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IM306-C
IDEALARC ® DC-600 March, 1999
9773 to 10419
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR 5 6
4
7
REPAIR THIS EQUIPMENT 3
8
2
WITHOUT READING THIS 9
1
10
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ............................................................................................. A-1
Safety Precautions ..................................................................................................... A-2
Select Proper Location.................................................................................................A-2
Stacking .................................................................................................................A-2
Tilting .....................................................................................................................A-2
Electrical Input Connections ....................................................................................... A-3
Fuses and Wire Sizes............................................................................................A-3
Ground Connection .............................................................................................. A-3
Input Power Supply Connections...........................................................................A-3
Reconnect Procedure ................................................................................................ A-4
Output Connections ................................................................................................... A-7
Electrode and Work Leads ....................................................................................A-7
Connection for Wire Feeder Control ......................................................................A-8
Connection for Stick Welding and Air Carbon Arc .................................................A-8
Operation .........................................................................................................Section B
Safety Precautions ............................................................................................... B-1
General Description ............................................................................................. B-2
Recommended Processes and Equipment ...........................................................B-2
Operational Features and Controls .......................................................................B-2
Design Features and Advantages ........................................................................B-2
Welding Capacity ................................................................................................. B-3
Controls and Settings ...........................................................................................B-4
Operating Steps ................................................................................................... B-5
Remote Control of Machine Operation ..................................................................B-5
Welding Procedure Recommendations .................................................... B-5 � B-8
Semi-Automatic and Automatic Wire Feeding
with a DC-600 and Wire Feeders ..........................................................................B-6
NA-3 Automatic Wire Feeder.................................................................................B-6
NA-5 Automatic Wire Feeder.................................................................................B-8
LN-8 Semi-Automatic Wire Feeder........................................................................B-8
LN-7 & LN-9 Semi-Automatic Wire Feeders..........................................................B-8
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Multi-Process Switch .............................................................................................C-1
Undercarriage........................................................................................................C-3
Meters....................................................................................................................C-3
Paralleling Kit.........................................................................................................C-3
Connections for Wire Feeder Control ....................................................................C-4
NA-3 ......................................................................................................................C-4
NA-5 ......................................................................................................................C-5
LN-8 or LN-9..........................................................................................................C-6
LN-7.......................................................................................................................C-7
vii TABLE OF CONTENTS
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-2
3-D Exploded View ................................................................................................D-3
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams ..............................................................................................Section F
Parts List ......................................................................................................P282 Series
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - IDEALARC DC-600
INPUT - THREE PHASE ONLY
Input Current at Rated Output
Standard Voltage
208/230/416/460/575/3/60 125/113/63/57/45
RATED OUTPUT
Duty Cycle AMPS Volts at Rated Amps
100% 600 44
60% 680 44
50% 750 44
OUTPUT
Auxiliary Power
Mode Maximum Open
Current
Circuit Voltage
Range
115 VAC, 8 Amps
Constant Current 72 VDC
90 to 850 Amps
Constant Voltage 55 VDC
70 to 850 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
Type 75oC
Input Voltage / Fuse Input Ampere Type 75oC
Copper Ground
Frequency (Super Lag) Rating on Copper Wire in
Wire in Conduit
or Breaker Size Nameplate Conduit AWG
AWG (IEC) Sizes
(IEC) Sizes
208/60 175 125 2 (35mm2) 6 (16 mm2)
230/60 175 113 2 (35mm2) 6 (16 mm2)
416/60 100 63 6 (16mm2) 8 (10 mm2)
460/60 90 57 6 (16mm2) 8 (10 mm2)
575/60 80 45 6 (16mm2) 8 (10 mm2)
PHYSICAL DIMENSIONS
Weight
Height Width Depth
522 lbs.
30.75 in. 22.25 in. 39.0 in.
(237 kg.)
(781 mm.) (567 mm.) (988 mm.)
IDEALARC DC-600
A-2 A-2
INSTALLATION
Read entire Installation Section before installing DO NOT stack the IDEALARC DC-600 on another
the IDEALARC DC-600. type of machine.
Follow these guidelines when stacking:
SAFETY PRECAUTIONS
1. Select a firm, level surface capable of sup-
WARNING porting the total weight of up to three
machines (1570 pounds/712 kilograms).
ELECTRIC SHOCK CAN KILL.
2. Set the bottom machine in place.
� Only qualified personnel should
install this machine. 3. Stack the second machine on top of it by
aligning the two holes in the base rails of the
� Turn the input power OFF at the
second machine with the two pins on top front
disconnect switch or fuse box before
of the bottom machine.
working on the equipment.
� Do not touch electrically hot parts. 4. Repeat process for third machine.
� Always connect the IDEALARC
NOTE: The machines must be stacked with the Case
DC-600 grounding terminal to a good
electrical earth ground. Front of each machine flush with each other. See
Figure A.1.
� Set the IDEALARC DC-600 Power ON/OFF PUSH BUTTON to
the OFF position when connecting power cord to input power.
__________________
SELECT PROPER LOCATION
STACKING HOLE
Place the IDEALARC DC-600 where clean air can
freely circulate in through the front intake and out
through the rear louvers. Dirt, dust, or any foreign
material that can be drawn into the machine should be
kept at a minimum. Not following these precautions
can result in the nuisance shutdown of the machine
because of excessive operating temperatures.
STACKING PINS
STACKING
Three IDEALARC DC-600 machines can be stacked.
FIGURE A.1 - Stacking IDEALARC DC-600
DO NOT stack more than three machines in one machines
grouping.
TILTING
The IDEALARC DC-600 must be placed on a
stable, level surface so it will not topple over.
IDEALARC DC-600
A-3 A-3
INSTALLATION
ELECTRICAL INPUT CONNECTIONS INPUT POWER SUPPLYCONNECTIONS
A qualified electrician should connect the input power
Before installing the machine, check that the input
supply leads.
supply voltage, phase, and frequency are the same as
the machine’s voltage, phase, and frequency as spec-
1. Follow all national and local electrical codes.
ified on the machine’s rating plate on the Case Front
Assembly Control Panel. Input power supply entry is
2. Follow Input Supply Connection Diagram located
through the hole in the Case Back Assembly. See
on the inside of the machine.
Figure A.2 for the location of the machine’s input
cable entry opening, Input Contactor (CR1), and
3. Use a three-phase line.
reconnect panel assembly for dual voltage machines.
4. Remove Input Access Door at upper rear of
INPUT SUPPLY machine.
CABLE ENTRY
INPUT
OPENING
CONTACTOR (CR1) 5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
terminals in the Input Box Assembly by passing
RECONNECT
them thru the three aligned .50� diameter holes in
PANEL ASSEMBLY
the baffle and tighten them in the terminal connec-
tors. Be sure to close the baffle by inserting the
tab into the slot in the baffle. See Figure A.3.
FIGURE A.2 - Rear Panel
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or ther-
mal/magnetic circuit breakers. INPUT
CONTACTOR (CR1)
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in INPUT POWER SUPPLY
“nuisance� tripping caused by inrush current even CABLE WITH BUSHING
RECONNECT
OR BOX CONNECTOR
when machine is not being used for welding at high PANEL ASSEMBLY
output currents.
Use input and grounding wire sizes that meet local
electrical codes or see the Technical Specifications
page in this manual.
GROUND CONNECTION
Ground the frame of the machine. A ground
terminal marked with the symbol ( ) is located inside
FIGURE A.3 - Input Power Supply
the Case Back of the machine near the input contac-
Connections
tor. Access to the Input Box Assembly is at the upper
rear of the machine. See your local and national elec-
trical codes for proper grounding methods.
IDEALARC DC-600
A-4 A-4
INSTALLATION
RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different
voltage, remove input power and change the position
of the reconnect board on the Reconnect Panel.
Multiple voltage machines are shipped connected to
Follow The Input Connection Diagram located on the
the highest input voltage listed on the machine’s rating
inside of Case Back Input Access Door. These con-
plate. Before installing the machine, check that the
nection diagrams for the following codes are listed
Reconnect Panel in the Input Box Assembly is con-
below.
nected for the proper voltage.
1. For Dual Voltage except 380/500-460/575, see
Figure A.4. (M15009)
CAUTION 2. For 220/380/460, see Figure A.5. (M15010)
Failure to follow these instructions can cause immedi-
3. For 380/500-460/575, see Figure A.6. (M15011)
ate failure of components within the machine.
__________________ 4. For Single Voltage, see Figure A.7. (S17894)
5. For 230/460/575, see Figure A.8. (M15666)
6. For Voltages not listed, see the Input Connection
Diagram pasted on the inside of the Case
Back Input Access Door.
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
W CRI
L3 2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES L2 LEAST 600 VOLT INSULATION.
V
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
CONTACTOR
INPUT L1 U THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H1
GND 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
H3 H2 DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
PILOT
REMAINING HEX NUTS IN PLACE.
TRANSF.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES L2 V LEAST 600 VOLT INSULATION.
INPUT L1 CTOR
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
U
THE CRI CONTACTOR AS SHOWN.
H1 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND H2 H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT
TRANSF.
FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines
IDEALARC DC-600
A-5 A-5
INSTALLATION
CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
W CRI
L3 2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LINES L2 LEAST 600 VOLT INSULATION.
V
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE
CONTACTOR
INPUT L1 U INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H3
GND H4 H1 5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE
H2 POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUM
PILOT
CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
LINKS TRANSF.
CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.
W CRI
L3 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
LINES L2 2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
V
LEAST 600 VOLT INSULATION.
CONTACTOR
INPUT L1 U 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
H4
GND H3 H1 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H2 5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,
PILOT
LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
LINKS TRANSF.
CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
W CRI
L3 2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LINES L2 V LEAST 600 VOLT INSULATION.
CONTACTOR
INPUT L1 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE
U
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
H4
GND H2 H1 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
PILOT
LINKS TRANSF.
FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines
CONNECTION FOR 500/575 VOLTAGES
CONNECTION FOR 380/460 VOLTAGES
H3
H2
L3 W CRI
W CRI
L3 LINES
LINES
INPUT L2
V
INPUT L2
V CONTACTOR
CONTACTOR
L1 U
L1 U
H1
GND
GND H1
H3 H2
LINK LINK
TAPE TAPE
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT 1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION. LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR. 2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN. AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES. 4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN 5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS ALL HEX NUTS
FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines
IDEALARC DC-600
A-6 A-6
INSTALLATION
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
W CRI
L3 2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
LINES
INPUT L2
V 3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
CONTACTOR
L1 U
GND
FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines
FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines
IDEALARC DC-600
A-7 A-7
INSTALLATION
OUTPUT CONNECTIONS
See Table A.1 for recommended IDEALARC DC-600 cable sizes for combined lengths of electrode and work
cables.
TABLE A.1
IDEALARC DC-600 Cable Sizes for Combined Lengths of Electrode and Work Cable (Copper)
at 100% Duty Cycle
Cable Length Parallel Cables Cable Size
2 1/0 (53mm2)
Lengths up to 150 ft. (46m)
150 ft.(46m) to 200 ft (61m) 2 2/0 (67mm2)
200 ft.(61m) to 250 ft.(76m) 2 3/0 (85mm2)
Connect Electrode and Work Leads to Output
Terminals.
1. Set the ON/OFF PUSH BUTTON to OFF.
2. Locate the retractable strain relief loops directly
below the output terminals in the lower right and
lower left corners of the Case Front Assembly.
See Figure A.9.
3. Pull out the retractable strain relief loops.
4. Insert the electrode lead through the loop directly
below the desired polarity (positive or negative).
Pull through enough cable to reach the output
terminals.
5. Connect electrode lead to the desired terminal
(positive/negative).
FIGURE A.9 - Output Terminals.
6. Tighten the output terminal nut with a wrench.
7. Connect the work lead to the other output
terminal following steps 4-6.
IDEALARC DC-600
A-8 A-8
INSTALLATION
Connection For Semi-Automatic or Automatic 1. Set ON/OFF PUSH BUTTON to OFF.
Wire Feeder Control
2. Locate and open the hinged access door on the
Front Case Assembly.
NOTE: See the ACCESSORIES Section of this manu-
al for specific instructions on connecting the following
3. If necessary, disconnect all wire feeder control
semi-automatic and automatic wire feeders:
cable connections from the DC-600 terminal strip.
}
� LN-7
4. Remove the leads from the unit by pulling them
� LN-8 Semi-Automatic Wire Feeders
through and out of the strain relief loops.
� LN-9
5. Connect a jumper wire from terminal #2 to termi-
� NA-3
} nal #4 on the terminal strip.
Automatic Wire Feeders
� NA-5
6. Set the Welding Mode Switch to the VV position
LT-56 }
� LT-7
Tractors for both stick welding and air/carbon arc cutting.
�
NOTE: To use the IDEALARC DC-600 for both stick
welding / air/carbon arc cutting, AND semi-automatic /
Connection for Stick Welding and Air/Carbon
automatic welding, the optional Multi-Process Switch
Arc Cutting Operation (K804) must be used. See the ACCESSORIES
Section of this manual for instructions on installing
and using the Multi-Process Switch. When the Multi-
WARNING Process Switch is not used, all control, work, and
electrode leads from semi-automatic or automatic wire
feeders must be disconnected from the IDEALARC
DC-600 before connecting the machine for stick weld-
THE OUTPUT TERMINALS ARE ENERGIZED AT
ing or air/carbon arc cutting.
ALL TIMES WHEN THE IDEALARC DC-600 IS CON-
NECTED FOR STICK WELDING AND AIR/CARBON
ARC CUTTING.
__________________
IDEALARC DC-600
B-1 B-1
OPERATION
OPERATING INSTRUCTIONS
Read and understand entire section before operating machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
can kill.
� Do not touch electrically live parts
or electrode with skin or wet
clothing.
� Insulate yourself from work and
ground.
� Always wear dry insulating
gloves.
FUMES AND GASES
can be dangerous.
� Keep your head out of fumes.
� Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
� Keep flammable material away.
� Do not weld, cut or gouge on
containers that have held combustibles.
ARC RAYS
can burn.
� Wear eye, ear and body
protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
IDEALARC DC-600
B-2 B-2
OPERATION
GENERAL DESCRIPTION OPERATIONAL FEATURES AND
CONTROLS
The IDEALARC DC-600 is an SCR controlled three
phase welding and cutting power source. It uses a The IDEALARC DC-600 comes with the following
single range potentiometer to control: standard controls:
� Submerged Arc Semi-Automatic or Automatic � ON/OFF PUSH BUTTON
Welding � OUTPUT CONTROL POTENTIOMETER
� Open Arc Semi-Automatic or Automatic Welding � OUTPUT CONTROL SWITCH (Remote or Panel)
� Stick Welding (Standard on All Machines) � WELDING MODE SWITCH
� Air/Carbon Arc Cutting (Carbon Rod Sizes up to � CONTROL CIRCUIT POLARITY SWITCH
3/8� Diameter) � POWER SOURCE PILOT LIGHT
� DC AMMETER (OPTIONAL)
� DC VOLTMETER (OPTIONAL)
The IDEALARC DC-600 has a three-position Welding
Mode Switch to enable the user to operate in one of
DESIGN FEATURES AND
three modes:
ADVANTAGES
� Constant Voltage (CV) Submerged Arc
� Constant Voltage (CV) Innershield The following list of design features will help you
� Constant Current (CC) Stick understand the machine’s total capabilities and how
you can take advantage of them to get maximum use
of your machine.
The IDEALARC DC-600 can be easily connected to
wire feeding equipment, including: � Excellent arc characteristics for optimum constant
voltage submerged arc and Innershield welding
� Semi-automatic wire feeders LN-7, LN-8, and performance.
LN-9 � A control circuit designed to provide good starting
� Automatic wire feeders NA-3 and NA-5 for a large variety of processes and procedures.
� Tractors LT-56 and LT-7 � Output Control Potentiometer that provides easy
single range continuous control.
The optional Multi-Process Switch allows the user to � Output Control Switch that provides simple switch-
switch between semi-automatic or automatic welding ing from local to remote control.
and stick welding or air/carbon arc cutting without dis- � Red neon pilot light to confirm that the Input
connecting the wire feeder equipment control, elec- Contactor is energized.
trode, and work leads.
RECOMMENDED PROCESSES AND
EQUIPMENT
The IDEALARC DC-600 is recommended for the fol-
lowing welding or cutting processes within its output
capacity of 70 amps to 850 amps in the Constant
Voltage mode and 90 amps to 850 amps in the
Constant Current mode:
� Submerged Arc Semi-Automatic or Automatic
Welding
� Open Arc Semi-Automatic or Automatic Welding
� Stick Welding (Standard on All Machines)
� Air/Carbon Arc Cutting (Carbon Rod Sizes up to
3/8� Diameter)
IDEALARC DC-600
B-3 B-3
OPERATION
� Auxiliary power source to provide 115-volt AC � Three circuit solid state control system provides
power (1000 VA) to wire feeding equipment. maximum performance and circuit protection.
� Multi-functional terminal strip for easy connection � Low profile case provides maximum use of space.
of wire feeding control cables and switching � Convenient access to all controls.
between CV Innershield and CV Submerged Arc � Output lead strain relief loops to prevent terminal
welding when using the Dual Process or Dual and cable damage.
Procedure Kits. � Easily removed case side, even when stacked.
� Recessed output terminals to avoid any person or � Outdoor operation because enclosure is designed
object from accidentally coming into contact with with air intake louvers that keep dripping water
the output terminals and labeled positive and neg- from entering the unit. Transformer, SCR bridge,
ative for easy identification. and choke have special corrosion resistant paint
� Thermostatically protected power source. for added protection.
� 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 repetitive
welding applications.
_____________________________________
WELDING CAPABILITY
The IDEALARC DC-600 has the following duty cycle ratings:
If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal
operating temperature.
Duty Cycle Amps Volts Hertz
750
50% 44 50/60
(Based on 10 min.)
60% 44 50/60
680
(Based on 10 min.)
100% 44 50/60
600
_____________________________________
IDEALARC DC-600
B-4 B-4
OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the Case Front Assembly of the IDEALARC DC-600. See
Figure B.1 for the location of each control.
3. WELDING MODE
7. AMMETER 8. VOLTMETER 4. OUTPUT CONTROL
SWITCH
(optional) (optional) SWITCH
1. ON/OFF
6
5
PUSH
4 7
BUTTON
3 8
2 9
1 10
6. POWER
SOURCE
PILOT
LIGHT
5. CONTROL CIRCUIT 2. OUTPUT CONTROL
POTENTIOMETER
POLARITY SWITCH
FIGURE B.1 - CONTROL PANEL KEYS
1. ON/OFF PUSH BUTTON: This push button turns 5. CONTROL CIRCUIT POLARITY SWITCH: This
the machine ON or OFF. toggle switch is used to set power source voltage
sensing polarity to match the polarity to which the
2. OUTPUT CONTROL POTENTIOMETER: This electrode is connected to the machine. This pro-
control provides tapered, continuous control of the vides the correct polarity at the terminal strip for
machine output. The control can be rotated from correct operation of the automatic wire feeding
minimum to maximum while machine is under equipment powered by the auxiliary power from
load to adjust the machine output. the power source.
3. WELDING MODE SWITCH: This toggle switch is 6. POWER SOURCE PILOT LIGHT: The red neon
used to select the proper welder performance light glows when the power source input contactor
characteristics for the process being used. There is energized.
are three modes: CV (Constant Voltage)
Submerged Arc, CV (Constant Voltage) 7. AMMETER: An optional ammeter is
Innershield, and CC (Constant Current) Stick. available.
4. OUTPUT CONTROL SWITCH: This toggle
8. VOLTMETER: An optional voltmeter is
switch is used to switch between "Panel" for local
available.
control of machine output and "Remote" for
remote control of machine output.
IDEALARC DC-600
B-5 B-5
OPERATION
OPERATING STEPS REMOTE CONTROL OF MACHINE
OPERATION
The following procedures are for using the IDEAL-
ARC DC-600 in the local control mode of operation. The toggle switch on the control panel labeled
For remote control of the machine, see the Remote “Remote - Panel� gives the operator the option of con-
Control of Machine Operation section. trolling the machine output from a remote location. If
in the Remote position a wire feeder with remote con-
Before operating the machine, make sure you have all trol capabilities or a remote control device such as a
materials needed to complete the job. Be sure you K775 must be connected to terminals 75, 76, and 77.
are familiar with and have taken all possible safety Refer to Accessories Section for wire feeder remote
precautions before starting work. It is important that information.
you follow these operating steps each time you use
the machine.
