Voltage and Circuit Breaker Ratings at Auxiliary Power
L --- ---
Connections for Various Models M --- ---
Auxiliary 60 Hz 50/60 Hz N --- ---
Power Models Models
Connections TERMINAL STRIPS
D=4
G=75
E=77 F=76
M
DC-600
B-1 OPERATION B-1
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
• Do not use AC welder if your cloth-
ing, gloves or work area is damp or
if working on, under or inside work-
piece.
Use the following equipment:
-Semiautomatic DC constant voltage
(wire) welder.
-DC manual (stick) welder.
-AC welder with reduced voltage
control.
• Do not operate with panels removed.
• Disconnect input power before ser-
vicing.
-------------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF &
OTHERS.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc,
or both,to keep fumes and gases
from your breathing zone and gener-
al area.
WELDING, CUTTING and GOUG-
ING SPARKS can cause fire or
explosion.
• Do not weld near flammable material.
• Do not weld, cut or gouge on contain-
ers which have held flammable materi-
al.
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
• White 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
FCAW/GMAW)
wire feeder, circuit breaker protected.
• 115VAC 15 Amp duplex plug receptacle available
Three models are available:
on 60 Hertz models, circuit breaker protected.
• Multi-functional terminal strip for easy connection
• Domestic - all 60 Hertz models except
of wire feeding control cables.
230/460/575V.
• Recessed output terminals to avoid any person or
• Canadian-230/460/575V 60 Hertz models
object from accidentally coming into contact with
• Export-50/60 Hertz models
the output terminals and labeled " + " and " - " for
easy identification.
The optional Multi-Process Switch allows the user to
• Thermostatically protected power source.
switch between semi-automatic or automatic welding
• Electronic protection circuit to protect power
and stick welding or air/carbon arc cutting without dis-
source against overloads.
connecting the wire feeder equipment control, elec-
• Input line voltage compensation to provide an
trode,and work leads.
essentially constant output.
• SCR electronically controlled welder output pro-
RECOMMENDED PROCESSES AND vides extra long life, especially for highly repetitive
EQUIPMENT welding applications.
• Solid state 2 and 4 circuit for extra long life.
The DC-600 is designed for GMAW (MIG), FCAW, • Two circuit solid state control system provides
and submerged arc (SAW) within the capacity of the maximum performance and circuit protection.
machine. It can also be used for stick welding • Low profile case provides maximum use of space.
(SMAW) and for air carbon arc (AAC) cutting with car- • Convenient access to all controls.
bon rods up to 3/8" diameter. • Output lead strain relief loops to prevent terminal
and cable damage.
The DC-600 is provided with a three position mode • Easily removed case side, even when stacked.
switch that selects CV Innershield, CV Submerged • Outdoor operation because enclosure is designed
Arc, or CC Stick. with air intake louvers that keep dripping water
from entering the unit. Transformer, SCR bridge,
The DC-600 can be easily connected to wire feeding and choke have special corrosion resistant paint
equipment, including: for added protection.
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).
WARNING Identification
TERMINALS ON/REMOTE Switch
Warning 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
Line Connection
5
1
7
6
4
7
2
9
1
10
DC-600
2
Flux Cored Arc Welding (FCAW) 11
10
Shielded Metal Arc Welding (SMAW)
12
13
Submerged Arc Welding (SAW)
FIGURE B.1 - CONTROL PANEL KEYS
1. Input POWER ON/OFF Switch
Designates welder complies with This toggle switch turns the machine on or off.
R
both Underwriters Laboratories (UL) Putting the switch in the ON “ ” position ener-
standards and Canadian Standards gizes the machine’s input contactor applying input
NRTL/C power to the machine. Switching the switch to the
Association (CSA) standards. (60
OFF “ ” position de-energizes the input con-
Hertz Models) tactor.
2. POWER Light
When the POWER switch is in the ON position the
machine’s white POWER light will illuminate. If the
input contactor de-energizes the machine in an
abnormal situation the pilot light will still illuminate.
