operator’s manual idealarc dc 600 - auburn … ® dc-600 operator’s manual ... materials from...
TRANSCRIPT
IDEALARC ® DC-600
Operator’s Manual
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM642-D | Issue D ate 11-Aug
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
10588; 10589; 10590; 10591; 10592; 10593; 10594; 10595; 10596; 10639; 10640; 10641; 10700; 10701; 11071; 11072; 11129; 11130; 11131; 11132; 11133; 11140; 11335; 11336; 11337; 11338; 11339; 11537; 11538; 11539; 11540; 11541; 11568
Register your machine: www.lincolnelectric.com/register
Authorized Service and Distributor Locator: www.lincolnelectric.com/locator
FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
____________________________________________________1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.
____________________________________________________1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND MAGNETIC FIELDSmay be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
IDEALARC® DC-600
iiSAFETYii
IDEALARC® DC-600
ARC RAYS can burn.4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.f. Also see item 1.b.
iiiSAFETYiii
IDEALARC® DC-600
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.
Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d. Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.
c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
IDEALARC® DC-600
vv
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound 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 youhave recorded above. The code number is especially important when identifying the correct replacement parts.
CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.
On-Line Product Registration- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying 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 “Support” and then “RegisterYour Product”. Please complete the form and submit your registration.
vi vi TABLE OF CONTENTSPage
Installation .......................................................................................................Section ATechnical Specifications ............................................................................................. A-1Safety Precautions ..................................................................................................... A-2Select Proper Location.................................................................................................A-2
Limit on Stacking ...................................................................................................A-2Stacking.................................................................................................................A-2Tilting .....................................................................................................................A-2
Electrical Input Connections ....................................................................................... A-3Fuses and Wire Sizes............................................................................................A-3Ground Connection .............................................................................................. A-3Input Power Supply Connections...........................................................................A-3
Reconnect Procedure ................................................................................................ A-4Output Connections ................................................................................................... A-7
Electrode, Work and #21 Lead ..............................................................................A-7Auxiliary Power and Control Connections .............................................................A-8
________________________________________________________________________
Operation .........................................................................................................Section BSafety Precautions ............................................................................................... B-1General Description ............................................................................................. B-2Recommended Processes and Equipment ...........................................................B-2Design Features and Advantages ........................................................................B-2Welding Capability ............................................................................................... B-3Meaning of Graphical Symbols on Case Front ......................................................B-3Meaning of Graphical Symbols on Rating Plate ....................................................B-4Meaning of Graphical Symbol for Ground Connection ..........................................B-4Controls and Settings ....................................................................................B-4, B-5Auxiliary Power in MS - Receptacle.......................................................................B-6Overload, Overcurrent and Fault Protection ..........................................................B-6Operating Steps ................................................................................................... B-7Remote Control of Machine Operation ..................................................................B-7Welding Procedure Recommendations ............................................................... B-7Semi-Automatic and Automatic Wire Feeding with a IDEALARC® DC-600 and Wire Feeders.....................................................B-8
NA-3 Automatic Wire Feeder ..........................................................................B-8NA-5 Automatic Wire Feeder ........................................................................B-10LN-8 Semi-Automatic Wire Feeder ...............................................................B-10LN-7 & LN-9 Semi-Automatic Wire Feeders .................................................B-10
________________________________________________________________________
Accessories .....................................................................................................Section CWire Feeders and Tractors....................................................................................C-1Field Installed Options...........................................................................................C-1
Remote Output Control (K775 or K857)..........................................................C-1Remote Control Adapter Cable (K864) ...........................................................C-1Undercarriages (K817P, K842).......................................................................C-1Paralleling Kit (K1611-1) .................................................................................C-1TIG Module (K930-2) ......................................................................................C-1
Factory or Field Installed Options..........................................................................C-1Multi-Process Switch (K804-1)........................................................................C-1
Connections for Semi-Automatic or Automatic Wire Feeder Control ....................C-3________________________________________________________________________
vii viiTABLE OF CONTENTSPage
Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Routine and Periodic Maintenance........................................................................D-2
Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F
Parts List .....................................................................................................P-349 Series
60% Duty Cycle
122/61122/61/49
6149
128/74/6474/56
64140/70
68
A-1INSTALLATION
IDEALARC® DC-600
A-1
TECHNICAL SPECIFICATIONS – IDEALARC® DC-600
Volts at Rated Amperes444444
Auxiliary PowerSee the OPERATION section
for Auxiliary Power information by model
Amps600680750
Maximum Open Circuit Voltage72V for 60 HZ models
69V for 50/60 HZ models
Duty Cycle100% Duty Cycle60% Duty Cycle50% Duty Cycle
Output Range70A/13V-780A/44V (CV)90A/24V-780A/44V (CC)
INPUT - THREE PHASE ONLY
OUTPUT
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.
RECOMMENDED INPUT WIRE AND FUSE SIZES
StandardVolatge
230/460/60230/460/575/60
460/60575/60
220/380/440/50/60380/500/50/60
440/50/60200/400/50/60
415/50/60
100% Duty Cycle
108/54108/54/43
5443
116/67/5867/51
58128/64
62
50% Duty Cycle
134/67134/67/54
6754
138/80/6980/61
69152/76
73
Input Current at Rated Output
RATED OUTPUT
INPUTVOLTAGE /
FREQUENCY
230460575200220380400415440500
TYPE 75°C(SUPER LAG)OR BREAKERSIZE (AMPS)1
175 Amp90 Amp70 Amp175 Amp175 Amp100 Amp100 Amp100 Amp90 Amp80 Amp
TYPE 75°CGROUND WIRE
IN CONDUITAWG(IEC-MM2) SIZES
6 (14)8 (8.4)8 (8.4)6 (14)6 (14)8 (8.4)8 (8.4)8 (8.4)8 (8.4)8 (8.4)
TYPE 75°CCOPPER WIRE
IN CONDUITAWG(IEC-MM2) SIZES30°C (86°F) Ambient
2 (34)6 (14)8 (8.4)1 (43)2 (34)6 (14)6 (14)6 (14)6 (14)8 (8.4)
INPUT AMPERERATING ON
NAMEPLATE
10854431281166764615851
HERTZ
606060
50/6050/6050/6050/6050/6050/6050/60
PHYSICAL DIMENSIONSHEIGHT30.75 in781 mm
WIDTH22.25 in567 mm
DEPTH39.0 in
988 mm
WEIGHT522 lbs.237 kg.
A-2INSTALLATION
IDEALARC® DC-600
A-2
SAFETY PRECAUTIONSRead entire Installation Section before installingthe IDEALARC® DC-600.
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel shouldinstall this machine.
• Turn the input power OFF at the disconnect switch or fuse boxbeforeworking on the equipment.
• Do not touch electrically hot parts.
• Always connect the IDEALARC IDEALARC® DC-600 grounding terminal to agood electrical earth ground.
• Set the IDEALARC® DC-600 Power ON/OFFPUSH BUTTON to the OFF position when con-necting power cord to input power.
__________________SELECT PROPER LOCATION
Place the welder where clean cooling air can freelycirculate in through the front louvers and out throughthe rear louvers. Dirt, dust or any foreign material thatcan be drawn into the welder should be kept at a mini-mum. Failure to observe these precautions can resultin excessive operating temperatures and nuisanceshut-downs.
LIMIT ON STACKING
STACKING
Three IDEALARC® DC-600 machines can bestacked.
DO NOT stack more than three machines in onegrouping.
DO NOT stack the IDEALARC® DC-600 on anothertype of machine.
Follow these guidelines when stacking:1. Select a firm, level surface capable of sup-
porting the total weight of up to three machines (1570 pounds/712 kilograms).
2. Set the bottom machine in place.
3. Stack the second machine on top of it by aligning the two holes in the base rails of the second machine with the two pins on top front of the bottom machine.
4. Repeat process for third machine.
NOTE: The machines must be stacked with the CaseFront of each machine flush with each other. SeeFigure A.1.
FIGURE A.1 - Stacking IDEALARC® DC-600machines
TILTING
The IDEALARC® DC-600 must be placed on a stable,level surface so it will not topple over.
STACKING HOLE
STACKING PINS
WARNING
• Lift only with equipment of ade-quate lifting capacity.
• Be sure machine is stable whenlifting.
• Do not lift this machine using liftbail if it is equipped with a heavyaccessory such as trailer or gascylinder.
FALLING • Do not lift machine if lift bail is EQUIPMENT can damaged.
cause injury. • Do not operate machine whilesuspended from lift bail.
• Do not stack more than three high.• Do not stack the IDEALARC® DC-600 on top of anyother machine.------------------------------------------------------------------------
WARNING
A-3INSTALLATION
IDEALARC® DC-600
A-3
ELECTRICAL INPUT CONNECTIONS
Before installing the machine check that the input sup-ply voltage, phase, and frequency are the same as thevoltage, phase, and frequency as specified on thewelder Rating Plate located on the Case BackAssembly. Input power supply entry is through thehole in the Case Back Assembly. See Figure A.2 forthe location of the machineʼs input cable entry open-ing, Input Contactor (CR1), and reconnect panelassembly for dual voltage machines.
FIGURE A.2 - Rear Panel
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses ordelay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machinebeing used. They are also called inverse time or ther-mal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a loweramp rating than recommended. This can result in “nui-sance” tripping caused by inrush current even whenmachine is not being used for welding at high outputcurrents.
Use input and grounding wire sizes that meet localelectrical codes or see the Technical Specificationspage in this manual.
GROUND CONNECTION
Ground the frame of the machine. A ground terminal marked with the symbol ( ) is located insidethe Case Back of the machine near the input contac-tor. Access to the Input Box Assembly is at the upperrear of the machine. See your local and national elec-trical codes for proper grounding methods.
INPUT POWER SUPPLYCONNECTIONS
A qualified electrician should connect the input powersupply leads.
1. Follow all national and local electrical codes.
2. Use a three-phase line.
3. Remove Input Access Door at upper rear ofmachine.
4. Follow Input Supply Connection Diagram locatedon the inside of the door.
5. Connect the three-phase AC power supply leadsL1, L2, and L3 to the input contactorterminals in the Input Box Assembly by passingthem thru the three aligned .50” diameter holes inthe baffle and tighten them in the terminal connec-tors. Be sure to close the baffle by inserting thetab into the slot in the baffle. See Figure A.3.
FIGURE A.3 - Input Power SupplyConnections
INPUT SUPPLYCABLE ENTRY
OPENING INPUTCONTACTOR (CR1)
RECONNECTPANEL ASSEMBLY
INPUT POWER SUPPLYCABLE WITH BUSHINGOR BOX CONNECTOR
INPUTCONTACTOR (CR1)
RECONNECTPANEL ASSEMBLY
A-4INSTALLATION
IDEALARC® DC-600
A-4
RECONNECT PROCEDURE
Multiple voltage machines are shipped connected tothe highest input voltage listed on the machineʼs ratingplate. Before installing the machine, check that theReconnect Panel in the Input Box Assembly is con-nected for the proper voltage.