WELDING PROCEDURE
1. Turn on the main AC power supply to the
RECOMMENDATIONS
machine.
2. Set the CONTROL CIRCUIT POLARITY SWITCH Select Welding Mode Switch position based on type of
to the appropriate position. welding to be done.
- Set toggle to "Electrode Negative" position if the
electrode is connected to the negative (-) output 1. Innershield Welding/Other Open Arc Processes:
terminal. Use the CV Innershield mode.
- Set toggle to "Electrode Positive" position if the
electrode is connected to the positive (+) output 2. Submerged Arc Welding: Use the CV Submerged
terminal. Arc mode. If performing high speed welding,
switch between the CV Submerged Arc and the
3. Set the WELDING MODE SWITCH to welding CV Innershield mode and use the mode that pro-
process being used. duces the best welding results.
- CV Submerged Arc
- CV Innershield 3. Air/Carbon Arc Cutting / Stick Welding / High
- CC Stick Current, Large Puddle Submerged Arc Welding:
Use the CC Stick mode. When the IDEALARC
4. Push the ON/OFF PUSH BUTTON to the ON DC-600 is used for Air/Carbon Arc cutting, the
position OUTPUT CONTROL POTENTIOMETER should
- The red neon light glows. be set to "9" initially. Based on the size of the car-
- The fan starts. bon being used or the process, turn the poten-
tiometer to a lower setting as required by the
5. Set Output Control Potentiometer to desired volt- process. You can use carbon rods up to 3/8" in
age or current. diameter at currents as high as 750 amps with
excellent arc control. The welder protection circuit
6. Make the weld (NOTE: Terminal #2 and #4 must protects the machine from extremely high short cir-
be connected together to energize the machine cuiting pulses.
output).
IDEALARC DC-600
B-6 B-6
OPERATION
SEMI-AUTOMATIC AND AUTOMATIC 2. Set the NA-3 Open Circuit Voltage Control to the
same dial setting as the Arc Voltage Control. If
WIRE FEEDING WITH A IDEALARC this is a new welding procedure, a good starting
DC-600 AND WIRE FEEDERS point is to set the Open Circuit Voltage Control to
# 6.
When using the IDEALARC DC-600 with semi-auto-
NOTE: The open circuit voltage of the
matic or automatic wire feeding equipment and for
IDEALARC DC-600 varies from approximately 16
stick welding or air/carbon arc cutting, it is recom-
volts to 56 volts in the CV Innershield or CV
mended that the optional MULTI-PROCESS SWITCH
Submerged Arc modes. The open circuit voltage
be used. This switch permits you to easily change the
is constant in the CC Stick mode.
polarity of the connected wire feeding equipment or
switch to stick welding or air/carbon arc cutting.
3. Run a test weld. Set proper current, voltage, and
travel speed.
NA-3 AUTOMATIC WIRE FEEDER
a. For the best starting performance, the NA-
1. Set the DC-600 Output Control Switch to Remote.
3 Open Circuit Voltage Control and Voltage
NOTE: Later model NA-3 automatic wire feeders
Control setting should be the same. Set the
are capable of cold starts when the NA-3 Mode
Inch Speed Control for the slowest inch
switch is in the CV or CC mode position. Some
speed possible.
earlier models are capable of cold starting only in
the CC mode position. Cold starting enables you
b. To adjust the Open Circuit Voltage Control to
to inch the wire down to the work, automatically
get the best starting performance, make
stop, and automatically energize the flux hopper
repeated starts observing the NA-3 voltmeter.
valve.
When the voltmeter pointer swings smoothly up to
2. Set the DC-600 welding mode switch for the
the desired arc voltage, without undershooting or
desired process: CV Submerged Arc, CV
overshooting the desired arc voltage, the Open
Innershield mode or CC mode.
Circuit Voltage Control is set properly.
3. Set the NA-3 mode Switch Position to either CV or
If the voltmeter pointer overshoots the desired
CC to match the DC-600 mode selected in step 2.
voltage and then returns back to the desired volt-
age, the Open Circuit Voltage Control is set too
4. Refer to the NA-3 operators manual for instruc-
high. This can result in a bad start where the wire
tions on how to use the NA-3 in conjunction with
tends to "Blast off."
the DC-600.
If the voltmeter pointer hesitates before coming up
5. Follow the following guidelines for good arc strik-
to the desired voltage, the Open Circuit Voltage
ing detailed below for each welding mode.
Control is set too low. This can cause the elec-
trode to stub.
GOOD ARC STRIKING GUIDELINES FOR THE NA-
3 WITH THE IDEALARC DC-600 IN THE CV
4. Start and make the weld.
INNERSHIELD, CV SUBMERGED ARC OR CC
STICK WELDING MODES.
a. Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes posi-
Following are some basic arc striking techniques that
tive contact with the work piece.
apply to all wire feed processes. Using these proce-
dures should provide trouble-free starting. These pro-
b. Hot "On the Fly" starts. For hot starts, travel
cedures apply to single, solid wires and Innershield
should begin before the wire contacts the
wires.
work piece.
1. Cut the electrode to a sharp point.
IDEALARC DC-600
B-7 B-7
OPERATION
ARC STRIKING WITH IDEALARC DC-600 AND THE 6. Establish the correct arc striking procedure with
NA-3 START BOARD the NA-3 Start Board timer set at maximum.
When electrical strikeouts exceed 1 3/4� (44.4mm) an a. For the best starting performance, the NA-3
NA-3 Start Board may be required to improve arc Open Circuit Voltage Control and Voltage
striking. Control setting should be the same. Set the
Inch Speed Control for the slowest inch
When the NA-3 Start Board is used to improve arc speed possible.
striking, use the following procedures:
b. To adjust the Open Circuit Voltage Control to
1. Set start time at 0. get the best starting performance, make
repeated starts observing the NA-3 voltmeter.
2. Set NA-3 start current and start voltage at mid-
range. When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
3. Set the NA-3 output current and voltage to the overshooting the desired arc voltage, the Open
proper settings for the welding procedure to be Circuit Voltage Control is set properly.
used.
If the voltmeter pointer overshoots the desired
4. Turn the Start Board Timer to maximum. voltage and then returns back to the desired volt-
age, the Open Circuit Voltage Control is set too
5. Set Start Board current and voltage control. high. This can result in a bad start where the wire
tends to "Blast off."
a. Set the Start Board current control to 1 1/2
dial numbers below that set on the NA-3 cur- If the voltmeter pointer hesitates before coming up
rent control. to the desired voltage, the Open Circuit Voltage
Control is set too low. This can cause the elec-
b. Set the Start Board voltage control equal with trode to stub.
the NA-3 voltage control setting.
c. Set NA-3 Start Board current and voltage as
NOTE: These Start Board current and voltage close to the welding procedure current and
settings result in a start up current that is lower voltage as possible.
than the NA-3 current setting and approximately
equal with the NA-3 voltage setting for the desired NOTE: The Start Board current and voltage
welding procedure. should be as close as possible to the welding pro-
cedure current and voltage, while still getting sat-
isfactory starts.
d. Set the start time to as low a time as possible
while still getting satisfactory starts.
7. Start and make the weld.
IDEALARC DC-600
B-8 B-8
OPERATION
IDEALARC DC-600 POWER SOURCE LN-8 SEMI-AUTOMATIC WIRE FEEDER
SETTING WHEN CONNECTED TO NA-5
To use the LN-8 Semi-Automatic Wire Feeder with
WIRE FEEDER
IDEALARC DC-600
When using the IDEALARC DC-600 with the NA-5
1. Set the IDEALARC DC-600 WELDING MODE
wire feeder, set the controls on the IDEALARC DC-
SWITCH to either CV Innershield mode or CV
600 as follows for the best performance:
Submerged Arc mode depending on the welding
process being used.
1. Turn OFF main AC input power supply to the IDE-
ALARC DC-600.
2. Set the IDEALARC DC-600 OUTPUT
CONTROL SWITCH to the REMOTE position.
2. Connect the electrode cables to terminal polarity
to be used.
3. Set the LN-8 Welding Mode Switch to the CV
position. The LN-8 Welding Mode Switch is locat-
3. Set the CONTROL CIRCUIT POLARITY SWITCH
ed on the variable voltage (CC) board.
to the same polarity as the electrode cable con-
nection.
4. Refer to the LN-8 Operator’s Manual for instruc-
tions on how to use the LN-8.
4. Set the OUTPUT CONTROL SWITCH to
REMOTE.
LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
5. Set the IDEALARC DC-600 WELDING MODE
SWITCH to the position that matches the welding FEEDERS OR OTHER CONSTANT WIRE
process being used. FEEDERS
a. For submerged arc welding, set WELDING To use the LN-7, LN-9, or other constant wire feed
MODE SWITCH TO CV SUBMERGED ARC speed semi-automatic wire feeders with IDEALARC
position. DC-600
b. For all open arc welding processes set 1. Set the IDEALARC DC-600 WELDING MODE
WELDING MODE SWITCH TO CV INNER- SWITCH to either CV Innershield mode or CV
SHIELD position. Submerged Arc mode depending on the welding
process being used.
NOTE: These semi-automatic wire feeders can-
not be used in the CC Stick mode.
2. Set the IDEALARC DC-600 OUTPUT
CONTROL SWITCH.
a. LN-7: Use either an optional K775 Remote
Control Box Assembly or set the
IDEALARC DC-600 OUTPUT CONTROL
SWITCH in the Local position.
b. LN-9: Refer to the LN-9 Operator’s Manual for
instructions of how to use the LN-9.
IDEALARC DC-600
C-1 C-1
ACCESSORIES
OPTIONS/ACCESSORIES The MULTI-PROCESS SWITCH has two sets of out-
put terminals. You connect the wire feeder unit cables
� Multi-Process Switch (K804)
to the set of terminals on the left side of the box and
� Remote Control Box Assembly (K775)
the stick or air/carbon arc cables to the set of termi-
� Undercarriages ( K817P, K842)
nals on the right side (facing the front of the machine)
� Paralleling Kit (S20428)
as shown in Figure C.1.