In this situation it may be necessary to reset the
machine by switching the POWER switch to the
OFF and then to the ON position. (See Overload,
Overcurrent, and Fault Protection Section)
DC-600
B-5 OPERATION B-5
3. OUTPUT CONTROL 11.Terminal Strip Cover Panel
This control provides continuous control of the Rotate this panel to gain access to the circuits
machine’s output voltage and current from mini- made available at the two terminal strips (T.S.1
mum to maximum (typical full pot range between and T.S.2). These terminal strips contains the
15 to 44 volts and 90 to 750 amps) as it is rotated same circuits as the 14 pin MS-receptacle. There
clock-wise. Voltage or current control is deter- is a box connector adjacent to this cover for routing
mined by setting of Mode Switch (CV or CC). leads to the terminal strips.
DC-600
B-6 OPERATION B-6
The power source circuitry is protected from faults on REMOTE CONTROL OF MACHINE
leads 75, 76, or 77. If any of these leads are connect-
ed to either the positive or negative output leads, the OPERATION
DC-600 will either shut down completely (input con-
tactor opens and white POWER light stays illuminat- The toggle switch on the control panel labeled
ed), or will operate at minimum output thus preventing “Remote - Panel” gives the operator the option of con-
any damage to the DC-600. If DC-600 shuts down, it trolling the machine output from a remote location. If
must be manually started by resetting the POWER in the Remote position a wire feeder with remote con-
ON/OFF toggle switch. trol capabilities or a remote control device such as a
K775 must be connected to terminals 75, 76, and 77.
Refer to Accessories Section for wire feeder remote
OPERATING STEPS information.
The following procedures are for using the DC-600 in
the local control mode of operation. For remote con- WELDING PROCEDURE
trol of the machine, see the Remote Control of RECOMMENDATIONS
Machine Operation section.
Select Welding Mode Switch position based on type of
Before operating the machine, make sure you have all welding to be done.
materials needed to complete the job. Be sure you
are familiar with and have taken all possible safety 1. Innershield Welding (FCAW)/MIG (GMAW)
precautions before starting work. It is important that Welding: Use the CV INNERSHIELD mode.
you follow these operating steps each time you use
the machine. 2. Submerged Arc Welding (SAW): Use the CV
SUBMERGED ARC mode. If performing high
1. Turn on the main AC power supply to the speed welding, switch between the CV
machine. Submerged Arc and the CV Innershield mode and
use the mode that produces the best welding
2. Connect the #21 work lead to either + or - on ter- results.
minal strip (T.S.2).
3. Air/Carbon Arc Cutting (AAC) / Stick Welding
3. Set the Welding Mode switch to welding process (SMAW) / High Current, Large Puddle Submerged
being used: Arc Welding (SAW): Use the CC STICK mode.
When the DC-600 is used for Air/Carbon Arc cut-
• CC STICK (for SMAW and AAC) ting, the OUTPUT CONTROL potentiometer
should be set to "9" initially. Based on the size of
• CV SUBMERGED ARC (for SAW) the carbon being used or the process, turn the
potentiometer to a lower setting as required by the
• CV INNERSHIELD (for FCAW and GMAW) process. You can use carbon rods up to 3/8" in
diameter at currents as high as 750 amps with
4. Turn the POWER ON/OFF Toggle Switch to the excellent arc control. The welder protection circuit
“ON” position protects the machine from extremely high short
circuiting pulses.
• The white pilot light glows.
DC-600
B-7 OPERATION B-7
NA-3 AUTOMATIC WIRE FEEDER • To adjust the Open Circuit Voltage Control to get
the best starting performance, make repeated
1. Set the DC-600 LOCAL/REMOTE Switch to starts observing the NA-3 voltmeter.
REMOTE. Set the OUTPUT TERMINALS switch
to REMOTE. NOTE: Later model NA-3 automatic When the voltmeter pointer swings smoothly up to
wire feeders are capable of cold starts when the the desired arc voltage, without undershooting or
NA-3 Mode switch is in the CV or CC mode posi- overshooting the desired arc voltage, the Open
tion. Some earlier models are capable of cold Circuit Voltage Control is set properly.
starting only in the CC mode position. Cold start-
ing enables you to inch the wire down to the work, If the voltmeter pointer overshoots the desired
automatically stop, and automatically energize the voltage and then returns back to the desired volt-
flux hopper valve. age, the Open Circuit Voltage Control is set too
high. This can result in a bad start where the wire
2. Set the DC-600 welding mode switch for the tends to "Blast off."
desired process: CV SUBMERGED ARC, CV
INNERSHIELD mode or CC STICK mode. If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit Voltage
3. Set the NA-3 mode Switch Position to either CV or Control is set too low.This can cause the elec-
CC to match the DC-600 mode selected in step 2. trode to stub.