Failure to follow these instructions can causeimmediate failure of components within themachine.
When powering welder from a generator be sureto turn off welder first, before generator is shutdown, in order to prevent damage to the welder
------------------------------
To reconnect a multiple voltage machine to a differentvoltage, remove input power and change the positionof the reconnect board on the Reconnect Panel.Follow The Input Connection Diagram located on theinside of Case Back Input Access Door. These con-nection diagrams for the following codes are listedbelow.
1. For Dual Voltage except 380/500-460/575, seeFigure A.4. (M15009)
2. For 220/380/460, see Figure A.5. (M15010)
3. For 380/500-460/575, see Figure A.6. (M15011)
4. For 460 and 440 Single Voltage, see Figure A.7.(S17894)
5. For 230/460/575, see Figure A.8. (M15666)
6. For Voltages not listed, see the Input ConnectionDiagram pasted on the inside of the Case Back Input Access Door.
L3L2L1
LINK
LINES INPUT
GND H2H1
H3
L3L2L1
LINK
LINES INPUT
H3H1
H2GND
W
V
U
W
V
U
CONTACTOR
CRI
CRI
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
CTOR
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN. 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS, DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE REMAINING HEX NUTS IN PLACE.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN. 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT TRANSF.
PILOT TRANSF.
FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines
CAUTION
A-5INSTALLATION
IDEALARC® DC-600
A-5
CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.
CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE
POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUMCLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,
LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
L3L2L1
LINKS
LINESINPUT
H4H1
H2GND
W
V
UCONTACTOR
CRI
H3
L3L2L1
LINKS
LINESINPUT
H3H1
H2GND
W
V
UCONTACTOR
CRI
H4
L3L2L1
LINKS
LINESINPUT
H2H1
H3GND
W
V
UCONTACTOR
CRI
H4
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.
PILOTTRANSF.
PILOTTRANSF.
PILOTTRANSF.
FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines
FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines
CONNECTION FOR 380/460 VOLTAGES
1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE ATLEAST 600 VOLT INSULATION.
2. CONNECT H3 LEAD TO CONTACTOR..3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS
L3L2L1
LINK
LINESINPUT
H2
H3GND
W
V
UCONTACTOR
CRI L3L2L1
LINK
LINESINPUT
GNDH2
W
V
U
CRI
CONTACTOR
H1
TAPE
CONNECTION FOR 500/575 VOLTAGESH3
H1
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE ATLEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN
ALL HEX NUTS
TAPE
A-6INSTALLATION
IDEALARC® DC-600
A-6
FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines
L3L2L1
LINESINPUT
GND
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
W
V
UCONTACTOR
CRI
FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines
A-7INSTALLATION
IDEALARC® DC-600
A-7
OUTPUT CONNECTIONSSee Table A.1 for recommended IDEALARC® DC-600 cable sizes for combined lengths of electrode and workcables.
TABLE A.1IDEALARC® DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable
at 100% Duty Cycle
Cable SizeParallel CablesCable Length
1/0 (53mm2)2
2
2
Lengths up to 150 ft. (46m)
2/0 (67mm2)150 ft.(46m) to 200 ft (61m)
3/0 (85mm2)200 ft.(61m) to 250 ft.(76m)
ELECTRODE, WORK AND #21 LEAD CONNECTIONS
A. Connect Electrode and Work Leads toOutput Terminals.
1. Set the ON/OFF toggle switch to OFF.
2. Locate the retractable strain relief loops directlybelow the output terminals in the lower right andlower left corners of the Case Front Assembly.See Figure A.9.
3. Pull out the retractable strain relief loops.
4. Insert the electrode lead through the loop directlybelow the desired polarity (positive or negative).Pull through enough cable to reach the output terminals.
5. Connect electrode lead to the desired terminal(positive/negative).
6. Tighten the output terminal nut with a wrench.
7. Connect the work lead to the other output terminal following steps 4-6.
FIGURE A.9 - Output Terminals.
B. Connect #21 Work Sense Lead to ProperTerminal
There are two work sense lead connection points (+21and -21) on terminal strip (T.S.2) located behind thehinged access panel on the right side of the casefront. See 14 Pin MS Type Receptacle section orTerminal Strip Section for connection procedure.
TERMINAL STRIPS
Terminal strips are available behind the cover on thecase front to connect wire feeder control cables thatdo not have a 14 Pin MS-type connector. These termi-nals supply the connections as shown in the followingTerminal Strip charts. NOTE: There are two worksense lead connection points on the terminal strip.Connect both the work sense lead #21 from the 14 pinconnector and #21 lead of the control cable to “-21”when welding positive polarity or to “+21” when weld-ing negative polarity.
TERMINAL STRIP 1 (T.S.1)
TERMINAL STRIP 2 (T.S.2)
Lead No. Function
75 Output Control76 Output Control77 Output Control
Lead No. Function
+21 Work Connection (Electrode Negative)-21 Work Connection (Electrode Positive)2
41 42 VAC 4 Trigger Circuit 2 Trigger Circuit 31 115 VAC1
32 115 VAC1
A-8INSTALLATION
IDEALARC® DC-600
A-8
AUXILIARY POWER AND CONTROL CONNECTIONS
Located at the left side of the front of the welderbehind a hinged cover is a 115VAC duplex receptaclefor auxiliary power (60 Hertz Models only). On the rightside of the case front is a 14 Pin MS type receptaclefor connection of auxiliary equipment such as wirefeeders. Also, terminal strips with 115VAC and con-nections for auxiliary equipment are located behind thehinged access panel on the right side of the case front.(see Auxiliary Power Table for details)
115VAC DUPLEX RECEPTACLE (60 HERTZMODELS ONLY)
The 115VAC duplex receptacle is protected by a circuitbreaker located on the nameplate. The receptacle is aNEMA 5-15R.
AUXILIARY POWER TABLEVoltage and Circuit Breaker Ratings at Auxiliary Power
Connections for Various ModelsAuxiliary 60 Hz 50/60 HzPower Models Models
Connections
At Duplex 115V 15A No DuplexReceptacle
Terminal strip 115V 15A 115V 15Aterminals 31 & 32
MS-Receptacle 115V 15A 115V 15Apins A & J
MS-Receptacle 42V 10A 42V 10Apins I & K
PIN LEAD NO. FUNCTION
A 32 115 VACB GND Chassis ConnectionC 2 Trigger CircuitD 4 Trigger CircuitE 77 Output ControlF 76 Output ControlG 75 Output Control
H 21 Work Sense Connection2
I 41 42 VAC
J 31 115 VAC1.
K 42 42 VACL --- ---M --- ---N --- ---
F=76
G=75
H=21
I=41
J=31K=42
A=32
B=GND
C=2
D=4
E=77
L N
M
1.115VAC circuit is on all models.
2.As shipped from the factory Lead #21 from the 14 Pin connector isconnected to “-21” on the terminal strip (T.S.2). This is the config-uration for positive welding. If welding negative polarity, connectlead #21 to the “+21” connection point on the terminal strip(T.S.2).
14 PIN MS TYPE RECEPTACLE(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
Refer to the figure A.10 for the available circuits in the14 pin receptacle.
42 VAC is available at receptacle pins I and K.A 10 amp circuit breaker protects this circuit.
115 VAC is available at receptacle pins A and J (AllModels). A 15 amp circuit breaker protects this circuit.Note that the 42 VAC and 115 VAC circuits are electri-cally isolated from each other.
FIGURE A.10 FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE
B-1OPERATION
IDEALARC® DC-600
B-1
SAFETY PRECAUTIONS
Read this entire section of operating instructionsbefore operating the machine.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts orelectrodes with your skin or wetclothing.
• Insulate yourself from the work andground.
• Always wear dry insulating gloves.• Do not use AC welder if your cloth-
ing, gloves or work area is damp or ifworking on, under or inside work-piece.Use the following equipment:-Semiautomatic DC constant voltage(wire) welder.
-DC manual (stick) welder.-AC welder with reduced voltagecontrol.
• Do not operate with panels removed.• Disconnect input power before servicing.------------------------------------------------------------------------
READ THIS WARNING, PROTECTYOURSELF & OTHERS.
FUMES AND GASES can bedangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc, or both,tokeep fumes and gases from your breathing zoneand general area.
WELDING, CUTTING and GOUG-ING SPARKS can cause fire orexplosion.
• Do not weld near flammable material.
• Do not weld, cut or gouge on contain-ers which have held flammable materi-al.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed inthe beginning of this manual.
WARNING
B-2OPERATIONB-2
IDEALARC® DC-600
GENERAL DESCRIPTION
The IDEALARC® DC-600 is an SCR controlled threephase welding and cutting power source. It uses asingle range potentiometer to control:
• Submerged Arc Semi-Automatic or AutomaticWelding
• Open Arc Semi-Automatic or Automatic Welding• Stick Welding• Air/Carbon Arc Cutting (Carbon Rod Sizes up to
3/8” Diameter)
The IDEALARC® DC-600 has a three-posit ionWelding Mode Switch to enable the user to operate inone of three modes:
• Constant Current (CC) Stick (also used for AAC)• Constant Voltage (CV) Submerged Arc• Constant Voltage (CV) Innershield (also used for
FCAW/GMAW)
Three models are available:
• Domestic - al l 60 Hertz models except230/460/575V.
• Canadian-230/460/575V 60 Hertz models• Export-50/60 Hertz models
The optional Multi-Process Switch allows the user toswitch between semi-automatic or automatic weldingand stick welding or air/carbon arc cutting without dis-connecting the wire feeder equipment control, elec-trode,and work leads.
RECOMMENDED PROCESSES ANDEQUIPMENT
The IDEALARC® DC-600 is designed for GMAW(MIG), FCAW, and submerged arc (SAW) within thecapacity of the machine. It can also be used for stickwelding (SMAW) and for air carbon arc (AAC) cuttingwith carbon rods up to 3/8" diameter.
The IDEALARC® DC-600 is provided with a threeposition mode switch that selects CV Innershield, CVSubmerged Arc, or CC Stick.
The IDEALARC® DC-600 can be easily connected towire feeding equipment, including:
• Semi-automatic wire feeders LN-7, LN-7 GMA,LN-742, LN-8, LN-9, LN-9 GMA, LN- 10, LN-15LN-23P, LN-25, and DH-10.
• Automatic wire feeders NA-3, NA-5, and NA-5R.• Tractors LT-56 and LT-7
DESIGN FEATURES AND ADVANTAGES
• Excellent arc characteristics for optimum constantvoltage submerged arc and Innershield weldingperformance.
• A control circuit designed to provide good startingfor a large variety of processes and procedures.
• Output Control Potentiometer that provides easysingle range continuous control.
• Output Control Switch that provides simple switch-ing from local to remote control.
• Output Terminals Switch to energize output termi-nals either local or remote.
• White neon pilot light to confirm that the InputContactor is energized.