Semi-Automatic and Automatic Wire Feeders
When the MULTI-PROCESS SWITCH is in the "Stick
� LN-7
} or Air/Carbon Arc" position, only those
Semi-Automatic Wire Feeders
� LN-8
terminals are energized. The wire feeder nozzle or
� LN-9
gun and electrode are not electrically "hot" when in
this mode.
}Automatic Wire Feeders
� NA-3
� NA-5
Follow these steps to install the MULTI-PROCESS
SWITCH:
MULTI-PROCESS SWITCH 1. Confirm that the IDEALARC DC-600 ON/OFF
PUSH BUTTON is in the OFF position.
The MULTI-PROCESS SWITCH gives you the ability
to: 2. Disconnect main AC input power to the IDE-
� Switch between "stick welding or air/carbon arc ALARC DC-600.
cutting" and using a semi-automatic or automatic
wire feeder. 3. Open the terminal strip access door located on
the Case Front Assembly.
� Change the polarity of a semi-automatic or auto-
matic wire feeder without changing any electrical 4. Remove the two front, middle screws that secure
cable connections. the two side panels of the machine. See Figure
C.2.
See Figure C.1
REMOVE SCREWS
TO MOUNT
MULTI-PROCESS
SWITCH
POSITIVE
STICK OR
NEGATIVE AIR
CARBON
ARC
POSITIVE
STICK OR
NEGATIVE AIR
CARBON
+
� ARC
STICK OR
WIRE
AIR/CARBON
FEEDER
+
�
ARC CABLES
CABLES
FIGURE C.1 - MULTI-PROCESS SWITCH FIGURE C.2 - SIDE PANEL REMOVAL
IDEALARC DC-600
C-2 C-2
ACCESSORIES
5. Attach the MULTI-PROCESS SWITCH bracket 8. Connect the control leads from the MULTI-
across the front of the machine with the flange PROCESS SWITCH to terminals #2 and #4 on
down. Use the long, self-tapping screws and lock the IDEALARC DC-600's terminal strip.
washers provided. The bracket should be on the
outside of the side panel. See Figure C.3. 9. Position the MULTI-PROCESS SWITCH flush
with the front of the machine about 2" lower than
the bracket. Slide the switch straight up to the
NOTE: If the machine does not have any holes in
bracket.
the front of the machine, use the switch template
and drill two .153" diameter holes.
10. Check that the bottom of the switch is hooked
6. Position the MULTI-PROCESS SWITCH at the behind the top of the bottom louver.
front of the machine. See Figure C.3.
11. Connect the right cable from the MULTI-
MULTI- PROCESS SWITCH (facing the front of the
PROCESS machine) to the IDEALARC DC-600 positive (+)
SELF TAPPING
SWITCH output terminal. See Figure C.4.
SCREWS
BRACKET CONTROL (DRILL .153"
LEADS HOLE IF
NEEDED) TERMINAL
STRIP
21 4 2 31 32 75 76 77 80 81
CONTROL
LEADS
NEGATIVE (�) POSITIVE (+)
+
�
OUTPUT OUTPUT
STUD STUD
ELECTRODE
ELECTRODE
CABLE
CABLE
WORK +
STICK AIR/CARBON
WIRE
ARC WELDING
MULTI- FEEDER
EQUIPMENT
ELECTRODES
PROCESS
SWITCH WIRE FEED WORK
WORK
CABLE
CABLE JUMPER (IF NEEDED
CONTROL SEE INSTRUCTIONS)
CABLE
FIGURE C.3 - ATTACHING THE MULTI-
FIGURE C.4 - MULTI-PROCESS SWITCH
PROCESS SWITCH BRACKET.
CABLE CONNECTIONS.
7. Route the MULTI-PROCESS SWITCH control
12. Connect the left cable from the MULTI-PROCESS
leads through the strain-relief box connectors and
SWITCH (facing the front of the machine) to the
into the terminal strip. The wire feeder control
IDEALARC DC-600 negative (-) output terminal.
cable is routed through the strain-relief box con-
See Figure C.4.
nector also. See Figure C.3.
IDEALARC DC-600
C-3 C-3
ACCESSORIES
13. Connect the wire feeder electrode and work NOTE: The instructions above are for connecting
cables. See Figure C.4. the stick polarity positive. To change the polarity,
turn the IDEALARC DC-600 OFF, and reverse the
a. Insert the wire feeder electrode and work cables.
cables through the strain relief loop on the left
side of the IDEALARC DC-600 (facing the NOTE: When it is not necessary to have separate
front of the machine). ground cables for stick and semi-automatic or
automatic welding, connect a jumper from the
b. Connect the wire feeder electrode and work MULTI-PROCESS SWITCH "Work" terminal to
cables to the electrode and work the MULTI-PROCESS SWITCH "negative" termi-
terminals on the left side of the MULTI- nal. See Figure C.4.
PROCESS SWITCH.
To operate the MULTI-PROCESS SWITCH, refer to
NOTE: When using Dual Process Kits K317 or the operating instructions on the switch nameplate.
K318, connect the electrode and work cables to
these terminals instead of the power source output
terminals. See connection diagrams for details. UNDERCARRIAGE (K817P, K842)
14. Connect wire feeder control cable to the terminal The IDEALARC DC-600 is designed for use with the
strip of the IDEALARC DC-600. Lincoln K817P, or K842 Undercarriage. Complete
installation instructions are included with the under-
NOTE: Connect the control cable ground lead to carriage. When any of the undercarriages are
the frame terminal marked ( ). installed, the IDEALARC DC-600 lift bail is no longer
functional. Do not attempt to lift the machine with the
NOTE: See the connection diagram for the wire undercarriage attached. The undercarriage is
feeder being used for connection instructions. designed for moving the machine by hand only.
Mechanized towing can lead to injury and/or damage
15. Connect stick or air/carbon arc electrode and work to the IDEALARC DC-600.
cable. See Figure C.4.
METERS
a. Insert the electrode and work cables through
the strain relief loop on the right side (facing
Optional factory-installed voltmeter and ammeter are
the front of the machine) of the IDEALARC
available.
DC-600.
b. Connect the electrode cable to the "Positive"
PARALLELING KIT FOR DC-600
terminal on the right side of the MULTI-
PROCESS SWITCH.
Kit S20428 - field installation only, permits paralleling
c. Connect the work cable to the "Negative" ter- of two DC-600’s for welding currents of up to 1200
minal on the right side of the MULTI- amps, 100% duty cycle. (See instructions shipped
PROCESS SWITCH. with the kit for installation and operation.)
IDEALARC DC-600
C-4 C-4
ACCESSORIES
CONNECTIONS FOR SEMI-AUTO- NA 3 WIRE
FEEDER
CONTROL
MATIC OR AUTOMATIC WIRE FEED- CABLE
ER CONTROL TO
AUTOMATIC
CONTROL
BOX
77
1. Set the ON/OFF PUSH BUTTON to OFF. 76
75
2. Locate and open the hinged access door on the 21 4 2 31 32 75 76 77 80 81 32
Front Case Assembly. 31
2
4
21
3. Insert control cable through the strain relief box
GND
+
connector and pull enough cable through to reach �
the terminal strip. POSITIVE
NEGATIVE
ELECTRODE
CABLE TO
TO WORK AUTOMATIC
4. Connect the automatic wire feeder control cable to EQUIPMENT
the terminal strip. See corresponding connection
diagram in this Section of the manual, or the
FIGURE C.5 - NA-3 WIRE FEEDER
instructions included with the wire feeder.
CONNECTION TO THE IDEALARC DC-600
5. Connect the wire feeder grounding wire to the chas-
5. Extend wire feeder control cable lead # 21 so it
sis ground screw marked with the symbol ( ).
can be connected directly to the work piece.
NOTE: The IDEALARC DC-600 Auxiliary Power
a. Make a bolted connection using AWG #14 or
Circuit supplies 115-volt AC power to the wire
larger insulated wire. Tape the bolted con-
feeding equipment. The circuit has a 1000 volt
nection with insulating tape.
ampere rating. An 8-amp slow blow fuse on the
machine’s control panel protects the auxiliary
b. An S-16586- X remote voltage sensing work
power supply from excessive overloads.
lead is available for this purpose.
c. Keep the # 21 lead electrically separate from
the work cable circuit and connection.
CONNECTING THE NA-3 IDEALARC DC-600
d. Tape the # 21 lead to work cable for ease of
1. Disconnect main AC input power to the IDE- use.
ALARC DC-600.
NOTE: The connection diagram shown in Figure C.5
2. Set IDEALARC DC-600 ON/OFF PUSH BUTTON shows the electrode connected for positive polarity.
to OFF. To change polarity:
a. Set the IDEALARC DC-600 ON/OFF PUSH
3. Connect the wire feeder control cable leads to the
BUTTON to OFF
IDEALARC DC-600 terminal strip as shown in
Figure C.5.
b. Move the electrode cable to the Negative (-)
output terminal
4. Connect the wire feeder control cable ground lead
to the frame terminal marked ( ).
c. Move the work cable to the Positive (+) output
terminal.
NOTE: The IDEALARC DC-600 must be properly
grounded.
d. Set the IDEALARC DC-600 CONTROL CIR-
CUIT POLARITY SWITCH to NEGATIVE.
e. Reverse the leads at the back of the ammeter
and voltmeter on the wire feeder automatic
control box.
IDEALARC DC-600
C-5 C-5
ACCESSORIES
CONNECTING THE NA-5 TO THE 5. Extend wire feeder control cable lead # 21 so it
can be connected directly to the work piece.
IDEALARC DC-600
a. Make a bolted connection using AWG #14 or
NOTE: For optimum performance use the NA-5 with
larger insulated wire. Tape the bolted con-
IDEALARC DC-600 codes 8288 and above.
nection with insulating tape.
1. Disconnect main AC input power to the IDE-
b. An S-16586- X remote voltage sensing work
ALARC DC-600.
lead is available for this purpose.
2. Set the IDEALARC DC-600 ON/OFF PUSH
c. Keep the # 21 lead electrically separate from
BUTTON to OFF.
the work cable circuit and connection.