4. Refer to the NA-3 operators manual for instruc- 4. Start and make the weld.
tions on how to use the NA-3 in conjunction with
the DC-600. • Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes posi t i v e
5. Follow the following guidelines for good arc strik- contact with the work piece.
ing detailed below for each welding mode.
• Hot "On the Fly" starts. For hot starts, travel
GOOD ARC STRIKING GUIDELINES FOR THE NA- should begin before the wire contacts the work
3 WITH THE DC-600 IN THE CV INNERSHIELD, CV piece.
SUBMERGED ARC OR CC STICK WELDING
MODES. ARC STRIKING WITH DC-600 AND THE NA-3
START BOARD
Following are some basic arc striking techniques that
apply to all wire feed processes. Using these proce- When electrical strikeouts exceed 1 3/4” (44.4mm) an
dures should provide trouble-free starting. \These pro- NA-3 Start Board may be required to improve arc
cedures apply to single, solid wires and Innershield striking.
wires.
When the NA-3 Start Board is used to improve arc
1. Cut the electrode to a sharp point. striking, use the following procedures:
2. Set the NA-3 Open Circuit Voltage Control to the 1. Set start time at 0.
same dial setting as the Arc Voltage Control. If
this is a new welding procedure, a good starting 2. Set NA-3 start current and start voltage at mid-
point is to set the Open Circuit Voltage Control to # 6. range.
NOTE: The open circuit voltage of the 3. Set the NA-3 output current and voltage to the
DC-600 varies from approximately 16 volts to 56 proper settings for the welding procedure to be
volts in the CV INNERSHIELD or CV used.
SUBMERGED ARC modes. The open circuit volt-
age is constant in the CC STICK mode. 4. Turn the Start Board Timer to maximum.
3. Run a test weld. Set proper current, voltage, and 5. Set Start Board current and voltage control.
travel speed.
• Set the Start Board current control to 1 1/2 dial
• For the best starting performance, the NA-3 Open numbers below that set on the NA-3 current control.
Circuit Voltage Control and Voltage Control set-
ting should be the same. Set the Inch Speed • Set the Start Board voltage control equal with the
Control for the slowest inch speed possible. NA-3 voltage control setting.
DC-600
B-8 OPERATION B-8
NOTE: These Start Board current and voltage set- DC-600 POWER SOURCE SETTING WHEN
tings result in a start up current that is lower than CONNECTED TO NA-5 WIRE FEEDER
the NA-3 current setting and approximately equal
with the NA-3 voltage setting for the desired weld- When using the DC-600 with the NA-5 wire feeder, set
ing procedure. the controls on the DC-600 as follows for the best per-
formance:
6. Establish the correct arc striking procedure with
the NA-3 Start Board timer set at maximum. 1. Turn OFF main AC input power supply to the DC-
600.
• For the best starting performance, the NA-3 Open
Circuit Voltage Control and Voltage Control set- 2. Connect the electrode cables to terminal polarity
ting should be the same. Set the Inch Speed to be used.
Control for the slowest inch speed possible.
3. Connect the #21 work lead (on T.S.2) to the
• To adjust the Open Circuit Voltage Control to get
the best starting performance, make repeated
same polarity as the work cable connection.
starts observing the NA-3 voltmeter.
4. Set the DC-600 LOCAL/REMOTE Switch to
When the voltmeter pointer swings smoothly up to REMOTE.
the desired arc voltage, without undershooting or
overshooting the desired arc voltage, the Open 5. Set the DC-600 OUTPUT TERMINALS switch to
Circuit Voltage Control is set properly. REMOTE.
If the voltmeter pointer overshoots the desired 6. Set the DC-600 WELDING MODE SWITCH to the
voltage and then returns back to the desired volt- position that matches the welding process being
age, the Open Circuit Voltage Control is set too used.
high. This can result in a bad start where the wire
tends to "Blast off." • For submerged arc welding, set WELDING MODE
SWITCH to CV SUBMERGED ARC position.
If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit Voltage • For all open arc welding processes set WELDING
Control is set too low. This can cause the elec- MODE SWITCH to CV INNERSHIELD position.
trode to stub.
DC-600
C-1 ACCESSORIES C-1
The DC-600 can be used to power any of the follow- For easy moving of the machine, optional undercar-
ing Lincoln 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.