• DC Ammeter and Voltmeter• 42VAC 10 Amp auxiliary power available for the
wire feeder, circuit breaker protected.• Single MS-type (14 pin) connector for wire feeder.• 115VAC 15 Amp auxiliary power available for the
wire feeder, circuit breaker protected.• 115VAC 15 Amp duplex plug receptacle available
on 60 Hertz models, circuit breaker protected.• Multi-functional terminal strip for easy connection
of wire feeding control cables. • Recessed output terminals to avoid any person or
object from accidentally coming into contact withthe output terminals and labeled " + " and " - " foreasy identification.
• Thermostatically protected power source.• Electronic protection circuit to protect power
source against overloads.• Input line voltage compensation to provide an
essentially constant output.• SCR electronically controlled welder output pro-
vides extra long life, especially for highly repetitivewelding applications.
• Solid state 2 and 4 circuit for extra long life.• Two circuit solid state control system provides
maximum performance and circuit protection.• Low profile case provides maximum use of space.• Convenient access to all controls.• Output lead strain relief loops to prevent terminal
and cable damage.• Easily removed case side, even when stacked.• Outdoor operation because enclosure is designed
with air intake louvers that keep dripping waterfrom entering the unit. Transformer, SCR bridge,and choke have special corrosion resistant paintfor added protection.
B-3OPERATIONB-3
IDEALARC® DC-600
WELDING CAPABILITYThe IDEALARC® DC-600 has the following Outputand Duty Cycle based on operation for a 10 minuteperiod:600 Amps, 44 Volts at 100%680 Amps, 44 Volts at 60%750 Amps, 44 Volts at 50%
MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT
Input POWER ON/OFF Switch
SYMBOL MEANING
ON
OFF
INPUT POWER
Input power on when light is illuminated(except for abnormal conditions).
Always indicates POWER ON/OFFswitch is in ON position.
Pilot Light
OUTPUT CONTROL
OUTPUT VOLTAGEAND CURRENT
Clockwise Increase of OutputVoltage and Current
TERMINALS ON/REMOTE Switch
OUTPUT TERMINALSENERGIZED
Remote Control of Output Terminals(Energized or Non-Energized)
LOCAL/REMOTE Switch
SYMBOL MEANING
Control Of Output Voltage andCurrent is Via IDEALARC® DC-600's
Control Dial
Remote Control of Output Voltageand Current
MODE Switch
CC STICK: Shielded Metal ArcWelding (SMAW), this switchposition is also used for AirCarbon Arc Cutting (AAC)
CV SUBMERGED ARC:Constant Voltage Submerged
Arc Welding (SAW)
CV INNERSHIELD: Flux CoredArc Welding (FCAW), this switch
position is also used for GasMetal Arc Welding (GMAW).
Output Terminal Connections
Positive Output Terminal
Negative Output Terminal
WARNING Identification
Warning Identification
Circuit Breaker
Circuit Breaker (two breakers: 15Afor 115V circuit and 10A for 42V
circuit)
CONTROLS AND SETTINGSAll operator controls and adjustments are located onthe Case Front Assembly of the IDEALARC® DC-600.See Figure B.1 for the location of each control.
FIGURE B.1 - CONTROL PANEL KEYS
1
2
3
4
5 6
7
8
9
10
DC-600
1312
7
5
11
2
1
49863
10
B-4OPERATION
IDEALARC® DC-600
B-4
3 Phase transformer with rectifiedDC output
Line Connection
Three Phase Input Power
Designates welder complies withNational Electrical ManufacturersAssociation requirements EW 1Class I with 100% duty cycle at600Amps output.
Designates welder complies withboth Underwriters Laboratories (UL)standards and Canadian StandardsAssociation (CSA) standards. (60Hertz Models)
Gas Metal Arc Welding (GMAW)
Flux Cored Arc Welding (FCAW)
MEANING OF GRAPHICALSYMBOLS ON RATING PLATE(LOCATED ON CASE BACK)
NEMA EW 1 (100%)
Shielded Metal Arc Welding (SMAW)
Submerged Arc Welding (SAW)
MEANING OF GRAPHICALSYMBOL FOR GROUND CON-NECTION
Signifies the equipment connectionpoint for the protective earth ground
NRTL/C
1. Input POWER ON/OFF SwitchThis toggle switch turns the machine on or off.Putting the switch in the ON “ ” position ener-gizes the machineʼs input contactor applying inputpower to the machine. Switching the switch to theOFF “ ” position de-energizes the input con-tactor.
2. POWER LightWhen the POWER switch is in the ON position themachineʼs white POWER light will illuminate. If theinput contactor de-energizes the machine in anabnormal situation the pilot light will still illuminate.In this situation it may be necessary to reset themachine by switching the POWER switch to theOFF and then to the ON position. (See Overload,Overcurrent, and Fault Protection Section)
B-5OPERATIONB-5
IDEALARC® DC-600
3. OUTPUT CONTROLThis control provides continuous control of themachineʼs output voltage and current from mini-mum to maximum (typical full pot range between15 to 44 volts and 90 to 750 amps) as it is rotatedclock-wise. Voltage or current control is deter-mined by setting of Mode Switch (CV or CC).
4. OUTPUT TERMINALS ON/REMOTE SwitchWhen this switch is in the REMOTE “ ” posi-tion, the IDEALARC® DC-600ʼs output terminalswill be electrically “cold” until a remote device suchas a wire feeder closes the #2 and #4 circuit in theMS-receptacle or terminal strip (T.S.2). When thisswitch is in the ON “ ” position the machineʼsoutput terminals will be electrically energized allthe time.
5. LOCAL/REMOTE SwitchWhen this switch is set to the LOCAL “ “ posi-tion, control of the output voltage and current is viathe OUTPUT CONTROL on the IDEALARC® DC-600ʼs control panel. When this switch is set to theREMOTE “ ” position, control is through aremote source such as a wire feeder via the #75,#76, and #77 leads in the MS-receptacle or termi-nal strip (T.S.1).
6. Mode SwitchThis switch allows for selecting the weldingprocess to be used:CC STICK-for SMAW and AACCV SUBMERGED ARC- for SAWCV INNERSHIELD- for FCAW and GMAW
7. 115VAC Duplex Receptacle (60 Hertz Models)This receptacle provides up to 15 amps of 115VAC auxiliary power.
8. 115VAC 15 Amp Circuit BreakerThis breaker protects the 115 VAC auxiliary cir-cuits located in the duplex receptacle, terminalstrip (T.S.2) and MS-receptacle.
9. 42VAC 10 Amp Circuit BreakerThis breaker protects the 42VAC auxiliary circuitslocated in the terminal strip (T.S.2) and MS-recep-tacle.
10.14 Pin MS-ReceptacleThis connector provides easy connection for a wirefeeder control cable. It provides connections forauxiliary power, output switching, remote outputcontrol, wire feeder voltmeter sense lead andground. Refer to 14 Pin MS Type Receptacle in theInstallation Section for information about the cir-cuits made available at this receptacle.
11.Terminal Strip Cover PanelRotate this panel to gain access to the circuitsmade available at the two terminal strips (T.S.1and T.S.2). These terminal strips contains thesame circuits as the 14 pin MS-receptacle. Thereis a box connector adjacent to this cover for routingleads to the terminal strips.
12.Negative Output TerminalThis output terminal is for connecting a weldingcable. To change welding polarity and for properwelding cable size refer to Electrode and WorkCables in the Installation Section.
13.Positive Output TerminalThis output terminal is for connecting a weldingcable. To change welding polarity and for properwelding cable size refer to Electrode and WorkCables in the Installation Section.
AUXILIARY POWER IN MS-RECEPTACLE
42 volt AC auxiliary power, as required for some wirefeeders, is available through the wire feeder MS-receptacle. A 10 amp circuit breaker protects the 42volt circuit from overloads.
IDEALARC® DC-600 machines can also supply 115volt AC auxiliary power through the wire feeder recep-tacle. A 15 amp circuit breaker protects the 115 voltcircuit from overloads.
OVERLOAD, OVERCURRENT, ANDFAULT PROTECTION
This welder has thermostatic protection from exces-sive duty cycles, overloads, loss of cooling, and highambient temperatures. When the welder is subjectedto an overload or loss of cooling, a thermostat willopen. The input contactor will open and remain openuntil the machine cools; the white POWER light staysilluminated. No welding is possible during this cooldown period. The machine will reset automaticallywhen the thermostat cools.
The power source is also protected against overcur-rents in the SCR bridge assembly through an elec-tronic protection circuit. This circuit senses currentsover 780 amps on the power source and opens theinput contactor should the overcurrent remain for apredetermined time (the white POWER light stays illu-minated). The predetermined time varies with theamount of overcurrent; the greater the overcurrent,the shorter the time. The input contactor will remainopen until the power source is manually started byresetting the POWER ON/OFF toggle switch.
REMOTE CONTROL OF MACHINEOPERATION
The toggle switch on the control panel labeled“Remote - Panel” gives the operator the option of con-trolling the machine output from a remote location. Ifin the Remote position a wire feeder with remote con-trol capabilities or a remote control device such as aK775 must be connected to terminals 75, 76, and 77.Refer to Accessories Section for wire feeder remoteinformation.
WELDING PROCEDURE RECOMMENDATIONS
Select Welding Mode Switch position based on type ofwelding to be done.
1. Innershield Welding (FCAW)/MIG (GMAW)Welding: Use the CV INNERSHIELD mode.
2. Submerged Arc Welding (SAW): Use the CVSUBMERGED ARC mode. If performing highspeed welding, switch between the CVSubmerged Arc and the CV Innershield mode anduse the mode that produces the best weldingresults.
3. Air/Carbon Arc Cutting (AAC) / Stick Welding(SMAW) / High Current, Large Puddle SubmergedArc Welding (SAW): Use the CC STICK mode.When the IDEALARC® DC-600 is used forAir/Carbon Arc cutting, the OUTPUT CONTROLpotentiometer should be set to "9" initially. Basedon the size of the carbon being used or theprocess, turn the potentiometer to a lower settingas required by the process. You can use carbonrods up to 3/8" in diameter at currents as high as750 amps with excellent arc control. The welderprotection circuit protects the machine fromextremely high short circuiting pulses.
SEMI-AUTOMATIC ANDAUTOMATIC WIRE FEEDING WITHTHE IDEALARC® DC-600 AND WIREFEEDERS
When using the IDEALARC® DC-600 with semi-auto-matic or automatic wire feeding equipment and forstick welding or air/carbon arc cutting, it is recom-mended that the optional MULTI-PROCESS SWITCHbe used. This switch permits you to easily change thepolarity of the connected wire feeding equipment orswitch to stick welding or air/carbon arc cutting.
B-6OPERATIONB-6
The power source circuitry is protected from faults onleads 75, 76, or 77. If any of these leads are connect-ed to either the positive or negative output leads, theIDEALARC® DC-600 will either shut down completely(input contactor opens and white POWER light staysilluminated), or will operate at minimum output thuspreventing any damage to the IDEALARC® DC-600. IfIDEALARC® DC-600 shuts down, it must be manuallystarted by resetting the POWER ON/OFF toggleswitch.