3. Connect the wire feeder control cable leads to the
d. Tape the # 21 lead to work cable for ease of
IDEALARC DC-600 terminal strip as shown in
use.
Figure C.6.
6. Connect NA-5 wire feeder control jumpers on
LN8 OR LN 9
Voltage Control Board. See NA-5 Operator's
WIRE
FEEDER
Manual.
CONTROL
CABLE
a. Connect red jumper on Voltage Control Board
TO INPUT
CABLE
to pin "S."
C
B
b. Connect white jumper on Voltage Control
A
Board to pin "B."
21 4 2 31 32 75 76 77 80 81 32
31
2
NOTE: The connection diagram shown in Figure C.6
4
shows the electrode connected for positive polarity.
21
GND
To change polarity:
+
�
POSITIVE
NEGATIVE
a. Set the IDEALARC DC-600 ON/OFF PUSH
ELECTRODE
CABLE TO WIRE
TO WORK
BUTTON to OFF.
FEEDER
b. Move the electrode cable to the Negative (-)
FIGURE C.6 - NA-5 WIRE FEEDER CONNEC- output terminal.
TION TO THE IDEALARC DC-600
c. Move the work cable to the Positive (+) output
terminal.
NOTE: If using a K215 control cable, connect
control cable leads #75, #76, and #77 to the d. Set the IDEALARC DC-600 CONTROL
matching #75, #76, and #77 terminals on the ter- CIRCUIT POLARITY SWITCH to NEGATIVE.
minal strip of the IDEALARC DC- 600.
NOTE: For proper NA-5 operation, the electrode
4. Connect the wire feeder control cable ground lead cables must be secured under the clamp bar on the
to the frame terminal marked ( ). left side of the NA-5 Control Box.
NOTE: The IDEALARC DC-600 must be properly
grounded.
IDEALARC DC-600
C-6 C-6
ACCESSORIES
CONNECTING THE LN-8 OR LN-9 TO THE LN8 OR LN 9
IDEALARC DC-600 WIRE
FEEDER
CONTROL
CABLE
1. Disconnect AC input power to the IDEALARC DC- TO INPUT
CABLE
600.
C
2. Set the IDEALARC DC-600 ON/OFF PUSH B
A
BUTTON to OFF.
21 4 2 31 32 75 76 77 80 81 32
31
3. Connect the wire feeder control cable leads to the 2
IDEALARC DC-600 terminal strip as shown in 4
21
Figure C.7. GND
+
�
4. Connect the wire feeder control cable ground lead POSITIVE
NEGATIVE
ELECTRODE
to the frame terminal marked ( ). CABLE TO WIRE
TO WORK FEEDER
NOTE: The IDEALARC DC-600 must be properly
grounded.
FIGURE C.7 - LN-8 OR LN-9 WIRE FEEDER
5. Extend wire feeder control cable lead #21 so it CONNECTION TO THE IDEALARC DC-600
can be connected directly to the work piece.
NOTE: On earlier units, the blue jumper on Voltage
a. Make a bolted connection using AWG #14 or Control Board is connected to Pin "B" on Start Board.
larger insulated wire. Tape the bolted con-
nection with insulating tape. NOTE: The connection diagram shown in Figure C.7
shows the electrode connected for positive polarity.
b. An S-16586- X remote voltage sensing work To change polarity:
lead is available for this purpose.
a. Set the IDEALARC DC-600 ON/OFF PUSH
c. Keep the #21 lead electrically separate from BUTTON to OFF
the work cable circuit and connection.
b. Move the electrode cable to the Negative (-)
d. Tape the #21 lead to work cable for ease of output terminal
use.
c. Move the work cable to the Positive (+) output
NOTE: Using the extended #21 lead eliminates terminal.
the need to use the LN-9's remote work lead
accessory which has a direct work lead jack.
d. Set the IDEALARC DC-600 CONTROL CIR-
CUIT POLARITY SWITCH to NEGATIVE.
6. Connect LN-9 wire feeder control jumpers on
Voltage Control board. See LN-9 Operator's
Manual.
a. White jumper on Voltage Control Board to pin
"S."
b. Blue jumper on Voltage Control Board to pin
"B."
IDEALARC DC-600
C-7 C-7
ACCESSORIES
LN-7 IDEALARC DC-600
b. An S-16586- X remote voltage sensing work
lead is available for this purpose.
1. Disconnect main AC input power to the
IDEALARC DC-600.
c. Keep the #21 lead electrically separate from
the work cable circuit and connection.
2. Set the IDEALARC DC-600 ON/OFF PUSH
BUTTON to OFF.
d. Tape the #21 lead to work cable for ease of
3. Connect the wire feeder control cable leads to the use.
IDEALARC DC-600 terminal strip as shown in
Figure C.8. NOTE: The connection diagram shown in Figure C.8
shows the electrode connected for positive polarity.
To change polarity:
LN -7 WIRE
FEEDER
CONTROL
a. Set the IDEALARC DC-600 ON/OFF PUSH
CABLE
BUTTON to OFF.
TO LN-7
INPUT
CABLE
b. Move the electrode cable to the Negative (-)
PLUG
77
output terminal.
76
75
c. Move the work cable to the Positive (+) output
21 4 2 31 32 75 76 77 80 81 32
31
terminal.
2
4
21
d. Set the IDEALARC DC-600 CONTROL
GND
+
� CIRCUIT POLARITY SWITCH to NEGATIVE.
POSITIVE
NEGATIVE
ELECTRODE
CABLE TO LN
TO WORK CONDUCTOR
BLOCK
FIGURE C.8 - LN-7 WIRE FEEDER CONNEC-
TION TO THE IDEALARC DC-600
4. Connect the wire feeder control cable ground lead
to the frame terminal marked ( ).
NOTE: The IDEALARC DC-600 must be properly
grounded.
5. PERFORM THIS STEP ONLY IF THE LN-7 IS
EQUIPPED WITH A METER KIT.
Extend wire feeder control cable lead #21 so it
can be connected directly to the work piece.
a. Make a bolted connection using AWG #14 or
larger insulated wire. Tape the bolted con-
nection with insulating tape.
NOTE: If the work cable length is less than 25
feet and the connections to the work piece are
secure, then wire feeder control cable lead #21
can be connected directly to the DC-600 terminal
strip.
IDEALARC DC-600
D-1 D-1
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
CAN KILL.
Only qualified personnel should
perform this maintenance.
Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
Do not touch electrically hot parts.
__________________
IDEALARC DC-600
D-2 D-2
MAINTENANCE
ROUTINE AND PERIODIC
MAINTENANCE
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1
Perform the following daily:
1. Check that no combustible materials are in the
welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits or
punctures in the cable jacket, or any condition that
would affect the proper operation of the machine.
Perform Periodically:
Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure
D.1.
� Main transformer and choke.
� Electrode and work cable connections.
� SCR rectifier bridge and heat sink fins.
� Control board.
� Firing board.
� Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
IDEALARC DC-600
D-3 D-3
MAINTENANCE
FIGURE D.1 - General Assembly Exploded View
IDEALARC DC-600
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. RECOMMENDED COURSE OF
Step 1. LOCATE PROBLEM (SYMPTOM).
ACTION
Look under the column labeled “PROBLEM
This column provides a course of action for
(SYMPTOMS)�. This column describes
the Possible Cause, generally it states to
possible symptoms that the machine may
contact you local Lincoln Authorized Field
exhibit. Find the listing that best describes
Service Facility.
the symptom that the machine is exhibiting.
If you do not understand or are unable to
Step 2. POSSIBLE CAUSE.
perform the Recommended Course of
The second column labeled “POSSIBLE
Action safely, contact you local Lincoln
CAUSE� lists the obvious external possibili-
Authorized Field Service Facility.
ties that may contribute to the machine
symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-2 E-2
TROUBLESHOOTING
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING - Remove the P.C. Board from the static-
shielding bag and place it directly into the
ELECTRIC SHOCK can equipment. Don’t set the P.C. Board on or near
kill. paper, plastic or cloth which could have a static
Have an electrician install and
charge. If the P.C. Board can’t be installed
service this equipment. Turn the
immediately, put it back in the static-shielding
input power OFF at the fuse box
bag.
before working on equipment. Do
not touch electrically hot parts.
- If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation is
CAUTION: Sometimes machine failures complete.
appear to be due to PC board failures. These
problems can sometimes be traced to poor - If you return a P.C. Board to The Lincoln
electrical connections. To avoid problems Electric Company for credit, it must be in the
when troubleshooting and replacing PC static-shielding bag. This will prevent further
damage and allow proper failure analysis.
boards, please use the following procedure:
1. Determine to the best of your technical abili- 4. Test the machine to determine if the failure
symptom has been corrected by the
ty that the PC board is the most likely com-
replacement PC board.
ponent causing the failure symptom.
2. Check for loose connections at the PC NOTE: It is desirable to have a spare (known
board to assure that the PC board is proper- good) PC board available for PC board trou-
bleshooting.
ly connected.
NOTE: Allow the machine to heat up so that
3. If the problem persists, replace the suspect
all electrical components can reach their oper-
PC board using standard practices to avoid
ating temperature.
static electrical damage and electrical
shock. Read the warning inside the static
5. Remove the replacement PC board and
resistant bag and perform the following pro-
substitute it with the original PC board to
cedures:
recreate the original problem.
P.C. Board can be dam-
a. If the original problem does not reappear
aged by static electricity.
by substituting the original board, then
the PC board was not the problem.
- Remove your body’s
Continue to look for bad connections in
static charge before open-
ATTENTION the control wiring harness, junction
ing the static-shielding
Static-Sensitive blocks, and terminal strips.
bag. Wear an anti-static
Devices wrist strap. For safety,
Handle only at b. If the original problem is recreated by the
use a 1 Meg ohm resis-
Static-Safe substitution of the original board, then
tive cord connected to a
Workstations the PC board was the problem. Reinstall
grounded part of the
the replacement PC board and test the
equipment frame.
Reusable machine.
Container - If you don’t have a wrist
Do Not Destroy strap, touch an unpainted, 6. Always indicate that this procedure was
followed when warranty reports are to be
grounded, part of the equipment frame. Keep
submitted.
touching the frame to prevent static build-up.