+
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
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 • Insert the wire feeder electrode and work cables
the switch. Support the switch in position and start through the strain relief loop on the left side of the
the four screws, then tighten them. DC-600 (facing the front of the machine).
5. Route the MULTI-PROCESS SWITCH control • Connect the wire feeder electrode and work
leads through the strain-relief box connectors and cables to the electrode and work
into the terminal strip. Connect wire feeder control terminals on the left side of the MULTI-PROCESS
cable as specified in specific connection diagram SWITCH.
and make other terminal strip connections as
specified on the connection diagram for the 10. Connect wire feeder control cable and make other
Lincoln wire feeder being used. terminal strip connections as specified on the
connection diagram for the Lincoln wire feeder
6. Connect the control leads from the MULTI- being used.
PROCESS SWITCH to terminals #2 and #4 on
the DC-600's terminal strip. 11. Set the DC-600 OUTPUT TERMINALS switch to
REMOTE.
7. Connect the right cable from the MULTI-
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
• 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.
• Connect the electrode cable to the "Positive" ter- 2. Set the DC-600 LOCAL/REMOTE switch to
minal on the right side of the MULTI-PROCESS REMOTE.
SWITCH.
3. Set the DC-600 OUTPUT TERMINALS switch to
• Connect the work cable to the "Negative" terminal REMOTE.
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.
DC-600
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN
KILL.
Only qualified personnel should
perform this maintenance.
Perform Periodically:
• Control board.
• Firing board.
• Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
DC-600
E-1 TROUBLESHOOTING E-1
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
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 Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-2 TROUBLESHOOTING E-2
3. If the problem persists, replace the suspect PC • If the original problem does not reappear by substi-
board using standard practices to avoid static elec- tuting the original board, then the PC board was not
trical damage and electrical shock. Read the warn- the problem. Continue to look for bad connections
ing inside the static resistant bag and perform the in the control wiring harness, junction blocks, and
following procedures: terminal strips.
P.C. Board can be damaged by static electricity.
• If the original problem is recreated by the substitu-
• Remove your body’s static tion of the original board, then the PC board was
charge before opening the static- the problem. Reinstall the replacement PC board
shielding bag. Wear an anti-static and test the machine.
wrist strap. For safety, use a 1
Meg ohm resistive cord connect- 6. Always indicate that this procedure was followed
ATTENTION ed to a grounded part of the when warranty reports are to be submitted.
Static-Sensitive equipment frame.
Devices NOTE: Following this procedure and writing on the
Handle only at • If you don’t have a wrist strap,
warranty report, “INSTALLED AND SWITCHED PC
Static-Safe touch an unpainted, grounded,
BOARDS TO VERIFY PROBLEM,” will help avoid
Workstations part of the equipment frame.
denial of legitimate PC board warranty claims.
Keep touching the frame to pre-
Reusable vent static build-up. Be sure not
Container to touch any electrically live parts
Do Not Destroy at the same time.
DC-600
E-3 TROUBLESHOOTING E-3
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-5 TROUBLESHOOTING E-5
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-6 TROUBLESHOOTING E-6
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-7 TROUBLESHOOTING E-7
Observe all Safety Guidelines detailed throughout this manual
2. Put LOCAL/REMOTE
SWITCH (SW3) in "LOCAL"
position. If problem is
solved then check remote
control unit or wire feeder.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-8 TROUBLESHOOTING E-8
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-9 TROUBLESHOOTING E-9
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-10 TROUBLESHOOTING E-10
Observe all Safety Guidelines detailed throughout this manual
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
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-11 TROUBLESHOOTING E-11
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-12 TROUBLESHOOTING E-12
Observe all Safety Guidelines detailed throughout this manual
PC BOARD TROUBLESHOOTING GUIDE Voltage across leads 255 and 256 should be
approximately 115VAC. Check voltage across sec-
FIRING P.C. BOARD ondary winding of the control transformer (T2) which
supplies leads 255 and 256. Measure +16VDC from
1. All 10 LED’s must be ON when the POWER TEST POINTS “A” to “C” and -10VDC from TEST
SOURCE is turned “ON” and the trigger circuit* is POINTS “A” to “J” on Control board.
closed.