OPERATING STEPS
The following procedures are for using the IDE-ALARC® DC-600 in the local control mode of opera-tion. For remote control of the machine, see theRemote Control of Machine Operation section.
Before operating the machine, make sure you have allmaterials needed to complete the job. Be sure youare familiar with and have taken all possible safetyprecautions before starting work. It is important thatyou follow these operating steps each time you usethe machine.
1. Turn on the main AC power supply to themachine.
2. Connect the #21 work lead to either + or - on ter-minal strip (T.S.2).
3. Set the Welding Mode switch to welding processbeing used:
• CC STICK (for SMAW and AAC)
• CV SUBMERGED ARC (for SAW)
• CV INNERSHIELD (for FCAW and GMAW)
4. Turn the POWER ON/OFF Toggle Switch to the“ON” position
• The white pilot light glows.
• The fan starts.
5. Set OUTPUT CONTROL Potentiometer to desiredvoltage or current.
6. Set the OUTPUT TERMINALS switch to either“ON” ( output terminals energized) or “REMOTE”(output terminals energized when #2 and #4closed by remote device such as wire feeder)
7. Make the weld.
IDEALARC® DC-600
• To adjust the Open Circuit Voltage Control to get thebest starting performance, make repeated startsobserving the NA-3 voltmeter.
When the voltmeter pointer swings smoothly up tothe desired arc voltage, without undershooting orovershooting the desired arc voltage, the OpenCircuit Voltage Control is set properly.
If the voltmeter pointer overshoots the desired volt-age and then returns back to the desired voltage, theOpen Circuit Voltage Control is set too high. Thiscan result in a bad start where the wire tends to"Blast off."
If the voltmeter pointer hesitates before coming up tothe desired voltage, the Open Circuit Voltage Controlis set too low.This can cause the electrode to stub.
4. Start and make the weld.
• Cold starts. For cold starts, be sure the work piece isclean and the electrode makes positive contact withthe work piece.
• Hot "On the Fly" starts. For hot starts, travel shouldbegin before the wire contacts the work piece.
ARC STRIKING WITH IDEALARC® DC-600 AND THENA-3 START BOARD
When electrical strikeouts exceed 1 3/4” (44.4mm) anNA-3 Start Board may be required to improve arc strik-ing.
When the NA-3 Start Board is used to improve arc strik-ing, use the following procedures:1. Set start time at 0.
2. Set NA-3 start current and start voltage at mid-range.
3. Set the NA-3 output current and voltage to the prop-er settings for the welding procedure to be used.
4. Turn the Start Board Timer to maximum.
5. Set Start Board current and voltage control.
• Set the Start Board current control to 1 1/2 dial num-bers below that set on the NA-3 current control.
• Set the Start Board voltage control equal with theNA-3 voltage control setting.
B-7OPERATIONB-7
IDEALARC® DC-600
NA-3 AUTOMATIC WIRE FEEDER
1. Set the IDEALARC® DC-600 LOCAL/REMOTESwitch to REMOTE. Set the OUTPUT TERMINALSswitch to REMOTE. NOTE: Later model NA-3 auto-matic wire feeders are capable of cold starts whenthe NA-3 Mode switch is in the CV or CC mode posi-tion. Some earlier models are capable of cold start-ing only in the CC mode position. Cold startingenables you to inch the wire down to the work, auto-matically stop, and automatically energize the fluxhopper valve.
2. Set the IDEALARC® DC-600 welding mode switchfor the desired process: CV SUBMERGED ARC, CVINNERSHIELD mode or CC STICK mode.
3. Set the NA-3 mode Switch Position to either CV orCC to match the IDEALARC® DC-600 mode select-ed in step 2.
4. Refer to the NA-3 operators manual for instructionson how to use the NA-3 in conjunction with the IDE-ALARC® DC-600.
5. Follow the following guidelines for good arc strikingdetailed below for each welding mode.
GOOD ARC STRIKING GUIDELINES FOR THE NA-3WITH THE IDEALARC® DC-600 IN THE CVINNERSHIELD, CV SUBMERGED ARC OR CC STICKWELDING MODES.
Following are some basic arc striking techniques thatapply to all wire feed processes. Using these proceduresshould provide trouble-free starting. \These proceduresapply to single, solid wires and Innershield wires.
1. Cut the electrode to a sharp point.
2. Set the NA-3 Open Circuit Voltage Control to thesame dial setting as the Arc Voltage Control. If this isa new welding procedure, a good starting point is toset the Open Circuit Voltage Control to # 6.
NOTE: The open circuit voltage of the IDEALARC® DC-600 varies from approximately 16volts to 56 volts in the CV INNERSHIELD or CVSUBMERGED ARC modes. The open circuit voltageis constant in the CC STICK mode.
3. Run a test weld. Set proper current, voltage, andtravel speed.
• For the best starting performance, the NA-3 OpenCircuit Voltage Control and Voltage Control settingshould be the same. Set the Inch Speed Control forthe slowest inch speed possible.
IDEALARC® DC-600 POWER SOURCESETTING WHEN CONNECTED TO NA-5WIRE FEEDER
When using the IDEALARC® DC-600 with the NA-5wire feeder, set the controls on the IDEALARC® DC-600 as follows for the best performance:
1. Turn OFF main AC input power supply to the IDE-ALARC® DC-600.
2. Connect the electrode cables to terminal polarityto be used.
3. Connect the #21 work lead (on T.S.2) to thesame polarity as the work cable connection.
4. Set the IDEALARC® DC-600LOCAL/REMOTE Switch to REMOTE.
5. Set the IDEALARC® DC-600 OUTPUT TERMI-NALS switch to REMOTE.
6. Set the IDEALARC® DC-600 WELDING MODESWITCH to the position that matches the weldingprocess being used.
• For submerged arc welding, set WELDING MODESWITCH to CV SUBMERGED ARC position.
• For all open arc welding processes set WELDINGMODE SWITCH to CV INNERSHIELD position.
B-8OPERATIONB-8
IDEALARC® DC-600
NOTE: These Start Board current and voltage set-tings result in a start up current that is lower thanthe NA-3 current setting and approximately equalwith the NA-3 voltage setting for the desired weld-ing procedure.
6. Establish the correct arc striking procedure withthe NA-3 Start Board timer set at maximum.
• For the best starting performance, the NA-3 OpenCircuit Voltage Control and Voltage Control set-ting should be the same. Set the Inch SpeedControl for the slowest inch speed possible.
• To adjust the Open Circuit Voltage Control to getthe best starting performance, make repeatedstarts observing the NA-3 voltmeter.
When the voltmeter pointer swings smoothly up tothe desired arc voltage, without undershooting orovershooting the desired arc voltage, the OpenCircuit Voltage Control is set properly.
If the voltmeter pointer overshoots the desiredvoltage and then returns back to the desired volt-age, the Open Circuit Voltage Control is set toohigh. This can result in a bad start where the wiretends to "Blast off."
If the voltmeter pointer hesitates before coming upto the desired voltage, the Open Circuit VoltageControl is set too low. This can cause the elec-trode to stub.
• Set NA-3 Start Board current and voltage asclose to the welding procedure current and volt-age as possible.
NOTE: The Start Board current and voltageshould be as close as possible to the welding pro-cedure current and voltage, while still getting sat-isfactory starts.
• Set the start time to as low a time as possible while still getting satisfactory starts.
7. Start and make the weld.
C-1ACCESSORIESC-1
IDEALARC® DC-600
WIRE FEEDERS AND TRACTORS
The IDEALARC® DC-600 can be used to power anyof the following Lincoln Wire Feeders and Tractors:
Semi-Automatic Wire Feeders:DH-10 LN-9 LN-7 LN-9 GMA LN-7 GMA LN-23P LN-742 LN-25 LN-8 LN-10
Automatic Wire Feeders:NA-3 NA-5RNA-5
Tractors: LT-7 LT-56
FIELD INSTALLED OPTIONS
Remote Output Control (K775 or K857with K864 Adapter)
An optional “remote out control” is available. TheK775 is the same remote control that is used on otherLincoln power sources. The K775 consist of a controlbox with 28 feet (8.5mm) of four conductor cable. Thisconnects to terminals 75,76, and 77 on the terminalstrip (T.S.1) and the case grounding screw so markedwith the symbol “ ” on the machine. These termi-nals are located behind the hinged cover on the casefront. This control will give the same control as theoutput control on the machine.
The K857 is similar to the K775, except the K857 hasa 6-pin MS-style connector. The K857 requires aK864 adapter cable which connects to the 14-pin con-nector on the case front.
Remote Control Adapter Cable (K864)
A "V" cable 12" (.30 m) long to connect a K857Remote Control (6-pin connector) with an LN-7 wire-feeder (14-pin connector) and the machine (14-pinconnector). If a remote control is used alone the wire-feeder connection is then not used.
Undercarriages (K817P, K842)
For easy moving of the machine, optional undercar-riages are available with polyolefin wheels (K817P) ora platform undercarriage (K842) with mountings fortwo gas cylinders at rear of welder.
Paralleling Kit (K1611-1)
Permits paralleling of two IDEALARC® DC-600's forwelding currents of up to 1200 amps, 100% dutycycle.
Tig Module (K930-2)
Portable high frequency generator for AC/DC TIGwelding.
FACTORY OR FIELD INSTALLEDOPTIONS
Multi-Process Switch (K804-1)
The MULTI-PROCESS SWITCH gives you the abilityto:• Switch between "stick welding or air/carbon arc
cutting" and using a semi-automatic or automaticwire feeder.
• Change the polarity of a semi-automatic or auto-matic wire feeder without changing any electricalcable connections.
See Figure C.1
FIGURE C.1 - MULTI-PROCESS SWITCH
STRA IGHT PLUG (14 P IN )TO POWER SOURCE
CABLE RECEPTACLE (6 SOCKET )
CABLE RECEPTACLE (14 SOCKET )
TO : K857 REMOTE CONTROL
TO: LN-7 WIRE FEEDERS – +
WIREFEEDERCABLES
STICK ORAIR/CARBONARC CABLES
STICK ORAIR
CARBONARC
+
-
C-2ACCESSORIESC-2
IDEALARC® DC-600
The MULTI-PROCESS SWITCH has two sets of out-put terminals. You connect the wire feeder unit cablesto the set of terminals on the left side of the box andthe stick or air/carbon arc cables to the set of termi-nals on the right side (facing the front of the machine)as shown in Figure C.1. The output terminals are pro-tected against accidental contact by hinged covers.
When the MULTI-PROCESS SWITCH is in the "Stickor Air/Carbon Arc" position, only those terminals areenergized. The wire feeder nozzle or gun and elec-trode are not electrically "hot" when in this mode.