Be sure not to touch any electrically live parts
NOTE: Following this procedure and writing
at the same time.
on the warranty report, “INSTALLED AND
- Tools which come in contact with the P.C. SWITCHED PC BOARDS TO VERIFY PROB-
Board must be either conductive, anti-static or LEM,� will help avoid denial of legitimate PC
board warranty claims.
static-dissipative.
IDEALARC DC-600
E-3 E-3
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical Contact the Lincoln Electric Service
Damage is Evident Dept. (216) 383-2531 or 1-800-
833-9353 (WELD)
The Machine is dead- The Input 1. Check for blown or missing
contactor does not operate. fuses in input lines.
If all recommended possible areas
of misadjustment have been
2. Check the three- phase input
checked and the problem persists,
line voltage at the machine.
Contact your local Lincoln
The input voltage must match
Authorized Field Service Facility.
the rating plate and reconnect
panel.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-4 E-4
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Input contactor (CR1) chatters. 1. The input line voltage may be
low. Check all three phases.
2. Make sure input line voltage
matches machine rating and
the reconnect panel is connect-
ed correctly for the line voltage.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Input contactor pulls in when start 1. Make sure input line voltage
Authorized Field Service Facility.
button is pressed but immediately matches machine rating and
drops out when start button is the reconnect panel is connect-
released. ed correctly for the line voltage.
2. Remove all external wires
attached to terminal strip. ( 2,
4, 31, 32 75,76,77). If contac-
tor (CR1) functions correctly
there may be a "ground" or
negative intrusion on the
remote control leads (75, 76, or
77). There may also be a
"short" at the welder output ter-
minals.
3. If the problem persists after
performing steps #1 and #2 the
problem is in the DC600.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-5 E-5
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine input contactor operates 1. Install a jumper from #2 to #4
but machine has no weld on machine terminal strip. If
output.Fan runs and pilot light machine weld output is
glows. restored the problem is in the
wire feeder or control cable.
2. If remote control is not being
used make certain the OUT- If all recommended possible areas
PUT CONTROL SWITCH of misadjustment have been
(SW3) is in the "Panel" posi- checked and the problem persists,
tion. Contact your local Lincoln
Authorized Field Service Facility.
3. Check 8AMP fuse in the front
panel.Replace if blown.
4. Check for loose or faulty weld
cable connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-6 E-6
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine has maximum weld out- 1. If remote control is being used
put and no control. set OUTPUT CONTROL
SWITCH (SW3) in "Panel"
position and control weld out- If all recommended possible areas
put with the OUTPUT CON- of misadjustment have been
TROL POTENTIOMETER (R1) checked and the problem persists,
at DC600. If the problem is Contact your local Lincoln
solved check the remote con- Authorized Field Service Facility.
trol unit (or wire feeder) and
associated control cable.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-7 E-7
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine has minimum output and 1. If a remote control unit is NOT
no control. connected to the terminal strip
#75, #76, and #77 terminals,
the OUTPUT CONTROL
SWITCH must be in the
"Panel" position.
2. If a remote control cable is con-
nected to terminals #75, #76
and #77 the leads may be
"shorted" to the positive weld
output.
3. Make certain the Three Phase
input voltage is correct and
matches the machine rating
and the reconnect panel.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
The machine does not have maxi-
1. Check all Three-Phase input
Authorized Field Service Facility.
mum weld output.
lines at the DC600. Make
sure input voltages match
machine rating and recon-
nect panel.
2. Put OUTPUT CONTROL
SWITCH (SW3) in "Panel"
position. If problem is
solved then check remote
control unit or wire feeder.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-8 E-8
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine shuts off (input contactor 1. Remove all welding cables and
drops out) when the welder output control cables from the DC
terminals are made electrically 600. Jumper #2 to #4 at the
"hot". terminal strip. If the machine
(#2 to #4 closure at terminal strip.) does NOT shut off and normal
open circuit voltage is present
at the welder output terminals
the problem is external to the
DC600. Either the remote
leads #75, #76 or #77 are
grounded to the negative out-
put cable or there is a short on
the welding output terminals.
2. If the machine still shuts off
when all control and welding
cables are removed then the
problem is internal to the
DC600.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
The DC600 will NOT shut off when 1. Contact your local Lincoln Authorized Field Service Facility.
the Stop button is pushed.
Authorized Field Ser vice
Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-9 E-9
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The weld output terminals are 1. Remove any external leads
always electrically "hot". hooked to #2 and #4 on the ter-
minal strip. If the problem dis-
appears the fault is in the con- If all recommended possible areas
trol cable or wire feeder. of misadjustment have been
checked and the problem persists,
2. If some open circuit voltage is Contact your local Lincoln
present (over 3VDC.) after per- Authorized Field Service Facility.
forming Step #1. then the prob-
lem is within the DC600.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-10 E-10
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Poor arc starting when the DC600 1. Make sure the proper welding
If all recommended possible areas
is in the CV Sub-Arc or CV procedures are being used.
of misadjustment have been
Innershield Modes. (wire feed speed , arc voltage
checked and the problem persists,
and wire size)
Contact your local Lincoln
Authorized Field Service Facility.
2. Check weld cables for loose or
faulty connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
E-11 E-11
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Poor arc characteristics in all 1. Check for the correct input volt-
processes. ages on the three- phase input
If all recommended possible areas
lines at the DC600.
of misadjustment have been
checked and the problem persists,
2. Make sure the proper welding
Contact your local Lincoln
procedures are being
Authorized Field Service Facility.
used.(wire feed speed, arc volt-
age and wire size).
3. Check the welding cables for
loose or faulty connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC DC-600
WIRING DIAGRAM (Various Single, Dual and Triple Voltage Machines)
F-1
380/500V. & 460/575V.
TO
SINGLE VOLTAGE OVER 300 V. TO H2
H3 (SHOWN CONNECTED
SUPPLY
SUPPLY H1
H1
(EXCEPT 380V.) FOR LOW VOLTAGE) LINES
LINES
272
272 R1
236
X1 OUTPUT
TO GROUND PER
TO GROUND PER
T2
NATIONAL H1
NATIONAL CONTROL
15
9
6 3 START
3 215
ELECTRICAL 210
ELECTRICAL 237 75
STOP
L3
L3
CODE 229
CODE 14
2
5 8
2
L2
L2 32A 76
H2
13
1 RECONNECT
7
4
RECONNECT 1 SW3
L1
PANEL SW1
L1
PANEL 31 N.C.
77
210
1CR 1CR
271 VM
271 TO PRIMARY COILS
TO PRIMARY COILS 226 80
211 +-
212 SW2
255
238
H3
2 4
21
TO 222
H2 H2 F1
380V. OR TRIPLE VOLTAGE
SUPPLY TO
H1
DUAL & SINGLE VOLTAGE 5CR
H1
LINES SUPPLY 272 0 SW4
1
UNDER 300V.
LINES
272 272 222
TO GROUND PER 2
81
NATIONAL 232
TO GROUND PER
9
6 3 32
3 6 11
9
ELECTRICAL
NATIONAL 271 224
AM
L3
L3
CODE 2
ELECTRICAL 2 +-
5 8 10
5 8 X2
RECONNECT
CODE L2
L2 21 4 2 76 80 81
75 77
31 32
1
1
7
4 PANEL (SHOWN 12
4 7 N.G.
RECONNECT
L1
L1 CONNECTED
PANEL 271 280
FOR 380V.) 80 81
1CR 1CR 271
271 7 5
TO PRIMARY COILS
TO PRIMARY COILS T.S.3
271
T.S.2
2CR 255
B
A
PILOT
R 235
LEGEND
235 229
LIGHT 1 1
C7 .05 +.05 MFD 233 2 2
256 75
256
F1 8 AMP SLOW BLOW FUSE 232
3
255 3
R1 10K POT 4
231 80
4
PRIMARY
256
R2 30 , 100W 5
238 81
5 J2
THERMOSTAT
233
272 6
T1 MAIN POWER TRANSFORMER 226
6
273 J1
3 7
1 2 32A 224
7
N.A.
T2 CONTROL TRANSFORMER S
S SEC. LEAD
1 31 8 8 215
1CR INPUT CONTACTOR
T1 THERMOSTAT
AUX.2 31
15 9
14
13 9
F
2CR FAULT PROTECTION RELAY
F
205 10 10 280
PRI.
LEADS 4
3CR CURRENT ACTIVATED REED SWITCH F F
F
11
203 207
THRU 9
4CR OUTPUT PILOT RELAY 210 1
6 J3 12
4 5
5CR POWER INTERLOCK RELAY TO INPUT S 215
FAN 215 2
S
S 220
13
210
206
204 AUX. 1
SW1 INPUT POWER 208 MOTOR
PANEL
32A CONTROL 222
14
SW2 ELECTRODE POLARITY 7 8 9
P.C. BOARD
THERE IS NO 31
SW3 OUTPUT CONTROL
215
10, 11 & 12
PRI. 4
SW4 WELDING MODE (SHOWN IN STICK POSITION) 216
CONNECTION
B
NOTES: ON 380 OR
12
11
10 4 5 6
TRIPLE VOLTAGE
N.A. LEADS 4 THRU 9 ARE NOT PRESENT ON
MACHINES. 216
G3 1 1
460V., 380/500V. & 460/575V. MACHINES. TO OUTPUT
9
8 G6 203
2
7 2
N.B. FOR STICK WELDING OR AIR CARBON ARC RECTIFIER
A
206
G1 3 3
WITHOUT A MULTI-PROCESS SWITCH INSTALLED,
J4
ASSEMBLY
(-)
SEC. 214 4 204
G4
4CR 4
DISCONNECT ALL ELECTRODE, WORK, AND 222
222
R2 5 215
5
G5
CONTROL LEADS TO ANY WIRE FEEDERS.
6 215
6
JUMPER 2 TO 4. OUTPUT TERMINALS WILL G2
J5
NOW BE ENERGIZED. PLACE MODE SWITCH 205
7
1 208
IN VV FOR STICK AND CV (I) FOR AIR A 8
215
B 2 9 207
CARBON ARC. SEE OPERATING MANUAL
SEC. 231
3 10
FOR FURTHER INSTRUCTIONS.