2. LED 2 indicates welder output voltage is being sup-
2. LED’s 7, 8, and 9 indicate AC power being supplied plied to the control circuit. LED 2 will be “ON”
to the P.C. board from auxiliary windings on the brightly in CC STICK mode with trigger circuit*
main transformer (T1). If a LED is not “ON”, turn the closed and no load. (LED 2 diminishes in bright-
machine off and unplug P5 from the firing board. ness as output voltage is reduced). If LED 2 is not
Turn the machine back on and check the following “ON”, look for open connection in lead 222 circuit.
voltages:
LED that Check AC voltage between pins specified, 3. LED 3 indicates power is being applied to FAULT
was off it should be approximately 32VAC . PROTECTION RELAY (CR2). LED 3 will be “ON”
7 P5 pins 15 & 16 (wires 203,204) when machine POWER is “ON”. LED 3 goes “OUT”
8 P5 pins 7 & 8 (wires 205,206) when CR2 drops out which turns off the INPUT
9 P5 pins 5 & 6 (wires 207,208) CONTACTOR (CR1). When LED 3 goes out, LED 4
comes “ON”. See step 3.
3. If all voltages are present, turn power off, and plug
P5 back into J5. Turn power back on. If LED’s are 4. LED 4 indicates an overload or fault condition; LED
still “OUT”, replace Firing PCB. should not be on. If this LED comes “ON”, the
INPUT CONTACTOR (CR1) will turn off and the red
4. If voltages were not present then check the wiring POWER light stays illuminated. This was do to
back to the auxiliary windings for a possible open. either a short across output, or a current draw in
excess of 780A, or leads 75, 76, or 77 grounded to
5. LED 10 senses when trigger circuit* is closed. negative output lead. Remove short or reduce out-
Close trigger circuit, LED10 should be on be “ON”. put current or eliminate ground. Welder must be
Open trigger circuit, LED 10 should be “OFF”. If reset by turning POWER ON/OFF switch to “OFF”
LED does not come “ON”, check to make sure and then back to “ON”. If no short or loads above
leads 2,4, or 41 are not broken. 780A exists or no ground, replace Control PCB.
6. LED’s 1 through 6 indicate gate signals are being 5. LED 5 indicates DC control voltage (which supplies
sent to the main SCR’s 1 through 6 respectively. If Firing board) is present. LED 5 will be “ON” in CV
LED 5 (located on Control Board) is “ON”, along INNERSHIELD mode with trigger circuit* closed,
with LED’s 7, 8, and 9 (on Firing PCB), and LED’s 1 CONTROL POT at minimum, and no load. (LED 5
through 6 are “OFF”, check to make sure lead 231 diminishes in brightness as output voltage is
between Control board and Firing board is not bro- increased). Replace P.C. board if LED 5 did not go
ken “ON”.
7. If any one of LED’s 1 through 6 are “OFF” and 6. LED 6 indicates trigger circuit* condition. LED 6
LED’s 7, 8, and 9 are “ON”, replace the Firing PCB. “ON” indicates trigger circuit is closed. LED 6 “OFF”
indicates trigger circuit is open. If LED 6 does not
PC BOARD TROUBLESHOOTING GUIDE come “ON”, when trigger circuit closed, look for
CONTROL P.C. BOARD open connections in the 2 & 4 circuit and in leads
290 and 291.
1. LED 1 indicates AC input voltage necessary to gen-
erate the DC supply voltages is present. These volt- TRIGGER CIRCUIT is closed by any of the following:
ages power the Control board circuitry. If LED 1 is • Wire feeder’s trigger is closed.
not “ON” when machine POWER is “ON”, check • A jumper is placed across 2 & 4 on terminal strip
leads 255, 256, X1, and X2 for broken connection. T.S.2. or across pins C & D in 14 pin connector.
• OUTPUT TERMINAL switch is in the “ON” position.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
E-13 TROUBLESHOOTING E-13
Observe all Safety Guidelines detailed throughout this manual
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
F-1
WIRING DIAGRAM FOR CODES 10588, 10701, 11129, 11130, 11131, 11140
SINGLE VOLTAGE OVER 345 V.
H3 TO (EXCEPT 440 & 460V.) DUPLEX (ON 60 HZ MACHINES ONLY)
SUPPLY 32 42 31
H1 GND
LINES
272
TO GROUND 41 CIRCUIT
15A OUTPUT
PER NATIONAL A J 31 BREAKER
3 9 6 32 TERM.