Follow these steps to install the MULTI-PROCESSSWITCH:
1. Confirm that the IDEALARC® DC-600 POWERON/OFF switch is in the OFF position.
2. Disconnect main AC input power to the IDE-ALARC® DC-600.
3. Open the terminal strip hinged cover located onthe Case Front Assembly.
4. The MULTI-PROCESS SWITCH is mounted tothe case front with four 1/4” self-tapping screws.The screw holes are 13.8” apart side to side and4.5” apart top to bottom, Run one of the 1/4”screws part way in and out of the screw holes toopen them up. Make sure that the two sleevedcontrol leads do not get pinched when hangingthe switch; route them out the side to the right ofthe switch. Support the switch in position and startthe four screws, then tighten them.
5. Route the MULTI-PROCESS SWITCH controlleads through the strain-relief box connectors andinto the terminal strip. Connect wire feeder controlcable as specified in specific connection diagramand make other terminal strip connections asspecified on the connection diagram for theLincoln wire feeder being used.
6. Connect the control leads from the MULTI-PROCESS SWITCH to terminals #2 and #4 onthe IDEALARC® DC-600's terminal strip.
7. Connect the right cable from the MULTI-PROCESS SWITCH (facing the front of themachine) to the IDEALARC® DC-600 positive (+)output terminal. See Figure C.2.
FIGURE C.2 - MULTI-PROCESS SWITCHCABLE CONNECTIONS.
8. Connect the left cable from the MULTI-PROCESSSWITCH (facing the front of the machine) to theIDEALARC® DC-600 negative (-) output terminal.See Figure C.2.
9. Connect the wire feeder electrode and workcables. See Figure C.2.
• Insert the wire feeder electrode and work cablesthrough the strain relief loop on the left side of theIDEALARC® DC-600 (facing the front of themachine).
• Connect the wire feeder electrode and workcables to the electrode and work terminals on the left side of the MULTI-PROCESSSWITCH.
10. Connect wire feeder control cable and make otherterminal strip connections as specified on theconnection diagram for the Lincoln wire feederbeing used.
11. Set the IDEALARC® DC-600 OUTPUT TERMI-NALS switch to REMOTE.
WORKCABLE
WORK
ELECTRODES
21-21+ 41 4 2 31 32 75 76 77
TERMINALSTRIP COVER
BOX CONNECTOR
POSITIVE (+)OUTPUT
STUD– +
NEGATIVE (–)OUTPUT
STUD
ELECTRODECABLE
WORKCABLE
ELECTRODECABLE
JUMPER (IF NEEDEDSEE INSTRUCTIONS)
+
CONTROLLEADS
STICK AIR/CARBONARC WELDINGEQUIPMENT
WIREFEEDER
C-3ACCESSORIESC-3
12. Connect stick or air/carbon arc electrode and workcable. See Figure C.2.
• Insert the electrode and work cables through thestrain relief loop on the right side (facing the frontof the machine) of the IDEALARC® DC-600.
• Connect the electrode cable to the "Positive" ter-minal on the right side of the MULTI-PROCESSSWITCH.
• Connect the work cable to the "Negative" terminalon the right side of the MULTI-PROCESSSWITCH.
NOTE: The instructions above are for connectingthe stick polarity positive. To change the polarity,turn the IDEALARC® DC-600 OFF, and reversethe cables.
NOTE: When it is not necessary to have separateground cables for stick and semi-automatic orautomatic welding, connect a jumper from theMULTI-PROCESS SWITCH "Work" terminal tothe MULTI-PROCESS SWITCH "negative" termi-nal. See Figure C.2.
To operate the MULTI-PROCESS SWITCH, refer tothe operating instructions on the switch nameplate.
CONNECTIONS FOR SEMI-AUTO-MATIC OR AUTOMATIC WIRE FEED-ER CONTROL
1. Set the IDEALARC® DC-600 ON/OFF switch toOFF.
2. Set the IDEALARC® DC-600 LOCAL/REMOTEswitch to REMOTE.
3. Set the IDEALARC® DC-600 OUTPUT TERMI-NALS switch to REMOTE.
4. Set the IDEALARC® DC-600 MODE switch to thewelding process being used.
5. Refer to the proper connection diagram in the DIA-GRAMS section for more information.
IDEALARC® DC-600
ROUTINE AND PERIODIC MAINTENANCE
1. Disconnect input AC power supply lines to themachine before performing periodic maintenance,tightening, cleaning, or replacing parts.
Perform the following daily:
1. Check that no combustible materials are in thewelding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials thatcould block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits or punctures in the cable jacket, or any condition thatwould affect the proper operation of the machine.
Perform Periodically:
Clean the inside of the machine with low pressure airstream. Clean the following parts.
• Main transformer and choke.
• Electrode and work cable connections.
• SCR rectifier bridge and heat sink fins.
• Control board.
• Firing board.
• Fan Assembly.NOTE: The fan motor has sealed bearings whichrequire no maintenance.
D-1MAINTENANCED-1
IDEALARC® DC-600
SAFETY PRECAUTIONS
ELECTRIC SHOCK CANKILL.
Only qualified personnel shouldperform this maintenance.
Turn the input power OFF at the disconnectswitch or fuse box before working on this equip-ment.
Do not touch electrically hot parts.
WARNING
E-1TROUBLESHOOTINGE-1
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WARNING
ELECTRIC SHOCK can kill.Have an electrician install and ser-vice this equipment. Turn the inputpower OFF at the fuse box beforeworking on equipment. Do not touchelectrically hot parts.
E-2TROUBLESHOOTINGE-2
IDEALARC® DC-600
CAUTION: Sometimes machine failures appear to bedue to PC board failures. These problems can some-times be traced to poor electrical connections. Toavoid problems when troubleshooting and replacingPC boards, please use the following procedure:
1. Determine to the best of your technical ability thatthe PC board is the most likely component causingthe failure symptom.
2. Check for loose connections at the PC board toassure that the PC board is properly connected.
3. If the problem persists, replace the suspect PCboard using standard practices to avoid static elec-trical damage and electrical shock. Read the warn-ing inside the static resistant bag and perform thefollowing procedures:
P.C. Board can be damaged by static electricity.
• Remove your bodyʼs staticcharge before opening the static-shielding bag. Wear an anti-staticwrist strap. For safety, use a 1Meg ohm resistive cord connect-ed to a grounded part of theequipment frame.
• If you donʼt have a wrist strap,touch an unpainted, grounded,part of the equipment frame.Keep touching the frame to pre-vent static build-up. Be sure notto touch any electrically live partsat the same time.
• Tools which come in contact with the P.C. Boardmust be either conductive, anti-static or static-dis-sipative.
• Remove the P.C. Board from the static-shieldingbag and place it directly into the equipment. Donʼtset the P.C. Board on or near paper, plastic orcloth which could have a static charge. If the P.C.Board canʼt be installed immediately, put it back inthe static-shielding bag.
• If the P.C. Board uses protective shorting jumpers,donʼt remove them until installation is complete.
• If you return a P.C. Board to The Lincoln ElectricCompany for credit, it must be in the static-shield-ing bag. This will prevent further damage andallow proper failure analysis.
4. Test the machine to determine if the failure symp-tom has been corrected by the replacement PCboard.
NOTE: It is desirable to have a spare (known good)PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all electri-cal components can reach their operating tem-perature.
5. Remove the replacement PC board and substitute itwith the original PC board to recreate the originalproblem.
• If the original problem does not reappear by substi-tuting the original board, then the PC board was notthe problem. Continue to look for bad connectionsin the control wiring harness, junction blocks, andterminal strips.
• If the original problem is recreated by the substitu-tion of the original board, then the PC board wasthe problem. Reinstall the replacement PC boardand test the machine.
6. Always indicate that this procedure was followedwhen warranty reports are to be submitted.
NOTE: Following this procedure and writing on thewarranty report, “INSTALLED AND SWITCHED PCBOARDS TO VERIFY PROBLEM,” will help avoiddenial of legitimate PC board warranty claims.
PC BOARD TROUBLESHOOTING PROCEDURES
ATTENTIONStatic-SensitiveDevicesHandle only atStatic-SafeWorkstations
Reusable ContainerDo Not Destroy
WARNING
E-3TROUBLESHOOTINGE-3
IDEALARC® DC-600
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
Major Physical or ElectricalDamage is Evident
The Machine is dead- The Inputcontactor does not operate.
POSSIBLECAUSE
Contact the Lincoln Electric ServiceDept. 1-(888)-953-3877.
1. Check for blown or missingfuses in input lines.
2. Check the three- phase inputline voltage at the machine.The input voltage must matchthe rating plate and reconnectpanel.
3. Power ON/OFF switch may bedefective
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Observe all Safety Guidelines detailed throughout this manual
E-4TROUBLESHOOTINGE-4
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
Input contactor (CR1) chatters.
Variable or sluggish welding arc.
Output Control Pot. not functioningin “LOCAL” control.
No output control in “REMOTE”control.
115VAC duplex receptacle notworking. (60HZ machines only)
POSSIBLECAUSE
1. The input line voltage may below. Check all three phases.
2. Make sure input line voltagematches machine rating andthe reconnect panel is connect-ed correctly for the line voltage.
1. Poor electrode or work lead con-nection
2. Welding cables too small.
3. Welding current or voltage toolow.
1. LOCAL/REMOTE Switch (S3)faulty or in wrong position.
2. Faulty OUTPUT CONTROL Pot.
1. LOCAL/REMOTE Switch (S3)faulty or in wrong position.
2. Faulty Remote Control Unit.
1. 115VAC Circuit Breaker tripped.
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
Observe all Safety Guidelines detailed throughout this manual
E-5TROUBLESHOOTINGE-5
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
Machine input contactor operatesbut machine has no weldoutput.Fan runs and pilot lightglows.
POSSIBLECAUSE
1. Place OUTPUT TERMINALSwitch to “ON”, or install ajumper from #2 to #4 onmachine terminal strip. Ifmachine weld output isrestored the problem is in thewire feeder or control cable.
2. If remote control is not beingused make certain theLOCAL/REMOTE SWITCH(SW3) is in the "Local" position.
3. Check 42V Circuit Breaker inthe front panel.Reset if neces-sary.
4. Check for loose or faulty weldcable connections.
5. Trigger circuit not working.
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
E-6TROUBLESHOOTINGE-6
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
Machine has maximum weld out-put and no control.
POSSIBLECAUSE
1. LOCAL/REMOTE Switch (S3)in wrong position.
2. LOCAL/REMOTE Switch (S3)is faulty, or an open lead goingto the LOCAL/REMOTE Switch(S3).
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
E-7TROUBLESHOOTINGE-7
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
Machine has minimum output andno control.
The machine does not have maxi-mum weld output.
POSSIBLECAUSE
1. If a remote control unit is NOTconnected to the terminal strip#75, #76, and #77 terminals, or isnot connected to the 14 pin MSreceptacle the LOCAL/REMOTESWITCH must be in the "Local"position.
2. If a remote control cable is con-nected to terminals #75, #76 and#77 or is connected to the 14 pinMS receptacle the leads may be"shorted" to the positive weld out-put.