OUTPUT B' 4 11
J7
CHOKE
OUTPUT
N.C. CENTER TERMINAL OF FUSE HOLDER. 5
C 12
C7
C' 6
N.D. WELDING CABLE MUST BE OF THE PROPER GATE
1 X
DIAGRAMS
N.D.
LEADS TO 7
IDEALARC DC-600
CAPACITY FOR THE CURRENT AND DUTY CYCLE G1
8
A' 2 Y
FIRING J6
OF IMMEDIATE AND FUTURE APPLICATIONS.
TO T1 AUX. WINDING
G3 210
Z
3
CIRCUIT FIRING CIRCUIT
G5
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY 4
P.C.
SCR P.C. BOARD
"POSITIVE". TO CHANGE THE POLARITY, TURN BOARD (+)
SNUBBERS
J4
THE DC-600 OFF, AND REVERSE THE LEADS AT 210
A A A
THE MULTI-PROCESS SWITCH. 215
N.F. USING A WIRE FEEDER, K-317 OR K-318
3CR 2
SCR SCR
SCR
CONNECTION DIAGRAM, CONNECT ELECTRODE -
+ 4
3 5
AND WORK LEADS TO THESE TERMINALS 1 LEADS 210 & 215 ARE
INSTEAD OF THE POWER SOURCE OUTPUT SHUNT
210 TWISTED TOGETHER
OUTPUT TERMINALS. 215 (50MV @800 AMPS}
220 210
N.G. 2CR IS SHOWN AS SPST RELAY. IF 2CR IS A 215 215
C C C
3PDT, LEADS 255 CONNECTS TO TERMINAL 4
220
INSTEAD OF TERMINAL 5.
255
271 215
7 4 OUTPUT
255
271 215
SNUBBER C C C 215
2CR
A B
235
233
TO STICK ELECTRODE HOLDER OR
WORK +
AIR-CARBON ARC TORCH
THESE NOTES APPLY ONLY TO DC-600 WITH A SCR
SCR
SCR
N.E.
N.D.
MULTI-PROCESS SWITCH INSTALLED. N.D., N.F.
4
2 6
ELECTRODE
J6 TO "WORK" USED WITH STICK
J4 J7
J3
- OR AIR-CARBON ARC
A A A
OPTIONAL USER SUPPLIED JUMPER FOR
STICK WORK LEAD NOT
OUTPUT RECTIFIER OPTIONAL
J5 J1
J2
THOSE SITUATIONS WHERE IT IS NOT
G6 GATE LEADS TO
USED WHEN JUMPER IS
ASSEMBLY MULTI-PROCESS
NECESSARY TO HAVE SEPARATE GROUND
FIRING CIRCUIT
G4
USED.
SWITCH
P.C. BOARD
G2 CABLES FOR STICK AND SEMI-AUTOMATIC
J4 WELDING.
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
10-9-98F
L10575
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-1
WIRING DIAGRAM (Single Voltage 440 & 460)
F-2
H3
SINGLE VOLTAGE 440&460v H1
R1
236 OUTPUT
CONTROL
215
210 237 75
229
L3 X1
TO T2 H1 32A 76
START
SUPPLY STOP SW3
31 N.C.
L2 77
210
LINES 211
VM
226 80
+-
H2 SW2
SW1 238
L1
TO GROUND PER 4
2 21
212 222 F1
NATIONAL
255
1
ELECTRICAL 0 H3 SW4
222 2
CODE 81
232
32
224
AM
LEGEND 5CR +-
272
C7 .05 +.05 MFD 21 4 2 76 80 81
75 77
31 32
X2
271
D1 INPUT CONTACTOR BRIDGE (ONLY
271 271 280
80 81
N.G.
PRESENT WITH DC COIL CR1)
7 5 T.S.3
271
F1 8 AMP SLOW BLOW FUSE
T.S.2
2CR
1CR 255
R1 10K POT B
A
PILOT
R 235
R2 30 , 100W
235 229
LIGHT 1 1
272
T1 MAIN POWER TRANSFORMER
233 2 2
256 75
256
T2 CONTROL TRANSFORMER 232
3
255 3
272
TP1 (ONLY PRESENT WITH DC COIL CR1) 4
231 80
4
PRIMARY
256
1CR INPUT CONTACTOR 5
238 81
5 J2
THERMOSTAT
233 6
2CR FAULT PROTECTION RELAY 226
6
273 J1
3 7
1 2 32A 224
7
N.A. S
3CR CURRENT ACTIVATED REED SWITCH
S SEC. LEAD
1 31 8 8 215
4CR OUTPUT PILOT RELAY
T1 THERMOSTAT
AUX.2 31 9
15
14
13 9
F
5CR POWER INTERLOCK RELAY F
205 10 10 280
PRI.
LEADS 4
SW1 INPUT POWER F F
F
11
203 207
THRU 9
SW2 ELECTRODE POLARITY 210 1
6 J3 12
4 5
TO INPUT S FAN 215
SW3 OUTPUT CONTROL 215 2
S
S 220
13
210
206
204 AUX. 1 208 MOTOR
SW4 WELDING MODE (SHOWN IN STICK PANEL
32A CONTROL 222
14
POSITION) 7 8 9
P.C. BOARD
THERE IS NO 31
NOTES:
215
10, 11 & 12
PRI. 4 216
N.A. LEADS 4 THRU 9 ARE NOT PRESENT ON CONNECTION
B
460V., 380/500V. & 460/575V. MACHINES. ON 380 OR
12
11
10 4 5 6
N.B. FOR STICK WELDING OR AIR CARBON ARC TRIPLE VOLTAGE
WITHOUT A MULTI-PROCESS SWITCH INSTALLED, MACHINES. 216
G3 1 1
TO OUTPUT
DISCONNECT ALL ELECTRODE, WORK, AND 9
8 G6 203
2
7 2
RECTIFIER
CONTROL LEADS TO ANY WIRE FEEDERS. A
206
G1 3 3
J4
ASSEMBLY
JUMPER 2 TO 4. OUTPUT TERMINALS WILL (-)
SEC. 214 4 204
G4
4CR 4
222
NOW BE ENERGIZED. PLACE MODE SWITCH
222 5
R2 215
5
G5
IN VV FOR STICK AND CV (I) FOR AIR
6 215
6
G2
CARBON ARC. SEE OPERATING MANUAL J5
205
7
FOR FURTHER INSTRUCTIONS. 1 208
A 8
215
B 2 9 207
N.C. CENTER TERMINAL OF FUSE HOLDER.
SEC. 231
3 10
N.D. WELDING CABLE MUST BE OF THE PROPER OUTPUT B' 4 11
J7
CHOKE
CAPACITY FOR THE CURRENT AND DUTY CYCLE
OUTPUT
5
C 12
C7
OF IMMEDIATE AND FUTURE APPLICATIONS. C' 6
GATE
DIAGRAMS
IDEALARC DC-600
1 X
N.D.
LEADS TO 7
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY
G1
8
A' 2 Y
FIRING J6
"POSITIVE". TO CHANGE THE POLARITY, TURN
TO T1 AUX. WINDING
G3 210
Z
3
CIRCUIT FIRING CIRCUIT
THE DC-600 OFF, AND REVERSE THE LEADS AT G5
4
P.C.
SCR P.C. BOARD
THE MULTI-PROCESS SWITCH.
BOARD (+)
SNUBBERS
N.F. USING A WIRE FEEDER, K-317 OR K-318 J4 210
A A A
CONNECTION DIAGRAM, CONNECT ELECTRODE 215
AND WORK LEADS TO THESE TERMINALS
INSTEAD OF THE POWER SOURCE 3CR 2
SCR SCR
SCR -
+ 4
OUTPUT TERMINALS. 3 5
1 LEADS 210 & 215 ARE
N.G. 2CR IS SHOWN AS SPST RELAY. IF 2CR IS A
OUTPUT SHUNT
210 TWISTED TOGETHER
3PDT, LEADS 255 CONNECT
215 (50MV @800 AMPS}
TO TERMINAL 4 INSTEAD
220 210
255 215
OF TERMINAL 5. 271 4
7 215
C C C
255
271 220
215
OUTPUT
2CR
215
SNUBBER C C C 215
A B
235
233
TO STICK ELECTRODE HOLDER OR
WORK +
J6 J4 J7 AIR-CARBON ARC TORCH
J3 SCR
SCR
SCR
N.E.
N.D.
N.D., N.F.
4
2 6
ELECTRODE
TO "WORK" USED WITH STICK
- OR AIR-CARBON ARC
A A A
J5 J1
J2
OPTIONAL USER SUPPLIED JUMPER FOR
STICK WORK LEAD NOT
OUTPUT RECTIFIER OPTIONAL
THOSE SITUATIONS WHERE IT IS NOT
G6 GATE LEADS TO
USED WHEN JUMPER IS
ASSEMBLY MULTI-PROCESS
NECESSARY TO HAVE SEPARATE GROUND
FIRING CIRCUIT
G4
USED.
SWITCH
P.C. BOARD
G2 CABLES FOR STICK AND SEMI-AUTOMATIC
CONNECTOR CAVITY NUMBERING SEQUENCE J4 WELDING.
(VIEWED FROM COMPONENT SIDE OF BOARD) THESE NOTES APPLY ONLY TO DC-600 WITH A
ELECTRICAL SYMBOLS PER E1537 MULTI-PROCESS SWITCH INSTALLED. 10-9-98F
L10576
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-2
WIRING DIAGRAM (230/460/575)
F-3
230/460/575V. H4 R1
236 OUTPUT
N.A.
(SHOWN CONNECTED H3
CONTROL
FOR LOW VOLTAGE) TO 215
H2 210 237 75
SUPPLY 229
H1
LINES 32A
272 76
SW3
TO GROUND PER 31
X1 N.C.
X1 T2 77
210
H1
START VM
NATIONAL
226 80
9 STOP +-
3 SW2
ELECTRICAL 238
3 211
L3 21
6 222
2 H2
CODE F1
8
SW1
5
LEGEND 2 212 SW4
L2
4
222 2
1
C7 .05 +.05 MFD 7
RECONNECT 81
255 232
F1 8 AMP SLOW BLOW FUSE 1 32
L1
PANEL H3
224
AM
R1 10K POT
271
1CR +-
R2 30 , 100W
TO PRIMARY COILS 21 4 2 76 80 81
75 77
31 32
X2
271
T1 MAIN POWER TRANSFORMER
18,17,16
15,14,13
T2 CONTROL TRANSFORMER 280
N.G. 80 81
1CR INPUT CONTACTOR 7 5 T.S.3
4
2 271
N.A.