ELECTRICAL I
B 32A T.S.2 WELDING MODE
L3 CODE SWITCH
2 8 5 K 32 236 SWITCH S4
2 21 S2
L2 R1 (SHOWN IN CC
1 7 C L N H 31
4 RECONNECT
4 75 STICK POSITION)
L1 PANEL 10K 2W
M R.F.
CR1 4 D G OUTPUT 237
TO PRIMARY COILS
CHOKE 42 2
271 INPUT E F CONTROL
CONTACTOR N.C. AS’BLY 2 2
42
DUAL EXCEPT 380/500V AND 14 PIN 77 76 75 81
TO 4 4
H2
SINGLE VOLTAGE UNDER 346V. RECEPT. LOCAL/
H1 SUPPLY 76
(SHOWN CONNECTED FOR LOW VOLTAGE) 41 77
LINES (FRONT 41 REMOTE 80
272 41 226 SWITCH 232
VIEW) -
222 21 S3
9 TO GROUND
3 6 - 222
PER NATIONAL
+
L3
VM 210 21
ELECTRICAL H1 H2 H3
+
2 8 5 210
CODE CONTROL 237 236 280 215
L2
1 7 4 T2 TRANSFORMER
RECONNECT 229 224
L1 238
PANEL
X1
CR1
TO PRIMARY COILS 255 X2
271 INPUT FAULT
S1
CONTACTOR
INPUT PROTECTION R.F.
255 75 76 77
380/500V. & 460/575V.
POWER CHOKE
RELAY
SWITCH CR2
(SHOWN CONNECTED AS’BLY
FOR LOW VOLTAGE) 7 5
H2 TO T.S.1
271 255
H1 SUPPLY
LINES
272
A B
TO GROUND PILOT
W 235
PER NATIONAL LIGHT
15 3 CIRCUIT 233 1 1 229
ELECTRICAL
L3 CODE 10A BREAKER 233 256 2 2 75
14 2 256
T1 MAIN TRANSFORMER 42 3 3 232
L2
13 1 RECONNECT 4 4 80
L1 PANEL
PRIMARY 256
231 5 J2 5 226
272 THERMOSTAT
CR1 255 6 81
TO PRIMARY COILS 6
271 INPUT 273 J1
1 S 2 42A 3 32A 290 7 7
CONTACTOR
S SEC. LEAD 291
31 S 8 8 280
H2 220/380/440 VOLT N.A. THERMOSTAT
TO 13 AUX.2 14 F 41 15 F 31 TWISTED 238 9 9
H1 F
SUPPLY TOGETHER 10 10
PRI. 235 215
272 LINES 207
TO GROUND F F F R.F. 11 224
203 205 210 1
PER NATIONAL LEADS 4 6 CHOKE J3
4 S 5 S S 12 222
11 3 9 6 ELECTRICAL FAN 215 2
THRU 9 TO AS’BLY
L3 CODE AUX. 1 MOTOR
10 2 RECONNECT 204 206
8 5 208 32A CONTROL
L2 RECONNECT PANEL 7 8 9 R.F.
12 1 7 4 PANEL (SHOWN P.C. BOARD CHOKE
L1 CONNECTED
FOR 380V.)
PRI. N.B. AS’BLY
CR1
N.B.
271 TO PRIMARY COILS
INPUT
11 12 R2 214
CONTACTOR 10
222 222 30 100W G1 1 1 41
SINGLE VOLTAGE 440V & 460V 222
H3 G2 2 2
H1
G3 3 3
J4
3 G4 4 4 2
L3 TO (-)
SEC. G5 5 5 208
2 SUPPLY
222
L2 G6 6 6 207
LINES
J5
1 7 206
L1
A 1 8 205
CR1 TO GROUND
DC-600
.05 B 2 9 4
271 PER NATIONAL
INPUT mFd
ELECTRICAL 3 10 290
CONTACTOR
CODE SEC.
272 B’ 4 11 291
OUTPUT .05 J7
mFd C 5 12 215
CHOKE
OUTPUT
NOTES: C’ 6 13 231
C7
N.A. LEADS 4 THRU 9 ARE NOT PRESENT ON 7 14 214
460V., 380/500V. & 460/575V. MACHINES. N.D. A’ 8
DIAGRAMS
15 203
N.B. THERE IS NO 10, 11 AND 12 CONNECTION 16 204
210
ON 220/380/440 VOLT MACHINES. P22
N.C. LOCATION OF THIS LEAD ON T.S.2 TERMINAL STRIP
AM J6 1 261 1
MAY VARY. SEE IM MANUAL FOR LOCATION. 210 (+)
+ - 2 262 2
G1 G3 G5 SCR
N.D. WELDING CABLE MUST BE OF THE PROPER A A A FIRING CIRCUIT 3 263 3
SNUBBERS 4 4
CAPACITY FOR THE CURRENT AND DUTY CYCLE P.C. BOARD 342
215 210
OF IMMEDIATE AND FUTURE APPLICATIONS. 2
SCR SCR SCR + - J23
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY 1 3 5 FOR OPTIONAL
320V 4
"POSITIVE". TO CHANGE THE POLARITY, TURN PARALLELING
210 160J
THE DC-600 OFF, AND REVERSE THE LEADS AT TP1 KIT
OUTPUT SHUNT 215
THE MULTI-PROCESS SWITCH. (50MV @800 AMPS)
C1
N.F. USING A WIRE FEEDER, K-317 OR K-318 C C C
.05mFd
CONNECTION DIAGRAM, CONNECT ELECTRODE
OUTPUT 600 V
AND WORK LEADS TO THESE TERMINALS
SNUBBER C C C 215
INSTEAD OF THE POWER SOURCE
OUTPUT TERMINALS.
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
NECESSARY TO HAVE SEPARATE GROUND
6 10 8 8 16 MULTI-PROCESS USED.
14
CABLES FOR STICK AND SEMI-AUTOMATIC
SWITCH WELDING.
CONNECTOR CAVITY NUMBERING SEQUENCE
G3506
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
F-2
WIRING DIAGRAM FOR CODES 11071, 10702, 11073, 111073, 11132, 11133
H4 230/460/575V DUPLEX (ON 60 HZ MACHINES ONLY)
N.G. H3 (SHOWN CONNECTED 32 42 31
H2 TO FOR LOW VOLTAGE) GND FOR MACHINES WITH A GFCI
H1 SUPPLY
LINES 41 RECEPTACLE, LEAD 31 CONNECTS CIRCUIT
272 15A BREAKER OUTPUT
A J TO THE WHITE LINE TERMINAL; LEAD 32 31 32 TERM.
TO GROUND B I CONNECTS TO THE HOT LINE TERMINAL. 32A T.S.2 WELDING MODE
9 K 32 SWITCH 236
3 PER NATIONAL 2 21 S2 SWITCH S4
L3 6 ELECTRICAL
8 C L N H 31 R1 (SHOWN IN CC
5
(SILVER)
2 CODE 4 75 STICK POSITION)
L2 4 10K 2W
7 M R.F.
L1
A
1 RECONNECT 4 D G CHOKE OUTPUT 237
PANEL E F 42 2
CR1 N.C. AS’BLY 2 2 CONTROL
271 INPUT TO PRIMARY COILS 42
14 PIN 77 76 75 4 81
CONTACTOR 4
RECEPT. LOCAL/
41 76 77
18,17,16 15,14,13 (FRONT 41 41 REMOTE 80
226 SWITCH 232
VIEW) 222 21-
N.G. N.G. S3
- 222 +
H1 H3 VM 210 21
H2
+
210
CONTROL 237 236 280 215
T2 TRANSFORMER
229 224
X1 238
255 X2
S1 FAULT
INPUT PROTECTION
255 POWER 75 76 77
R.F.
SWITCH CR2 RELAY CHOKE
7 5 T.S.1 AS’BLY
271 255
A B
W PILOT 235
LIGHT 233
CIRCUIT 1 1 229
10A BREAKER 233 256 2 2 75
256
T1 MAIN TRANSFORMER 42 3 3 232
PRIMARY 4 4 80
256
THERMOSTAT 231 5 J2 5 226
272 255 6 6 81
17 273 290 J1
16 S 42A 18 32A 7 7
31 S SEC. LEAD 291
S 8 8 280
N.G. 1 AUX.2 2 F 41 3 F 31 THERMOSTAT TWISTED 238 9 9
F TOGETHER 235 10 10 215
PRI. 207
F 203 F 205 F R.F. 210 1 11 224
ALL PRIMARY 4 S 5 S 6 S CHOKE J3 12 222
LEADS TO FAN 215 2
AUX. 1 MOTOR AS’BLY
RECONNECT 13 204 206 15
208 32A CONTROL
PANEL 14 R.F.