3. Make certain the Three Phaseinput voltage is correct andmatches the machine rating andthe reconnect panel.
1. Check all Three-Phase inputlines at the DC600. Make sureinput voltages match machinerating and reconnect panel.
2. Put LOCAL/REMOTE SWITCH(SW3) in "LOCAL" position. Ifproblem is solved then checkremote control unit or wirefeeder.
3. Check for loose welding cableconnections.
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
E-8TROUBLESHOOTINGE-8
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
Machine shuts off (input contactordrops out) when the welder outputterminals are made electrically"hot".(#2 to #4 closure at terminal strip.)or OUTPUT TERMINALS switchis in ON position.
The DC600 will NOT shut off whenthe Power Switch is turned toOFF.
POSSIBLECAUSE
1. Remove all welding cables andcontrol cables from the DC 600.Jumper #2 to #4 at the terminalstrip or set OUTPUT TERMI-NALS switch to ON position. Ifthe machine does NOT shut offand normal open circuit voltageis present at the welder outputterminals the problem is exter-nal to the DC600. Either theremote leads #75, #76 or #77are grounded to the negativeoutput cable or there is a shorton the welding output terminals.
2. If the machine still shuts offwhen all control and weldingcables are removed then theproblem is internal to the DC-600.
1. Contact your local LincolnAuthorized Field ServiceFacility.
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
E-9TROUBLESHOOTINGE-9
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
The weld output terminals arealways electrically "hot".
POSSIBLECAUSE
1. Remove any external leadshooked to #2 and #4 on the ter-minal strip or any connectionsto the 14 pin MS connector.Set OUTPUT TERMINALSswitch to the OFF position. Ifthe problem disappears thefault is in the control cable orwire feeder.
2. If some open circuit voltage ispresent (over 3VDC.) after per-forming Step #1. then the prob-lem is within the IDEALARC®DC-600.
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
E-10TROUBLESHOOTINGE-10
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
Poor arc starting when the IDE-ALARC® DC-600 is in the CVSub-Arc or CV Innershield Modes.
Machine has output but trips offimmediately when wire feed unittrigger is activated
POSSIBLECAUSE
1. Make sure the proper weldingprocedures are being used.(wire feed speed , arc voltageand wire size)
2. Check weld cables for loose orfaulty connections.
1. Remove output cables fromIDEALARC® DC-600. If prob-lem is resolved check for exter-nal short between weldiongcables. Also check controlcable (#75, #76, & #77) forgrounds or shorts.
RECOMMENDEDCOURSE OF ACTION
WELDING PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
E-11TROUBLESHOOTINGE-11
IDEALARC® DC-600
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
PROBLEMS(SYMPTOMS)
Poor arc characteristics in allprocesses.
POSSIBLECAUSE
1. Check for the correct input volt-ages on the three- phase inputlines at the IDEALARC® DC-600.
2. Make sure the proper weldingprocedures are being used. (wirefeed speed, arc voltage and wiresize).
3. Check the welding cables forloose or faulty connections.
RECOMMENDEDCOURSE OF ACTION
WELDING PROBLEMS
Observe all Safety Guidelines detailed throughout this manual
PC BOARD TROUBLESHOOTING GUIDEFIRING P.C. BOARD
1. All 10 LEDʼs must be ON when the POWERSOURCE is turned “ON” and the trigger circuit* isclosed.
2. LEDʼs 7, 8, and 9 indicate AC power being suppliedto the P.C. board from auxiliary windings on themain transformer (T1). If a LED is not “ON”, turn themachine off and unplug P5 from the firing board.Turn the machine back on and check the followingvoltages:
3. If all voltages are present, turn power off, and plugP5 back into J5. Turn power back on. If LEDʼs arestill “OUT”, replace Firing PCB.
4. If voltages were not present then check the wiringback to the auxiliary windings for a possible open.
5. LED 10 senses when trigger circuit* is closed.Close trigger circuit, LED10 should be on be “ON”.Open trigger circuit, LED 10 should be “OFF”. IfLED does not come “ON”, check to make sureleads 2,4, or 41 are not broken.
6. LEDʼs 1 through 6 indicate gate signals are beingsent to the main SCRʼs 1 through 6 respectively. IfLED 5 (located on Control Board) is “ON”, alongwith LEDʼs 7, 8, and 9 (on Firing PCB), and LEDʼs 1through 6 are “OFF”, check to make sure lead 231between Control board and Firing board is not bro-ken
7. If any one of LEDʼs 1 through 6 are “OFF” andLEDʼs 7, 8, and 9 are “ON”, replace the Firing PCB.
PC BOARD TROUBLESHOOTING GUIDECONTROL P.C. BOARD
1. LED 1 indicates AC input voltage necessary to gen-erate the DC supply voltages is present. These volt-ages power the Control board circuitry. If LED 1 isnot “ON” when machine POWER is “ON”, checkleads 255, 256, X1, and X2 for broken connection.
E-12TROUBLESHOOTINGE-12
IDEALARC® DC-600
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Voltage across leads 255 and 256 should beapproximately 115VAC. Check voltage across sec-ondary winding of the control transformer (T2) whichsupplies leads 255 and 256. Measure +16VDC fromTEST POINTS “A” to “C” and -10VDC from TESTPOINTS “A” to “J” on Control board.
2. LED 2 indicates welder output voltage is being sup-plied to the control circuit. LED 2 will be “ON”brightly in CC STICK mode with trigger circuit*closed and no load. (LED 2 diminishes in bright-ness as output voltage is reduced). If LED 2 is not“ON”, look for open connection in lead 222 circuit.
3. LED 3 indicates power is being applied to FAULTPROTECTION RELAY (CR2). LED 3 will be “ON”when machine POWER is “ON”. LED 3 goes “OUT”when CR2 drops out which turns off the INPUTCONTACTOR (CR1). When LED 3 goes out, LED 4comes “ON”. See step 3.
4. LED 4 indicates an overload or fault condition; LEDshould not be on. If this LED comes “ON”, theINPUT CONTACTOR (CR1) will turn off and the redPOWER light stays illuminated. This was do toeither a short across output, or a current draw inexcess of 780A, or leads 75, 76, or 77 grounded tonegative output lead. Remove short or reduce out-put current or eliminate ground. Welder must bereset by turning POWER ON/OFF switch to “OFF”and then back to “ON”. If no short or loads above780A exists or no ground, replace Control PCB.
5. LED 5 indicates DC control voltage (which suppliesFiring board) is present. LED 5 will be “ON” in CVINNERSHIELD mode with trigger circuit* closed,CONTROL POT at minimum, and no load. (LED 5diminishes in brightness as output voltage isincreased). Replace P.C. board if LED 5 did not go“ON”.
6. LED 6 indicates trigger circuit* condition. LED 6“ON” indicates trigger circuit is closed. LED 6 “OFF”indicates trigger circuit is open. If LED 6 does notcome “ON”, when trigger circuit closed, look foropen connections in the 2 & 4 circuit and in leads290 and 291.
TRIGGER CIRCUIT is closed by any of the following:• Wire feederʼs trigger is closed. • A jumper is placed across 2 & 4 on terminal stripT.S.2. or across pins C & D in 14 pin connector.
• OUTPUT TERMINAL switch is in the “ON” position.
LED that was off
789
Check AC voltage between pins specified,it should be approximately 32VAC .P5 pins 15 & 16 (wires 203,204)P5 pins 7 & 8 (wires 205,206)P5 pins 5 & 6 (wires 207,208)
E-13TROUBLESHOOTINGE-13
IDEALARC® DC-600
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
CHECKING POWER ON/OFF SWITCH (S1)
1. Turn off the machine input power (" o "position).
SW1 has 115 volts across it when the input poweris connected.
2. Isolate the switch to be tested by removing all co-nnecting leads.
3. Check to make sure the switch is making open andclosed connections with a V.O.M. meter. Put ohmmeter on X1 scale. The meter should read zeroresistance with switch " I " and infinite with switch
" o "
4. Put the ohmmeter on X1K scale and measure theresistance between the terminal and the case of themachine (touch a self-tapping screw). Readingshould be infinite.
5. If either step (3) or step (4) fails, replace the switch.
CHECKING OUTPUT CONTROL RHEO-STAT ON MACHINE (R1)
1. Turn machine off (" o " position).
2. Remove the screws from the hinged control paneland open the panel.
3. Turn the LOCAL/REMOTE CONTROL switch to"REMOTE".
4. With an ohmmeter on X1K, connect it to lead 236and 237 on R1.
5. Exercise caution to avoid damaging rheostat tabs.
6. Rotate the OUTPUT voltage control rheostat. Theresistance reading should be from around zero to10K ohms. Check the resistance reading betweenthe two outer tabs on the rheostat (leads 236 and75). The reading must be 10K "10% ohms. Noreading will indicate an open rheostat and a lowreading will indicate a shorted or partially shortedrheostat; in either case, replace.
CONNECTING REMOTE OUTPUTCONTROL RHEOSTAT TO THE MACHINE
Extreme caution must be observed when installing orextending the wiring of a remote control. Improperconnection of this unit can lead to loss of controland/or poor welding. Only the green lead can andshould be grounded to the machine case. Whenextending the standard remote control, make sure theleads are the same and the splice is waterproof. Bevery careful not to ground the cable when in use anddon't let the lugs touch against the case.
CHECKING REMOTE OUTPUT CONTROLRHEOSTAT
Disconnect the remote output control and connect anohmmeter across 75 and 76 and rotate the rheostat inthe remote control. The resistance reading should gofrom zero to 10K ohms. Repeat with ohmmeter across77 and 76 with same results. Connect ohmmeteracross 75 and 77. The reading should be 10K "10%ohms. A lower reading will indicate a shorted or par-tially shorted rheostat. A very high reading will indicatean open rheostat. In either of the last two cases,replace rheostat. Check cable for any physical dam-age.
F-1DIAGRAMSF-1
IDEALARC® DC-600
NO
TE
: T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
If th
e di
agra
m is
ille
gibl
e, w
rite
to th
e S
ervi
ce D
epar
tmen
t for
a r
epla
cem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber.
F-2DIAGRAMSF-2
IDEALARC® DC-600
, 113
38
NO
TE
: T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
If th
e di
agra
m is
ille
gibl
e, w
rite
to th
e S
ervi
ce D
epar
tmen
t for
a r
epla
cem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber.
F-3DIAGRAMSF-3
IDEALARC® DC-600
NO
TE
: T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
If th
e di
agra
m is
ille
gibl
e, w
rite
to th
e S
ervi
ce D
epar
tmen
t for
a r
epla
cem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber.
F-4DIAGRAMSF-4
IDEALARC® DC-600
NO
TE
: T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
If th
e di
agra
m is
ille
gibl
e, w
rite
to th
e S
ervi
ce D
epar
tmen
t for
a r
epla
cem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber.