N.A. 5CR
272
2CR FAULT PROTECTION RELAY T.S.2
2CR 255
B
3CR CURRENT ACTIVATED REED SWITCH A
1 PILOT
0 R 235
4CR OUTPUT PILOT RELAY
235 229
LIGHT 1 1
5CR POWER INTERLOCK RELAY
271 233 2 2
256 75
SW1 INPUT POWER 256
232
3
255 3
272
SW2 ELECTRODE POLARITY
4
231 80
4
PRIMARY
SW3 OUTPUT CONTROL 256
5
238 81
5 J2
THERMOSTAT
SW4 WELDING MODE (SHOWN IN STICK POSITION)
233 6 226
6
273 J1
NOTES: 18 7
16 17 32A 224
7
N.A. S
S SEC. LEAD
1 31 8 8 215
N.A. TAPE UP SEPARATELY TO PROVIDE AT LEAST T1 THERMOSTAT
AUX.2 31 9
3
1 2 9
F
600V. INSULATION. F
205 10 10 280
PRI.
ALL LEADS
F F
F
N.B. FOR STICK WELDING OR AIR CARBON ARC
11
203 207
EXCEPT 210 1
WITHOUT A MULTI-PROCESS SWITCH INSTALLED, 6 J3 12
4 5
10, 11, 12 S FAN 215 215 2
S
S
DISCONNECT ALL ELECTRODE, WORK, AND 220
13
210
TO INPUT 206
204 AUX. 1 208 MOTOR
CONTROL LEADS TO ANY WIRE FEEDERS.
32A CONTROL 222
14
PANEL
JUMPER 2 TO 4. OUTPUT TERMINALS WILL 13 14 15
P.C. BOARD
THERE IS NO
NOW BE ENERGIZED. PLACE MODE SWITCH 7 8 9 31
215
10, 11 & 12
IN VV FOR STICK AND CV (I) FOR AIR 4 216
PRI. CONNECTION
CARBON ARC. SEE OPERATING MANUAL B
ON 380 OR
12
11
10
FOR FURTHER INSTRUCTIONS. 4 5 6
TRIPLE VOLTAGE
N.C. CENTER TERMINAL OF FUSE HOLDER. MACHINES. 216
G3 1 1
TO OUTPUT
9
N.D. WELDING CABLE MUST BE OF THE PROPER 8 G6 203
2
7 2
RECTIFIER
A
206
G1 3 3
CAPACITY FOR THE CURRENT AND DUTY CYCLE
J4
ASSEMBLY
(-)
SEC. 214 4 204
G4
4CR
OF IMMEDIATE AND FUTURE APPLICATIONS. 4
222
222
R2 5 215
5
G5
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY
6 215
6
G2
J5
"POSITIVE". TO CHANGE THE POLARITY, TURN
205
7
THE DC-600 OFF, AND REVERSE THE LEADS AT 1 208
A 8
215
THE MULTI-PROCESS SWITCH. B 2 9 207
SEC. 231
3 10
N.F. USING A WIRE FEEDER, K-317 OR K-318
OUTPUT B' 4 11
CONNECTION DIAGRAM, CONNECT ELECTRODE J7
CHOKE
OUTPUT
5
C 12
C7
AND WORK LEADS TO THESE TERMINALS
C' 6
GATE
INSTEAD OF THE POWER SOURCE
1 X
N.D.
LEADS TO 7
OUTPUT TERMINALS. G1
8
A' 2 Y
FIRING J6
TO T1 AUX. WINDING
G3 210
N.G. 2CR IS SHOWN AS SPST RELAY. IF 2CR IS A 3PDT, LEADS 255
DIAGRAMS
IDEALARC DC-600
Z
3
CIRCUIT FIRING CIRCUIT
G5
CONNECT TO TERMINAL 4 INSTEAD OF TERMINAL 5. 4
P.C.
SCR P.C. BOARD
BOARD (+)
SNUBBERS
J4 210
255 A A A
271 215
4
7
255
271 3CR 2
SCR SCR
SCR -
+ 4
3 5
1 LEADS 210 & 215 ARE
OUTPUT SHUNT
210
2CR TWISTED TOGETHER
215 (50MV @800 AMPS}
A B 220 210
215 215
C C C
220
215
OUTPUT
THESE NOTES APPLY ONLY TO DC-600 WITH A
215
SNUBBER C C C 215
MULTI-PROCESS SWITCH INSTALLED.
J6 J4 J7
J3
TO STICK ELECTRODE HOLDER OR
WORK +
AIR-CARBON ARC TORCH
SCR
SCR
SCR
N.E.
N.D.
N.D., N.F.
4
2 6
ELECTRODE
TO "WORK" USED WITH STICK
J5 J1
J2
- OR AIR-CARBON ARC
A A A
OPTIONAL USER SUPPLIED JUMPER FOR
STICK WORK LEAD NOT
OUTPUT RECTIFIER OPTIONAL
THOSE SITUATIONS WHERE IT IS NOT
G6 GATE LEADS TO
USED WHEN JUMPER IS
ASSEMBLY MULTI-PROCESS
NECESSARY TO HAVE SEPARATE GROUND
FIRING CIRCUIT
G4
CONNECTOR CAVITY NUMBERING SEQUENCE
USED.
SWITCH
P.C. BOARD
G2 CABLES FOR STICK AND SEMI-AUTOMATIC
(VIEWED FROM COMPONENT SIDE OF BOARD)
J4 WELDING.
ELECTRICAL SYMBOLS PER E1537
10-9-98F
L10577
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-3
NOTES
IDEALARC DC-600
NOTES
IDEALARC DC-600
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With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
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Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
$10.00 For order value between $50.00 & $99.99
$15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders) Name: _______________________________________________
CHECK ONE:
Address: _______________________________________________
Please Invoice (only if order is over $50.00)
_______________________________________________
Check or Money Order Enclosed, U.S. Funds only
Credit Card - Telephone: _______________________________________________
MasterCard
VISA ®
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Signature as it appears on Charge Card:
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Account No. Exp Date
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Month Year
USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
BOOKS OR FREE INFORMATIVE CATALOGS
Lincoln Welding School Titles: Price Code Quantity Cost
(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition� $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
LIMITED WARRANTY
STATEMENT OF LIMITED WARRANTY CONDITIONS OF WARRANTY
The Lincoln Electric Company (Lincoln) warrants to the TO OBTAIN WARRANTY COVERAGE:
end user (purchaser) of all new welding and cutting equip-
The purchaser must contact Lincoln or Lincoln’s Authorized
ment, electrode and flux (collectively called the “Goods�)
Service Facility about any defect claimed under Lincoln’s
that it will be free of defects in workmanship and material.
warranty.
This warranty is void if Lincoln or its Authorized Service
Facility finds that the equipment has been subjected to
Determination of warranty on welding and cutting equip-
improper installation, improper care or abnormal opera-
ment will be made by Lincoln or Lincoln’s Authorized
tions.
Service Facility.
WARRANTY PERIOD (1) (2) (3)
Lincoln will assume both the parts and labor expense of
WARRANTY REPAIR:
correcting defects during the full warranty period. All war-
If Lincoln or Lincoln’s Authorized Service Facility confirms
ranty periods date from the date of purchase to the original
end user or from the date of manufacture if the original the existence of a defect covered by this warranty, the
invoice cannot be provided and are as follows: defect will be corrected by repair or replacement at
Lincoln’s option.
7 Years
� Main power rectifiers on all non-inverter low frequency
(50 and 60 Hz) type welders. At Lincoln’s request, the purchaser must return, to Lincoln
or its Authorized Service Facility, any “Goods� claimed
3 Years
defective under Lincoln’s warranty.
� All Lincoln welding machines, wirefeeders and plasma
cutting machines unless listed below.
FREIGHT COSTS:
2 Years The purchaser is responsible for shipment to and from the
� Power Arc 4000, Power Arc 5000
Lincoln Authorized Service Facility.
Weldanpower 125
1 Year WARRANTY LIMITATIONS
� AC-100
Lincoln will not accept responsibility or liability for repairs
Invertec V100-S, Invertec V130-S, Invertec V200-T
made outside of a Lincoln Authorized Service Facility.
Pro-Cut 25, Handy MIG 101, Handy Core 100
� All water coolers (internal or external models) Lincoln’s liability under this warranty shall not exceed the
cost of correcting the defect of the Lincoln product.
� All stick electrode, welding wire and flux.
� Arc welding and cutting robots and robotic controllers Lincoln will not be liable for incidental or consequential
damages (such as loss of business, etc.) caused by the
� All Environmental Systems equipment, including portable
defect or the time involved to correct the defect.
units, central units and accessories. (Does not include
consumable items listed under 30 day warranty.)
This written warranty is the only express warranty provided
� All welding and cutting accessories including wire feed by Lincoln with respect to its products. Warranties implied
modules, undercarriages, field installed options that are
by law such as the warranty of merchantability are limited
sold separately, unattached options, welding supplies,
to the duration of this limited warranty for the equipment
standard accessory sets, replacement parts, and
Magnum products. (Does not include expendable parts involved.
and guns/torches listed under 90 and 30 day warranties)
This warranty gives the purchaser specific legal rights. The
90 Days
purchaser may also have other rights which vary from state
� All gun and cable assemblies, TIG and plasma torches
and spool guns. to state.
30 Days
Equipment manufactured for the Lincoln Electric Company is subject to
(1)
� All consumable items that may be used with the environ-
the warranty period of the original manufacturer.
mental systems described above. This includes hoses,
filters, belts and hose adapters.
All engines and engine accessories are warranted by the engine or
(2)
engine accessory manufacturer and are not covered by this warranty.
� Expendable Parts - Lincoln is not responsible for the
replacement of any expendable part that is required due
SAE400 WELD N� AIR compressor is warranted by the compressor man-
(3)
to normal wear.
ufacturer and not covered by this warranty.
March, �99
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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