7 8 9 P.C. BOARD CHOKE
AS’BLY
PRI.
R2 214
222 222 30 100W 41
G1 1 1
222
G2 2 2
G3 3 J4 3
G4 4 4 2
SEC. (-) G5 5 5 208
222
G6 6 6 207
J5 7 206
A 1 8 205
DC-600
.05 B 2 9 4
mFd 3 10 290
SEC. B’ 4 11 291
OUTPUT .05 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
DIAGRAMS
N.D. A’ 8 15 203
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 1 1
AM J6 261
OF IMMEDIATE AND FUTURE APPLICATIONS. 210 (+) 2 2
G1 + - 262
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY A A G3 A G5 SCR 263
FIRING CIRCUIT 3 3
SNUBBERS 4 342 4
"POSITIVE". TO CHANGE THE POLARITY, TURN 215 210 P.C. BOARD
THE DC-600 OFF, AND REVERSE THE LEADS AT SCR SCR SCR - 2 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
CONNECTION DIAGRAM, CONNECT ELECTRODE KIT
215
AND WORK LEADS TO THESE TE RMINALS OUTPUT SHUNT
C C (50MV @800 AMPS) C1
INSTEAD OF THE POWER SOURCE C
OUTPUT TERMINALS. .05mFD
OUTPUT 600 V
N.G. TAPE UP SEPARATELY TO PROVIDE AT SNUBBER C C C
LEAST 600V INSULATION. 215
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-2
CONNECTION OF LN-742 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-3
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
DC-600
INPUT CABLE N.C. PINS NOT LISTED ARE NOT CONNECTED
ELECTRODE CABLE
ASSEMBLY ON CABLE.
DIAGRAMS
S20409
CONNECTION OF LN-7 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-4
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
DC-600
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.)
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.
S22976
CONNECTION OF LN-8 OR LN-9 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-5
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.
N.A. Welding cables must be of proper capacity for the current and
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.
C Connect it directly to the work piece keeping it electrically
N.G.
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
DC-600
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.
marked near the power source terminal strip. The power
source grounding terminal (marked and located near 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" .
REMOTE VOLTAGE SENSING LEAD
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.
For proper setting of switches on power source,
see power source operating manual.
10-30-98F
F-5
S22977
CONNECTION OF NA-3, LT-5 OR LT-7 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
WITH 14 PIN MS-TYPE Disconnect power source before
PLUG CONNECTOR servicing.
N.A. Welding cables must be of proper capacity for the current and
duty cycle of immediate and future applications.
+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
physically suitable for the installation. An S16586-[LENGTH]
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
2 welding work lead. (If the length of work lead circuit is
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
DC-600
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.G. N.D. Connect the control cable ground lead to the frame terminal
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.
10-30-98F
S22978
F-6
CONNECTION OF NA-5/-5R TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-7
14-PIN
RECEPTACLE
POWER SOURCE CONTROL CABLE Do not operate with covers removed.
N.A. Welding cables must be of proper capacity for the current and
duty cycle of immediate and future applications.
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
physically suitable for the installation. An S16586-[LENGTH]
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
32 welding work lead. (If the length of work lead circuit is
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
DC-600
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
N.D. Connect the control cable ground lead to the frame terminal
N.H. marked near the power source terminal strip. The power
source grounding terminal (marked and located near 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,
REMOTE VOLTAGE SENSING LEAD
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-7
CONNECTION OF DH-10 OR LN-10 TO POWER SOURCE WITH 14 PIN AMPHENOL
F-8
LINCOLN servicing.
WIRE
POWER SOURCE Do not touch electrically live parts.
FEEDER
Only qualified persons should install, use or
service this machine.
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.
DC-600
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
C 2 TRIGGER CIRCUIT L N N L
S22980
F-9
38.00 22.25
17.75 11.12
5.90
3.25
27.50
DC-600
39.95
DIAGRAMS
9.20
27.87
1-20-89A
3.25
27.50
37.86
DC-600
DIAGRAMS
7.11
29.93
*
* .94 *
* 20.00
36.12
49.89 27.65
DC-600
NOTES
DC-600
● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
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.
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