IDEALARC® DC-600
F-5DIAGRAMSF-5
S
2040
9
1-28
-94
CO
NN
EC
TIO
N O
F L
N-7
42
TO
TH
E C
V-6
55
, D
C-6
55
OR
DC
-60
0 P
OW
ER
SO
UR
CE
Only
quali
fied
pers
ons
shou
ld in
stall
, use
or
serv
ice th
is m
achin
e.
ELEC
TRO
DE
CAB
LE
-+
14 P
INAM
PHEN
OL
POW
ER S
OU
RC
ELI
NC
OLN
TO W
OR
K
LN-7
42W
IRE
FEED
ER
Powe
r Sou
rce
befo
re c
onne
cting
the
wire
feed
er.
Turn
off
(0) t
he p
ower
swi
tch
on th
e W
elding
AND
14-
PIN
CAB
LE P
LUG
, R
EAR
VIE
WAN
D 1
4-PI
N C
ABLE
PLU
G,
FRO
NT
VIEW
K=4
2
C=2
D=4
E=77
F=76
G=7
5
H=2
1I=41
K=4
2
I=41 H
=21
G=7
5
F=76
E=77
D=4
C=2
PIN C D E F G H I K
42412175767742
LEAD
42V
AC42
V AC
WO
RK
OU
TPU
T C
ON
TRO
LO
UTP
UT
CO
NTR
OL
OU
TPU
T C
ON
TRO
LTR
IGG
ER C
IRC
UIT
TRIG
GER
CIR
CU
IT
(SEE
APP
RO
PRIA
TE W
IRIN
G D
IAG
RAM
)
FUN
CTI
ON
FUN
CTI
ON
S AR
E LI
STED
FO
R R
EFER
ENC
EO
NLY
AN
D E
ACH
MAY
OR
MAY
NO
T B
EPR
ESEN
T IN
YO
UR
EQ
UIP
MEN
T.
14-S
OC
KET
BO
X R
ECEP
TAC
LE,
FRO
NT
VIEW
14-S
OC
KET
BO
X R
ECEP
TAC
LE,
REA
R V
IEW
LN-7
42IN
PUT
CAB
LEAS
SEM
BLY
N.C
. PI
NS
NO
T LI
STED
AR
E N
OT
CO
NN
ECTE
D
ON
CAB
LE.
N.A
. W
ELD
ING
CAB
LE M
UST
BE
SIZE
D F
OR
CU
RR
ENT
A
ND
DU
TY C
YCLE
OF
APPL
ICAT
ION
.N
.B.
DIA
GR
AM S
HO
WS
ELEC
TRO
DE
POSI
TIVE
. TO
C
HAN
GE
POLA
RIT
Y, T
UR
N P
OW
ER "
OFF
",
REV
ERSE
ELE
CTR
OD
E AN
D W
OR
K C
ABLE
S AT
P
OW
ER S
OU
RC
E AN
D S
ET W
IRE
FEED
ER
VO
LTM
ETER
PO
LAR
ITY
SWIT
CH
ON
PO
WER
S
OU
RC
E TO
PR
OPE
R P
OLA
RIT
Y.
N.D
. IF
USI
NG
K58
9-1,
REM
OTE
CO
NTR
OL
KIT
,
SET
PO
WER
SO
UR
CE
CO
NTR
OL
SWIT
CH
T
O "
REM
OTE
" PO
SITI
ON
.
N.D
.
F-6DIAGRAMSF-6
IDEALARC® DC-600
N.C
. Ta
pe u
p bo
lted
conn
ectio
n if
lead
#21
is e
xten
ded.
N.D
. Co
nnec
t the
con
trol c
able
gro
und
lead
to th
e fra
me
term
inal
mar
ked
nea
r the
pow
er s
ourc
e te
rmin
al s
trip.
The
pow
er
s
ourc
e gr
ound
ing
term
inal
(mar
ked
and
loca
ted
near
the
pow
er
s
ourc
e in
put p
ower
con
nect
ions
) mus
t be
prop
erly
conn
ecte
d to
ele
ctric
al g
roun
d pe
r the
pow
er s
ourc
e op
erat
ing
man
ual.
N.E
. If
an o
ptio
nal r
emot
e vo
ltage
con
trol i
s us
ed, c
onne
ct it
to
this
term
inal s
trip.
N.
A. W
eldi
ng c
able
s m
ust b
e of
pro
per c
apac
ity fo
r the
cur
rent
and
du
ty c
ycle
of i
mm
edia
te a
nd fu
ture
app
licat
ions
. Se
e LN
-7
Ope
ratin
g M
anua
l for
pro
per s
izes.
N.
B. I
f LN-
7 is
equi
pped
with
a m
eter
kit,
ext
end
LN-7
con
trol c
able
su
itabl
e fo
r the
inst
alla
tion.
An
S165
86-[L
ENG
TH] r
emot
e
volta
ge s
ensin
g w
ork
lead
may
be
orde
red
for t
his
purp
ose.
Co
nnec
t it d
irect
ly to
the
wor
k pi
ece
inde
pend
ent o
f the
wel
ding
w
ork
cabl
e co
nnec
tion.
For
con
veni
ence
, thi
s ex
tend
ed #
21 le
ad
shou
ld b
e ta
ped
to th
e w
eldi
ng w
ork
lead
. (If
the
leng
th o
f
wel
ding
wor
k ca
ble
is sh
ort,
less
than
25
feet
, and
con
nect
ions
ca
n be
exp
ecte
d to
be
relia
ble,
then
con
trol c
able
lead
#21
doe
s
not n
eed
to b
e ex
tend
ed a
nd c
an b
e di
rect
ly co
nnec
ted
to
term
inal
#21
on
the
term
inal
stri
p. N
ote
that
this
is no
t the
pr
efer
red
conn
ectio
n be
caus
e it
adds
erro
r to
the
LN-7
vol
tmet
er
Abo
ve d
iagra
m sh
ows e
lectro
de co
nnec
ted p
ositiv
e. T
o ch
ange
pola
rity,
turn
pow
er o
ff, re
verse
the e
lectro
de an
d wo
rk lea
ds at
the p
ower
414
231
3275
7677
NEG
ATIV
EPO
SITI
VE
32 31 2 4 GND 21
N.A.
N.D.
ELEC
TRO
DE
CAB
LETO
WIR
E FE
ED U
NIT
TO W
OR
K
POW
ER S
OU
RC
E
N.E.
N.F
.
re
adin
g.)
N.F
. If
lead
#21
is to
be
conn
ecte
d to
the
term
inal s
trip,
con
nect
to th
e #2
1 te
rmina
l tha
t mat
ches
work
pol
arity
. Th
is c
onne
ctio
n m
ust b
e ch
ange
d wh
enev
er th
e ele
ctro
de p
olar
ity is
ch
ange
d.
Only
quali
fied p
erson
s sho
uld in
stall,
use o
rse
rvice
this
mach
ine.
Do no
t ope
rate w
ith co
vers
remov
ed.
Disco
nnec
t pow
er so
urce b
efore
servi
cing.
Do no
t tou
ch el
ectric
ally l
ive pa
rts.
LN-7
TO
INPU
T C
ABLE
PLU
G
LN-7
CO
NTR
OL
CAB
LE
21-
21
FOR
CONT
ROL
CABL
EW
ITH
14 P
INM
S-TY
PEPL
UG C
ONN
ECTO
R
OR
FOR
CONT
ROL
CABL
EW
ITH
TERM
INAL
STR
IPLE
AD C
ONN
ECTO
RS
CO
NTRO
L CA
BLE
S
2297
6
sour
ce an
d po
sition
the s
witch
on w
ire fe
eder
(if eq
uippe
d )
to p
rope
r pola
rity.
Also
refer
to no
te N.
F.
N.B.
& N
.C.
14-P
INRE
CEPT
ACLE
lead
#21
from
con
trol c
able
with
term
inal
stri
p co
nnec
tors
or f
rom
14-
pin
rece
ptac
le u
sing
#14
AWG
or l
arge
r ins
ulat
ed w
ire p
hysic
ally
21+
REM
OTE
VO
LTAG
E SE
NSI
NG
LEA
D
10-3
0-98
F
N.G
.
N.G
. Illu
stra
tion
does
not
nec
essa
rily
repr
esen
t act
ual p
ositi
on o
f
fo
r mor
e inf
orm
atio
n.
CO
NN
EC
TIO
N O
F L
N-7
TO
TH
E C
V-6
55
, D
C-6
55
OR
DC
-60
0 P
OW
ER
SO
UR
CE
ap
prop
riate
out
put s
tuds
. Ref
er to
pow
er s
ourc
e op
erat
ing m
anua
l
For p
rope
r set
ting
of s
witc
hes
on p
ower
sou
rce,
see
pow
er s
ourc
e op
erat
ing
man
ual.
F-7DIAGRAMSF-7
IDEALARC® DC-600
N.C
. Ta
pe u
p bo
lted
conn
ectio
n if
lead
#21
is e
xten
ded.
N.D
. Co
nnec
t the
con
trol c
able
gro
und
lead
to th
e fra
me
term
inal
mar
ked
near
the
pow
er s
ourc
e te
rmin
al s
trip.
The
pow
er
s
ourc
e gr
ound
ing
term
inal
(mar
ked
and
loca
ted
near
the
pow
er
s
ourc
e in
put p
ower
con
nect
ions
) mus
t be
prop
erly
conn
ecte
d to
ele
ctric
al g
roun
d pe
r the
pow
er s
ourc
e op
erat
ing
man
ual.
N.
A. W
eldi
ng c
able
s m
ust b
e of
pro
per c
apac
ity fo
r the
cur
rent
and
Abo
ve d
iagra
m sh
ows e
lectro
de co
nnec
ted p
ositiv
e. T
o ch
ange
pola
rity,
turn
pow
er o
ff, re
verse
the e
lectro
de an
d wo
rk lea
ds at
the p
ower
NEG
ATIV
EPO
SITI
VE
32 31 2 4 GND 21
N.A.
N.D.
ELEC
TRO
DE
CAB
LETO
WIR
E FE
ED U
NIT
TO W
OR
K
POW
ER S
OU
RC
E
N.E.
Only
quali
fied p
erson
s sho
uld in
stall,
use o
rse
rvice
this
mach
ine.
Do no
t ope
rate w
ith co
vers
remov
ed.
Disco
nnec
t pow
er so
urce b
efore
servi
cing.
Do no
t tou
ch el
ectric
ally l
ive pa
rts.
CAB
LE
21
FOR
CONT
ROL
CABL
EW
ITH
14 P
INM
S-TY
PEPL
UG C
ONN
ECTO
R
OR
FOR
CONT
ROL
CABL
EW
ITH
TERM
INAL
STR
IPLE
AD C
ONN
ECTO
RS
CO
NTRO
L CA
BLE
S
2297
7
sour
ce an
d po
sition
the s
witch
on w
ire fe
eder
(if eq
uippe
d )
to p
rope
r pola
rity.
Also
refer
to no
te N.
F.
N.B.
& N
.C.
14-P
INRE
CEPT
ACLE
ABC
N.E
. If
usin
g an
old
er L
N-8
cont
rol c
able
: con
nect
lead
#75
to #
75 o
nte
rmin
al s
trip,
con
nect
lead
#76
to #
76 o
n te
rmin
al s
trip,
con
nect
lead
#77
to #
77 o
n th
e te
rmin
al s
trip.
the
#21
term
inal t
hat m
atch
es w
ork
polar
ity. T
his c
onne
ctio
n m
ust b
e c
hang
ed w
hene
ver t
he e
lectro
de p
olar
ity is
cha
nged
.
N.G
. If
lead
#21
is to
be
conn
ecte
d to
the
term
inal s
trip,
con
nect
to
N.F.
The
LN-
9 vo
ltage
con
trol j
umpe
rs m
ust b
e co
nnec
ted
as fo
llow
s(re
fer t
o LN
-9 O
pera
ting
Man
ual):
Whi
te ju
mpe
r on
volta
ge b
oard
to p
in "S
" .Bl
ue ju
mpe
r on
volta
ge b
oard
(lat
er u
nits
onl
y),
or o
n st
art b
oard
(ear
lier u
nits
), to
pin
"B".
rem
ote
volta
ge s
ensin
g w
ork
lead
may
be
orde
red
for t
his
purp
ose.
N.B.
Ext
end
lead
#21
from
con
trol c
able
with
term
inal
stri
p co
nnec
tors
or
fro
m 1
4-pi
n re
cept
acle
usin
g #1
4 AW
G o
r lar
ger i
nsul
ated
wire
du
ty c
ycle
of i
mm
edia
te a
nd fu
ture
app
licat
ions
.
Con
nect
it d
irect
ly to
the
wor
k pi
ece
keep
ing
it el
ectri
cally
con
veni
ence
, thi
s ex
tend
ed #
21 le
ad s
houl
d be
tape
d to
the
wel
ding
wor
k le
ad.
(If th
e le
ngth
of w
ork
lead
circ
uit i
s
s
hort,
and
con
nect
ions
can
be
expe
cted
to b
e re
liabl
e, th
en
c
ontro
l cab
le le
ad #
21 d
oes
not n
eed
to b
e ex
tend
ed a
nd c
an b
e
d
irect
ly co
nnec
ted
to te
rmin
al #
21 o
n th
e te
rmin
al s
trip.
Not
e
t
hat t
his
is no
t the
pre
ferre
d co
nnec
tion
beca
use
it ad
ds e
rror
sep
arat
e fro
m th
e w
eldi
ng w
ork
lead
circ
uit a
nd c
onne
ctio
n. F
or
to
the
wire
feed
er v
oltm
eter
read
ing.
)
phy
sical
ly su
itabl
e fo
r the
inst
alla
tion.
An
S165
86-[L
ENG
TH]
TO L
N-8
OR
LN
-9
CO
NTR
OL
N.F
.IN
PUT
CAB
LE P
LUG
414
231
3275
7677
N.E.
N.G
.21-21+
REM
OTE
VO
LTAG
E SE
NSI
NG
LEA
D
10-3
0-98
F
N.H
. Ill
ustr
atio
n do
es n
ot n
eces
saril
y re
pres
ent a
ctua
l pos
ition
of a
ppro
pria
te
out
put s
tuds
. Ref
er to
pow
er s
ourc
e in
stru
ctio
n m
anua
l for
mor
e in
fo.
N.H.
CO
NN
EC
TIO
N O
F L
N-8
OR
LN
-9 T
O T
HE
CV
-65
5,
DC
-65
5 O
R D
C-6
00
PO
WE
R S
OU
RC
E
For p
rope
r set
ting
of s
witc
hes
on p
ower
sou
rce,
see
pow
er s
ourc
e op
erat
ing
man
ual.
F-8DIAGRAMSF-8
IDEALARC® DC-600
F-9DIAGRAMSF-9
IDEALARC® DC-600
F-10DIAGRAMSF-10
IDEALARC® DC-600
S22
980
ELEC
TRO
DE
CAB
LE
-+
14 P
INAM
PHEN
OL
POW
ER S
OU
RC
E TO W
OR
K
AND
14-
PIN
CAB
LE P
LUG
, R
EAR
VIE
WAN
D 1
4-PI
N C
ABLE
PLU
G,
FRO
NT
VIEW
K=4
2
I=41 H
=21
D=4
C=2
PIN B C D E F
75767742
LEAD
42V
AC42
V AC
TRIG
GER
CIR
CU
IT
(SEE
APP
RO
PRIA
TE W
IRIN
G D
IAG
RAM
)
FUN
CTI
ON
FUN
CTI
ON
S AR
E LI
STED
FO
R R
EFER
ENC
EO
NLY
AN
D E
ACH
MAY
OR
MAY
NO
T B
EPR
ESEN
T IN
YO
UR
EQ
UIP
MEN
T.
14-S
OC
KET
BO
X R
ECEP
TAC
LE,
FRO
NT
VIEW
14-S
OC
KET
BO
X R
ECEP
TAC
LE,
REA
R V
IEW
N.C
. PI
NS
NO
T LI
STED
AR
E N
OT
CO
NN
ECTE
D
ON
CAB
LE.
N.A
. W
ELD
ING
CAB
LE M
UST
BE
SIZE
D F
OR
CU
RR
ENT
A
ND
DU
TY C
YCLE
OF
APPL
ICAT
ION
.
G21
H41
I42
J
MF=
76E=
77
G=7
5NL
A
B=G
ND
K=4
2
I=41
H=2
1
D=4C
=2
J
MF=
76E=
77G
=75
NL
A
B=G
ND
9 PI
NAM
PHEN
OL
K
GN
DC
HAS
SIS
CO
NN
ECTI
ON
WO
RK
OU
TPU
T C
ON
TRO
LO
UTP
UT
CO
NTR
OL
OU
TPU
T C
ON
TRO
L
TRIG
GER
CIR
CU
IT
Only
quali
fied p
erson
s sho
uld in
stall,
use o
rse
rvice
this
mach
ine.
Do no
t ope
rate w
ith co
vers
remov
ed.
Disco
nnec
t pow
er so
urce b
efore
servi
cing.
Do no
t tou
ch el
ectric
ally l
ive pa
rts.
N.D
. IF
LEA
D #
21 IS
TO
BE
CO
NN
ECTE
D T
O T
HE
T
ERM
INAL
STR
IP, C
ON
NEC
T TO
TH
E #2
1
TER
MIN
AL T
HAT
MAT
CH
ES W
OR
K P
OLA
RIT
Y.
TH
IS C
ON
NEC
TIO
N M
UST
BE
CH
ANG
ED W
HEN
EVER
T
HE
ELEC
TRO
DE
POLA
RIT
Y IS
CH
ANG
ED.
10-3
0-98
F
N.E
.
N.E
. ILL
UST
RAT
ION
DO
ES N
OT
NEC
ESSA
RIL
Y R
EPR
ESEN
TAC
TUAL
PO
SITI
ON
OF
APPR
OPR
IATE
OU
TPU
T ST
UD
S.
MO
RE
INFO
RM
ATIO
N.
CO
NN
EC
TIO
N O
F D
H-1
0 O
R L
N-1
0 T
O P
OW
ER
SO
UR
CE
WIT
H 1
4 P
IN A
MP
HE
NO
L
REF
ER T
O P
OW
ER S
OU
RC
E O
PER
ATIN
G M
ANU
AL F
OR
LIN
CO
LN
WIR
EFE
EDER
WIR
E FE
EDER
IN
PUT
CAB
LEAS
SEM
BLY
N.B
. D
IAG
RAM
SH
OW
S EL
ECTR
OD
E PO
SITI
VE.
TO
CH
ANG
E PO
LAR
ITY,
TU
RN
PO
WER
"O
FF",
R
EVER
SE E
LEC
TRO
DE
AND
WO
RK
CAB
LES
AT
PO
WER
SO
UR
CE.
FOR
PR
OPE
R S
ETTI
NG
S O
F SW
ITC
HES
ON
PO
WER
SO
UR
CE,
SEE
POW
ER S
OU
RC
E O
PER
ATIN
G M
ANU
AL.
F-11DIAGRAMSF-11
IDEALARC® DC-600
LOCAT
ION
OF
BASE
MOUNT
ING
HOLES
.94
*
*
**
20.0
0
M12244-6
DC
-60
0
1-20
-89A
27.8
7
9.20
27.5
0
3.25
39.9
5
22.2
5
29.9
3
TH
IS D
IMENS
ION
WILL
VARY
WITH
POS
ITION
OF
HANDLE
DIM
EN
SIO
N P
RIN
T (
WIT
H K
81
7P
UN
DE
RC
AR
RIA
GE
)
11.1
217
.75
38.0
0
5.90
4.75
F-12DIAGRAMSF-12
IDEALARC® DC-600
6-18
-93C
36.1
2
M15200-3
17.7
638
.00
5.19
DIM
EN
SIO
N P
RIN
T (
WIT
H K
84
2 U
ND
ER
CA
RR
IAG
E)
20.0
0
27.6
5
*
37.8
6
LOCAT
ION
OF
BASE
MOUNT
ING
HOLES
*
*29.9
3.9
4
**
3.25
23.2
8
22.2
5
11.1
2
27.5
0
7.11
54.9
1
49.8
9
DC
-60
0
NOTES
IDEALARC® DC-600
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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.
� Do not touch electrically live parts orelectrode with skin or wet clothing.
� Insulate yourself from work andground.
� No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
� Aislese del trabajo y de la tierra.
� Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
� Isolez-vous du travail et de la terre.
� Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
� Isolieren Sie sich von denElektroden und dem Erdboden!
� Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
� Isole-se da peça e terra.
� Keep flammable materials away.
� Mantenga el material combustiblefuera del área de trabajo.
� Gardez à l’écart de tout matérielinflammable.
� Entfernen Sie brennbarres Material!
� Mantenha inflamáveis bem guarda-dos.
� Wear eye, ear and body protection.
� Protéjase los ojos, los oídos y elcuerpo.
� Protégez vos yeux, vos oreilles etvotre corps.
� Tragen Sie Augen-, Ohren- und Kör-perschutz!
� Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
� Keep your head out of fumes.� Use ventilation or exhaust to
remove fumes from breathing zone.
� Los humos fuera de la zona de res-piración.
� Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
� Gardez la tête à l’écart des fumées.� Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
� Vermeiden Sie das Einatmen vonSchweibrauch!
� Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
� Mantenha seu rosto da fumaça.� Use ventilação e exhaustão para
remover fumo da zona respiratória.
� Turn power off before servicing.
� Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
� Débranchez le courant avant l’entre-tien.
� Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
� Não opere com as tampas removidas.� Desligue a corrente antes de fazer
serviço.� Não toque as partes elétricas nuas.
� Do not operate with panel open orguards off.
� No operar con panel abierto oguardas quitadas.
� N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
� Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
� Mantenha-se afastado das partesmoventes.
� Não opere com os paineis abertosou guardas removidas.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •