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IDEALARC DC-600

OPERATORS MANUAL

IM642-DDecember, 2008

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

R E PA I R T H IS E Q UI P ME N T

W IT HO UT R EA DI NG T HI SM A N U A L A N D T H E SA F E T Y

PRECAUTIONS CONTAINED

THROUGHOUT. A nd , m os t

importantly, think before you act

and be careful.

1

2

3

4

5 6

7

8

9

10

DC-600

For use with machines having Code Numbers: 10588 to 10701,11071, 11072,11129,11130, 11131, 11132, 11133 and 1114011335, 11336, 11337, 11338, 1133911537,11538, 11539, 11540, 11541,11568

Sales and Service through Subsidiaries and Distributors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products

Copyright Lincoln Global Inc.

RETURN TO MAIN MENU

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FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, wellventilatedareas or vent the engine exhaust fumes

outdoors.

____________________________________________________1.c. D o not add the fuel near an open flame

welding arc or when the engine is running.

Stop the engine and allow it to cool before

refueling to prevent spilled fuel from vaporizing on con tact with hot eng ine par ts and

igniting. Do not spill fuel when fil ling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________

1.d.Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from Vbelts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. I n s om e c as es i t m ay b e n ec es sa ry t o rem ov e sa fe ty

g ua rd s t o p er fo rm r eq ui re d m ai nt en an ce . R em ov eguards only when necessary and replace them when the

m ai nt en an ce r eq ui ri ng t he ir r em ov al i s c om pl et e.

Always use the greates t care when working near mov ingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distr ibutor cap or

magneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of Safety in Welding & Cutting ANSI Standard Z49.1 from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.21974. A Free copy of Arc Welding Safety booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 441171199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar 95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current f lowing through any conductor causes

local ized Electric and Magnetic Fie lds (EMF). Welding

current creates EMF f ie lds around welding cables and

welding machines

2.b. EMF f ie lds may inter fe re with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the e lect rode and work cab les together - Securethem with tape when possible.

2 .d .2 . N ev er c oi l t he e le ct ro de l ea d a ro un d y ou r b od y.

2 .d .3 . Do n ot p la ce y ou r b od y b et we en t he e le ct ro de a nd

work cables. If the electrode cable is on your right

s ide, the work cable should also be on your r ight s ide.

2 .d .4 . Connect the work cab le to the workp iece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avo id scalding, do no t remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The eng ine exhaust f rom this product con ta inschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

IDEALARC DC-600

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iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper f il ter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flameresistant

material to protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, nonflammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically hot when the welder is on.

Do not touch these hot parts with your bare

skin or wet c lo th ing. Wear dry , hole free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

m us t b e p er fo rm ed u nd er e le ct ri ca ll y h az ardo us

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

e lectrode reel, welding head, nozzle or semiautomat ic

welding gun are also electrically hot.

3.d. A lways be sure the work cab le makes a good e lect rical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never s imul taneously touch e lect ri ca ll y ho t par ts o f

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i . When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j . Alsosee Items 6.c. and 8.

IDEALARC DC-600

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases . When welding , keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away f rom the breathing zone. Whenwe ldi ng wi th e le ct ro des w hic h r equ ir e sp eci al

v en ti la ti on s uc h a s s ta in le ss o r h ar d f ac in g ( se e

i ns tr uc ti on s o n c on ta in er o r M SD S) o r o n l ea d o r

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

u si ng l oc al e xh au st o r m ec ha ni ca l v en ti la ti on . I n

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

a ls o req ui re d w he n w el di ng o n g al va ni ze d s te el .

5. b. The operation of welding fume control equipment is affected

by various factors including proper use and positioning of

the equipment, maintenance of the equipment and the spe

cific welding procedure and application involved. Worker

exposure level should be checked upon installat ion andperiodically thereafter to be certain it is within applicable

OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod

ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or dea th . A lways use enough venti la ti on ,

especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer s instructions for this

equipment and the consumables to be used, including the

m at er ia l s af et y d at a s he et ( MS DS ) a nd f ol lo w y ou remployers safety practices. MSDS forms are available from

y ou r w el di ng d is tr ib ut or o r f ro m t he m an uf ac tu re r.

5.f. Also see item 1.b.

AUG 06

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iiiSAFETYiii

IDEALARC DC-600

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working onthe equipment.

8.b. Insta ll equipment in accordance with the U.S. Nat ional

Electrica l Code, a ll local codes and the manufacturers

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturers recommendations.

CYLINDER may explodeif damaged.7.a. U s e on ly co mp re ss ed g as cyl in de rs

containing the correct shielding gas for the

p ro ce ss u se d a nd p ro pe rl y o pe ra ti ng

regulators designed for the gas andpressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. A lways keep cyl inders in an upr ight pos it ion securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:Away from areas where they may be struck or subjected to

physical damage.

A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, e lectrode holder or any otherelectrically hot parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and handt ight except when the cy linder is in use or connected foruse.

7.g. Rea d a nd f ol lo w t he i ns tr uc ti on s o n c om pres se d g as

cylinders, associated equipment, and CGA publication Pl,Precautions for Safe Handling of Compressed Gases in

Cylinders, available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

Jan, 07

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks f rom s ta rt ing a f ire.Remember that welding sparks and hot

materials from welding can easily go through small cracks

a nd o pe ni ng s t o a dj ac en t a re as . Avo id wel di ng n ea r

hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job si te,

special precautions should be used to prevent hazardoussituations. Refer to Safety in Welding and Cutting (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they have

been cleaned. For information, purchase RecommendedSafe Practices for the Preparation for Welding and Cutting ofC on ta in er s a nd P ip in g T ha t H av e H el d H az ar do usSubstances, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with s ide shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the bui ldingframework or other locations away from the welding area

increase the possibi li ty of the welding current passing

through lifting chains, crane cables or other alternate cir

cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and fol low NFPA 51B Standard for Fire Prevention

During Welding, Cutting and Other Hot Work, available

from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma0226909101.

6.j. Do not use a welding power source for pipe thawing.

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ivSAFETYiv

PRCAUTIONS DE SRETPour votre propre protection lire et observer toutes les instructions

et les prcautions de sret specifiques qui parraissent dans ce

manuel aussi bien que les prcautions de sret gnrales suiv-

antes:

Sret Pour Soudage A LArc

1. Protegez-vous contre la secousse lectrique:

a . Les c ircuits llectrode e t la p ice son t sous tension

quand la machine souder est en marche. Eviter toujours

tout contact entre les par ties sous tension et la peau nue

ou les vtements mouil ls. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire t rs attention de bien s isoler de la masse quand on

soude dans des endro it s humides , ou sur un p lancher

metallique ou des grilles metalliques, principalement dans

les posit ions assis ou couch pour lesquelles une grande

partie du corps peut tre en contact avec la masse.

c. Maintenir le por te- lect rode, la pince de masse, le cble

de soudage et la machine souder en bon et sr tat

defonctionnement.d. Ne jamais plonger le por te- lect rode dans l eau pour le

refroidir.

e. Ne jamais toucher simultanment les parties sous tension

des porte-lectrodes connects deux machines souder

parce que la tens ion ent re les deux p inces peut tre le

total de la tension vide des deux machines.

f. Si on utilise la machine souder comm e une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-lectrode sapplicuent aussi au pistolet de

soudage.

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

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le cble-lectrode autour de n importe quelle partie

du corps.

3. U n c ou p da rc p eu t tre p lus s vr e q uu n co up d e s oliel,

donc:

a . Uti liser un bon masque avec un verre f il tran t appropr i

ainsi quun verre blanc afin de se protger les yeux du ray-

onnement de l a rc et des project ions quand on soude ou

quand on regarde larc.

b . Por te r des vtements convenables a fin de pro tger la

peau de soudeur et des aides contre le rayonnement de

larc.

c . P ro t ge r l a ut re p er so nn el t ra va il la nt p ro xi mi t a usoudage laide dcrans appropris et non-inflammables.

4. D es g ou tt es d e la itie r e n fu sio n s on t mis es d e l a rc d e

soudage. Se protger avec des vtements de protection libres

de l huile, tels que les gants en cui r, chemise paisse, pan-

talons sans revers, et chaussures montantes.

5. T ou jo urs p ort er d es lu ne tte s d e s c uri t d an s l a z on e d e

soudage. Uti liser des lunettes avec crans lateraux dans les

zones o lon pique le laitier.

6. Eloigner les matriaux inf lammables ou les recouvrir afin de

prvenir tout risque dincendie d aux tincelles.

7. Quand on ne soude pas, poser la pince une endroit isol de

la masse. Un court -c ir cu it acc iden ta l peu t p rovoquer un

chauffement et un risque dincendie.

8. Sassurer que la masse est connecte le plus prs possiblede la zone de travail qui l est pratique de le fai re. Si on place

la m as se s ur la c ha rp en te d e la c on st ru ct io n o u d a ut re s

endroits loigns de la zone de travail , on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, cbles de grue, ou autres circuits. Cela peut provoquer

des risques d incendie ou dechauffement des chaines et des

cbles jusqu ce qu ils se rompent.

9. Assurer une venti lation suffisante dans la zone de soudage.

Ceci est particulirement important pour le soudage de tles

galvanises plombes, ou cadmies ou tout autre mtal qui

produit des fumes toxiques.

10. Ne pas souder en prsence de vapeurs de chlore provenantd opra tions de dgra issage , net toyage ou p is to lage . La

chaleur ou les rayons de larc peuvent ragir avec les vapeurs

du solvant pour produire du phosgne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sret,

v oir le c od e C od e fo r s afe ty in w eld in g a nd c uttin g C SA

Standard W 117.2-1974.

PRCAUTIONS DE SRET POUR

LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Rel ier la terre le chassis du poste conformement au code de

llectricit et aux recommendations du fabricant. Le dispositif

de montage ou la piece souder doit tre branch une

bonne mise la terre.

2. Autant que possible, I installation et lentretien du poste seront

effectus par un lectricien qualifi.

3. Avant de faires des travaux l interieur de poste, la debranch-

er l interrupteur la boite de fusibles.

4. G ard er t ou s le s c ou ve rc le s e t d is po sit if s d e s re t le ur

place.

Mar. 93

IDEALARC DC-600

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vvThank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet. For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it. For OnLine Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose Quick Links and then

Product Registration. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip

ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses

sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor

mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers particular purpose,

with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any

warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in

applying these types of fabrication methods and service requirements.

Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com

for any updated information.

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vivi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications ............................................................................................. A1Safety Precautions ..................................................................................................... A2Select Proper Location.................................................................................................A2

Limit on Stacking ...................................................................................................A2Stacking.................................................................................................................A2Tilting .....................................................................................................................A2

Electrical Input Connections ....................................................................................... A3Fuses and Wire Sizes............................................................................................A3Ground Connection .............................................................................................. A3Input Power Supply Connections...........................................................................A3

Reconnect Procedure ................................................................................................ A4Output Connections ................................................................................................... A7

Electrode, Work and #21 Lead ..............................................................................A7Auxiliary Power and Control Connections .............................................................A8

________________________________________________________________________

Operation .........................................................................................................Section BSafety Precautions ............................................................................................... B1General Description ............................................................................................. B2

Recommended Processes and Equipment ...........................................................B2Design Features and Advantages ........................................................................B2Welding Capability ............................................................................................... B3Meaning of Graphical Symbols on Case Front......................................................B3Meaning of Graphical Symbols on Rating Plate ....................................................B4Meaning of Graphical Symbol for Ground Connection ..........................................B4Controls and Settings ....................................................................................B4, B5Auxiliary Power in MS Receptacle.......................................................................B6Overload, Overcurrent and Fault Protection ..........................................................B6Operating Steps ................................................................................................... B7Remote Control of Machine Operation ..................................................................B7Welding Procedure Recommendations ............................................................... B7SemiAutomatic and Automatic Wire Feeding

with a IDEALARC DC600 and Wire Feeders.....................................................B8NA3 Automatic Wire Feeder ..........................................................................B8NA5 Automatic Wire Feeder ........................................................................B10LN8 SemiAutomatic Wire Feeder ...............................................................B10LN7 & LN9 SemiAutomatic Wire Feeders .................................................B10

________________________________________________________________________

Accessories.....................................................................................................Section C

Wire Feeders and Tractors....................................................................................C1Field Installed Options ...........................................................................................C1

Remote Output Control (K775 or K857)..........................................................C1Remote Control Adapter Cable (K864) ...........................................................C1Undercarriages (K817P, K842) .......................................................................C1

Paralleling Kit (K16111) .................................................................................C1TIG Module (K9302) ......................................................................................C1

Factory or Field Installed Options..........................................................................C1MultiProcess Switch (K8041)........................................................................C1

Connections for SemiAutomatic or Automatic Wire Feeder Control ....................C3________________________________________________________________________

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vii viiTABLE OF CONTENTSPage

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D1Routine and Periodic Maintenance........................................................................D2

Troubleshooting..............................................................................................Section ESafety Precautions.................................................................................................E1How to Use Troubleshooting Guide.......................................................................E1Troubleshooting Guide ..........................................................................................E2

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

Parts List .....................................................................................................P-349 Series

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60% Duty Cycle

122/61122/61/49

6149

128/74/6474/56

64140/70

68

A-1INSTALLATION

IDEALARC DC-600

A-1

TECHNICAL SPECIFICATIONS IDEALARC DC-600

Volts at Rated Amperes444444

AuxiliaryPower

See the OPERATION sectionfor Auxiliary Power

information by model

Amps600680750

Maximum Open Circuit Voltage

72V for 60 HZ models69V for 50/60 HZ models

Duty Cycle100% Duty Cycle60% Duty Cycle50% Duty Cycle

Output Range

70A/13V780A/44V (CV)90A/24V780A/44V (CC)

INPUT - THREE PHASE ONLY

OUTPUT

1Also called inverse time or thermal/magnetic circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.

RECOMMENDED INPUT WIRE AND FUSE SIZES

StandardVolatge

230/460/60230/460/575/60

460/60575/60

220/380/440/50/60380/500/50/60

440/50/60200/400/50/60

415/50/60

100% Duty Cycle

108/54108/54/43

5443

116/67/5867/51

58128/64

62

50% Duty Cycle

134/67134/67/54

6754

138/80/6980/61

69152/76

73

Input Current at Rated Output

RATED OUTPUT

INPUTVOLTAGE /

FREQUENCY

230

460575200220380400415440500

TYPE 75C(SUPER LAG)OR BREAKERSIZE (AMPS)1

175 Amp

90 Amp70 Amp

175 Amp175 Amp100 Amp100 Amp100 Amp90 Amp80 Amp

TYPE 75CGROUND WIRE

IN CONDUITAWG(IEC-MM2) SIZES

6 (14)

8 (8.4)8 (8.4)6 (14)6 (14)8 (8.4)8 (8.4)8 (8.4)8 (8.4)8 (8.4)

TYPE 75CCOPPER WIRE

IN CONDUITAWG(IEC-MM2) SIZES

30C (86F) Ambient

2 (34)

6 (14)8 (8.4)1 (43)2 (34)6 (14)6 (14)6 (14)6 (14)8 (8.4)

INPUT AMPERERATING ON

NAMEPLATE

108

54431281166764615851

HERTZ

60

6060

50/6050/6050/6050/6050/6050/6050/60

PHYSICAL DIMENSIONS

HEIGHT30.75 in781 mm

WIDTH22.25 in567 mm

DEPTH39.0 in

988 mm

WEIGHT522 lbs.237 kg.

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A-2INSTALLATION

IDEALARC DC-600

A-2

SAFETY PRECAUTIONSRead entire Installation Section before installingthe IDEALARC DC600.

ELECTRIC SHOCK CAN KILL.

Only qualified personnel shouldinstall this machine.

Turn the input power OFF at thedisconnect switch or fuse boxbeforeworking on the equipment.

Do not touch electrically hot parts.

Always connect the IDEALARCIDEALARC DC-600 grounding terminal to a

good electrical earth ground.

Set the IDEALARC DC-600 Power ON/OFFPUSH BUTTON to the OFF position when con-necting power cord to input power.

__________________SELECT PROPER LOCATION

Place the welder where clean cooling air can freelycirculate in through the front louvers and out throughthe rear louvers. Dirt, dust or any foreign material that

can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can resultin excessive operating temperatures and nuisanceshutdowns.

LIMIT ON STACKING

STACKING

Three IDEALARC DC600 machines can bestacked.

DO NOT stack more than three machines in onegrouping.

DO NOT stack the IDEALARC DC600 on anothertype of machine.

Follow these guidelines when stacking:1. Select a firm, level surface capable of sup

porting the total weight of up to threemachines (1570 pounds/712 kilograms).

2. Set the bottom machine in place.

3. Stack the second machine on top of it byaligning the two holes in the base rails of thesecond machine with the two pins on top front

of the bottom machine.

4. Repeat process for third machine.

NOTE: The machines must be stacked with the CaseFront of each machine flush with each other. SeeFigure A.1.

FIGURE A.1 - Stacking IDEALARC DC-600

machines

TILTING

The IDEALARC DC600 must be placed on a stable,level surface so it will not topple over.

STACKING HOLE

STACKING PINS

WARNING

Lift only with equipment of ade-

quate lifting capacity.

Be sure machine is stable when

lifting. Do not lift this machine using lift

bail if it is equipped with a heavyaccessory such as trailer or gas

cylinder.FALLING Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. Do not operate machine whilesuspended from lift bail.

Do not stack more than three high. Do not stack the IDEALARC DC-600 on top of any

other machine.

------------------------------------------------------------------------

WARNING

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A-3INSTALLATION

IDEALARC DC-600

A-3

ELECTRICAL INPUT CONNECTIONS

Before installing the machine check that the input supply voltage, phase, and frequency are the same as thevoltage, phase, and frequency as specified on thewelder Rating Plate located on the Case BackAssembly. Input power supply entry is through thehole in the Case Back Assembly. See Figure A.2 for

the location of the machines input cable entry opening, Input Contactor (CR1), and reconnect panelassembly for dual voltage machines.

FIGURE A.2 - Rear Panel

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses or

delay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machinebeing used. They are also called inverse time or thermal/magnetic circuit breakers.

DO NOT use fuses or circuit breakers with a loweramp rating than recommended. This can result in nuisance tripping caused by inrush current even whenmachine is not being used for welding at high outputcurrents.

Use input and grounding wire sizes that meet localelectrical codes or see the Technical Specifications

page in this manual.

GROUND CONNECTION

Ground the frame of the machine. A groundterminal marked with the symbol ( ) is located insidethe Case Back of the machine near the input contactor. Access to the Input Box Assembly is at the upperrear of the machine. See your local and national electrical codes for proper grounding methods.

INPUT POWER SUPPLYCONNECTIONS

A qualified electrician should connect the input powersupply leads.

1. Follow all national and local electrical codes.

2. Use a threephase line.

3. Remove Input Access Door at upper rear ofmachine.

4. Follow Input Supply Connection Diagram locatedon the inside of the door.

5. Connect the threephase AC power supply leadsL1, L2, and L3 to the input contactorterminals in the Input Box Assembly by passingthem thru the three aligned .50 diameter holes inthe baffle and tighten them in the terminal connectors. Be sure to close the baffle by inserting the

tab into the slot in the baffle. See Figure A.3.

FIGURE A.3 - Input Power Supply

Connections

INPUT SUPPLYCABLE ENTRY

OPENINGINPUT

CONTACTOR (CR1)

RECONNECTPANEL ASSEMBLY

INPUT POWER SUPPLYCABLE WITH BUSHINGOR BOX CONNECTOR

INPUTCONTACTOR (CR1)

RECONNECTPANEL ASSEMBLY

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A-4INSTALLATION

IDEALARC DC-600

A-4

RECONNECT PROCEDURE

Multiple voltage machines are shipped connected tothe highest input voltage listed on the machines ratingplate. Before installing the machine, check that theReconnect Panel in the Input Box Assembly is connected for the proper voltage.

Failure to follow these instructions can causeimmediate failure of components within themachine.

When powering welder from a generator be sureto turn off welder first, before generator is shutdown, in order to prevent damage to the welder

To reconnect a multiple voltage machine to a differentvoltage, remove input power and change the positionof the reconnect board on the Reconnect Panel.Follow The Input Connection Diagram located on theinside of Case Back Input Access Door. These connection diagrams for the following codes are listedbelow.

1. For Dual Voltage except 380/500460/575, seeFigure A.4. (M15009)

2. For 220/380/460, see Figure A.5. (M15010)

3. For 380/500460/575, see Figure A.6. (M15011)

4. For 460 and 440 Single Voltage, see Figure A.7.(S17894)

5. For 230/460/575, see Figure A.8. (M15666)

6. For Voltages not listed, see the Input Connection

Diagram pasted on the inside of the CaseBack Input Access Door.

L3L2L1

LINK

LINESINPUT

GND H2H1

H3L3L2L1

LINK

LINES

INPUT

H3H1

H2GND

W

V

U

W

V

U

CONTACTOR

CRI

CRI

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

CTOR

1.TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX-2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE ATLEAST 600 VOLT INSULATION.-

3.CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OFTHE CRI CONTACTOR AS SHOWN. -4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.-

5.MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THEREMAINING HEX NUTS IN PLACE.

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX-2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE ATLEAST 600 VOLT INSULATION.-

3.CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OFTHE CRI CONTACTOR AS SHOWN. -

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.-

5.MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.

PILOTTRANSF.

PILOTTRANSF.

FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines

CAUTION

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A-5INSTALLATION

IDEALARC DC-600

A-5

CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.

CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX

2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE ATLEAST 600 VOLT INSULATION.

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THEINPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREEPOSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUM

CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.



3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THEINPUT SIDE OF THE CRI CONTACTOR AS SHOWN.


5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

L3L2L1

LINKS

LINESINPUT

H4H1

H2GND

W

V

UCONTACTOR

CRI

H3

L3L2L1

LINKS

LINESINPUT

H3H1

H2GND

W

V

UCONTACTOR

CRI

H4

L3L2L1

LINKS

LINES

INPUT

H2H1

H3GND

W

V

UCONTACTOR

CRI

H4



3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THEINPUT SIDE OF THE CRI CONTACTOR AS SHOWN.


5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.

PILOTTRANSF.

PILOTTRANSF.

PILOTTRANSF.

FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines

FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines

CONNECTION FOR 380/460 VOLTAGES

1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE ATLEAST 600 VOLT INSULATION.

2. CONNECT H3 LEAD TO CONTACTOR..

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTORAS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.

5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTENALL HEX NUTS

L3L2L1

LINK

LINESINPUT

H2

H3

GND

W

V

UCONTACTOR

CRI L3L2L1

LINK

LINESINPUT

GND

H2

W

V

U

CRI

CONTACTOR

H1

TAPE

CONNECTION FOR 500/575 VOLTAGESH3

H1

1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE ATLEAST 600 VOLT INSULATION.

2. CONNECT H2 LEAD TO CONTACTOR.

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTORAS SHOWN.


5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTENALL HEX NUTS

TAPE

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A-6INSTALLATION

IDEALARC DC-600

A-6

FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines

L3L2L1

LINESINPUT

GND

SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE



3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.

W

V

UCONTACTOR

CRI

FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines

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A-7INSTALLATION

IDEALARC DC-600

A-7

OUTPUT CONNECTIONS

See Table A.1 for recommended IDEALARC DC600 cable sizes for combined lengths of electrode and workcables.

TABLE A.1IDEALARC DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable

at 100% Duty Cycle

Cable SizeParallel CablesCable Length

1/0 (53mm2)2

2

2

Lengths up to 150 ft. (46m)

2/0 (67mm2)150 ft.(46m) to 200 ft (61m)

3/0 (85mm2)200 ft.(61m) to 250 ft.(76m)

ELECTRODE, WORK AND #21 LEADCONNECTIONS

A. Connect Electrode and Work Leads toOutput Terminals.

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

2. Locate the retractable strain relief loops directlybelow the output terminals in the lower right andlower left corners of the Case Front Assembly.See Figure A.9.

3. Pull out the retractable strain relief loops.

4. Insert the electrode lead through the loop directlybelow the desired polarity (positive or negative).Pull through enough cable to reach the outputterminals.

5. Connect electrode lead to the desired terminal(positive/negative).

6. Tighten the output terminal nut with a wrench.

7. Connect the work lead to the other outputterminal following steps 46.

FIGURE A.9 - Output Terminals.

B. Connect #21 Work Sense Lead to ProperTerminal

There are two work sense lead connection points (+21and 21) on terminal strip (T.S.2) located behind the

hinged access panel on the right side of the casefront. See 14 Pin MS Type Receptacle section orTerminal Strip Section for connection procedure.

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TERMINAL STRIPS

Terminal strips are available behind the cover on thecase front to connect wire feeder control cables that

do not have a 14 Pin MStype connector. These terminals supply the connections as shown in the followingTerminal Strip charts. NOTE: There are two worksense lead connection points on the terminal strip.Connect both the work sense lead #21 from the 14 pinconnector and #21 lead of the control cable to 21when welding positive polarity or to +21 when welding negative polarity.

TERMINAL STRIP 1 (T.S.1)

TERMINAL STRIP 2 (T.S.2)

Lead No. Function

75 Output Control76 Output Control77 Output Control

Lead No. Function

+21 Work Connection (Electrode Negative)21 Work Connection (Electrode Positive)2

41 42 VAC4 Trigger Circuit2 Trigger Circuit

31 115 VAC1

32 115 VAC1

A-8INSTALLATION

IDEALARC DC-600

A-8

AUXILIARY POWER ANDCONTROL CONNECTIONS

Located at the left side of the front of the welderbehind a hinged cover is a 115VAC duplex receptaclefor auxiliary power (60 Hertz Models only). On the rightside of the case front is a 14 Pin MS type receptaclefor connection of auxiliary equipment such as wire

feeders. Also, terminal strips with 115VAC and connections for auxiliary equipment are located behind thehinged access panel on the right side of the case front.(see Auxiliary Power Table for details)

115VAC DUPLEX RECEPTACLE (60 HERTZMODELS ONLY)

The 115VAC duplex receptacle is protected by a circuitbreaker located on the nameplate. The receptacle is aNEMA 515R.

AUXILIARY POWER TABLEVoltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various ModelsAuxiliary 60 Hz 50/60 HzPower Models Models

Connections

At Duplex 115V 15A No DuplexReceptacle

Terminal strip 115V 15A 115V 15Aterminals 31 & 32

MSReceptacle 115V 15A 115V 15Apins A & J

MSReceptacle 42V 10A 42V 10Apins I & K

PIN LEAD NO. FUNCTION

A 32 115 VACB GND Chassis ConnectionC 2 Trigger CircuitD 4 Trigger CircuitE 77 Output ControlF 76 Output Control

G 75 Output ControlH 21 Work Sense Connection

2

I 41 42 VAC

J 31 115 VAC1.

K 42 42 VACL M N

F = 7 6

G = 7 5

H = 2 1

I = 4 1

J = 3 1

K = 4 2

A= 32

B = G N D

C= 2

D= 4

E = 7 7

L N

M

1.

115VAC circuit is on all models.

2.

As shipped from the factory Lead #21 from the 14 Pin connector is

connected to 21 on the terminal strip (T.S.2). This is the configuration for positive welding. If welding negative polarity, connect

lead #21 to the +21 connection point on the terminal strip

(T.S.2).

14 PIN MS TYPE RECEPTACLE(For MS3106A2027PX Plug. L.E.C. Part #S1202032)

Refer to the figure A.10 for the available circuits in the14 pin receptacle.

42 VAC is available at receptacle pins I and K.A 10 amp circuit breaker protects this circuit.

115 VAC is available at receptacle pins A and J (AllModels). A 15 amp circuit breaker protects this circuit.Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other.

FIGURE A.10 FRONT VIEW OF 14-PINCONNECTOR RECEPTACLE

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B-1OPERATION

IDEALARC DC-600

B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructions

before operating the machine.

ELECTRIC SHOCK can kill.

Do not touch electrically live partsor electrodes with your skin or wet

clothing.

Insulate yourself from the work and

ground.

Always wear dry insulating gloves.

Do not use AC welder if your cloth-

ing, gloves or work area is damp or

if working on, under or inside work-

piece.

Use the following equipment:

-Semiautomatic DC constant voltage

(wire) welder.

-DC manual (stick) welder.

-AC welder with reduced voltage

control.

Do not operate with panels removed.

Disconnect input power before ser-

vicing.

-------------------------------------------------------------

READ THIS WARNING, PROTECT YOURSELF &

OTHERS.

FUMES AND GASES can bedangerous.

Keep your head out of fumes.

Use ventilation or exhaust at the arc,

or both,to keep fumes and gases

from your breathing zone and gener-

al area.

WELDING, CUTTING and GOUG-ING SPARKS can cause fire orexplosion.

Do not weld near flammable material.

Do not weld, cut or gouge on contain-

ers which have held flammable materi-

al.

ARC RAYS can burn.

Wear eye, ear, and body protection.

Observe additional Safety Guidelines detailed in

the beginning of this manual.

WARNING

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B-2OPERATIONB-2

IDEALARC DC-600

GENERAL DESCRIPTION

The IDEALARC DC600 is an SCR controlled threephase welding and cutting power source. It uses asingle range potentiometer to control:

Submerged Arc SemiAutomatic or AutomaticWelding

Open Arc SemiAutomatic or Automatic Welding Stick Welding Air/Carbon Arc Cutting (Carbon Rod Sizes up to

3/8 Diameter)

The IDEALARC DC600 has a threeposit ionWelding Mode Switch to enable the user to operate inone of three modes:

Constant Current (CC) Stick (also used for AAC) Constant Voltage (CV) Submerged Arc Constant Voltage (CV) Innershield (also used for

FCAW/GMAW)

Three models are available:

Domesti c a ll 60 Her tz models except230/460/575V.

Canadian230/460/575V 60 Hertz models Export50/60 Hertz models

The optional MultiProcess Switch allows the user toswitch between semiautomatic or automatic weldingand stick welding or air/carbon arc cutting without disconnecting the wire feeder equipment control, elec

trode,and work leads.

RECOMMENDED PROCESSES ANDEQUIPMENT

The IDEALARC DC600 is designed for GMAW(MIG), FCAW, and submerged arc (SAW) within thecapacity of the machine. It can also be used for stickwelding (SMAW) and for air carbon arc (AAC) cuttingwith carbon rods up to 3/8" diameter.

The IDEALARC DC600 is provided with a threeposition mode switch that selects CV Innershield, CVSubmerged Arc, or CC Stick.

The IDEALARC DC600 can be easily connected towire feeding equipment, including:

Semiautomatic wire feeders LN7, LN7 GMA,LN742, LN8, LN9, LN9 GMA, LN 10, LN15LN23P, LN25, and DH10.

Automatic wire feeders NA3, NA5, and NA5R. Tractors LT56 and LT7

DESIGN FEATURES ANDADVANTAGES

Excellent arc characteristics for optimum constantvoltage submerged arc and Innershield weldingperformance.

A control circuit designed to provide good startingfor a large variety of processes and procedures.

Output Control Potentiometer that provides easysingle range continuous control.

Output Control Switch that provides simple switching from local to remote control.

Output Terminals Switch to energize output terminals either local or remote.

White neon pilot light to confirm that the InputContactor is energized.

DC Ammeter and Voltmeter 42VAC 10 Amp auxiliary power available for the

wire feeder, circuit breaker protected. Single MStype (14 pin) connector for wire feeder. 115VAC 15 Amp auxiliary power available for the

wire feeder, circuit breaker protected. 115VAC 15 Amp duplex plug receptacle available

on 60 Hertz models, circuit breaker protected. Multifunctional terminal strip for easy connection

of wire feeding control cables. Recessed output terminals to avoid any person or

object from accidentally coming into contact withthe output terminals and labeled " + " and " " foreasy identification.

Thermostatically protected power source. Electronic protection circuit to protect power

source against overloads. Input line voltage compensation to provide an

essentially constant output. SCR electronically controlled welder output pro

vides extra long life, especially for highly repetitivewelding applications.

Solid state 2 and 4 circuit for extra long life. Two circuit solid state control system provides

maximum performance and circuit protection. Low profile case provides maximum use of space. Convenient access to all controls. Output lead strain relief loops to prevent terminal

and cable damage. Easily removed case side, even when stacked. Outdoor operation because enclosure is designed

with air intake louvers that keep dripping waterfrom entering the unit. Transformer, SCR bridge,and choke have special corrosion resistant paintfor added protection.

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B-3OPERATIONB-3

IDEALARC DC-600

WELDING CAPABILITYThe IDEALARC DC600 has the following Outputand Duty Cycle based on operation for a 10 minuteperiod:600 Amps, 44 Volts at 100%680 Amps, 44 Volts at 60%750 Amps, 44 Volts at 50%

MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT

Input POWER ON/OFF Switch

SYMBOL MEANING

ON

OFF

INPUT POWER

Input power on when light is illuminated(except for abnormal conditions).

Always indicates POWER ON/OFFswitch is in ON position.

Pilot Light

OUTPUT CONTROL

OUTPUT VOLTAGE

AND CURRENT

Clockwise Increase of OutputVoltage and Current

TERMINALS ON/REMOTE Switch

OUTPUT TERMINALSENERGIZED

Remote Control of Output Terminals(Energized or NonEnergized)

LOCAL/REMOTE Switch

SYMBOL MEANING

Control Of Output Voltage andCurrent is Via IDEALARC DC600's

Control Dial

Remote Control of Output Voltageand Current

MODE Switch

CC STICK: Shielded Metal ArcWelding (SMAW), this switchposition is also used for AirCarbon Arc Cutting (AAC)

CV SUBMERGED ARC:Constant Voltage Submerged

Arc Welding (SAW)

CV INNERSHIELD: Flux CoredArc Welding (FCAW), this switch

position is also used for GasMetal Arc Welding (GMAW).

Output Terminal Connections

Positive Output Terminal

Negative Output Terminal

WARNING Identification

Warning Identification

Circuit Breaker

Circuit Breaker (two breakers: 15Afor 115V circuit and 10A for 42V

circuit)

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CONTROLS AND SETTINGSAll operator controls and adjustments are located onthe Case Front Assembly of the IDEALARC DC600.See Figure B.1 for the location of each control.

FIGURE B.1 - CONTROL PANEL KEYS

1

2

3

4

5 6

7

8

9

10

DC-600

1312

7

5

11

2

1

49863

10

B-4OPERATION

IDEALARC DC-600

B-4

3 Phase transformer with rectifiedDC output

Line Connection

Three Phase Input Power

Designates welder complies with

National Electrical Manufacturers

Association requirements EW 1Class I with 100% duty cycle at

600Amps output.

Designates welder complies with

both Underwriters Laboratories (UL)

standards and Canadian Standards

Association (CSA) standards. (60

Hertz Models)

Gas Metal Arc Welding (GMAW)

Flux Cored Arc Welding (FCAW)

MEANING OF GRAPHICALSYMBOLS ON RATING PLATE

(LOCATED ON CASE BACK)

NEMA EW 1 (100%)

Shielded Metal Arc Welding (SMAW)

Submerged Arc Welding (SAW)

MEANING OF GRAPHICALSYMBOL FOR GROUND CON-

NECTION

Signifies the equipment connectionpoint for the protective earth ground

R

NRTL/C

1. Input POWER ON/OFF Switch

This toggle switch turns the machine on or off.Putting the switch in the ON position energizes the machines input contactor applying inputpower to the machine. Switching the switch to theOFF position deenergizes the input contactor.

2. POWER LightWhen the POWER switch is in the ON position themachines white POWER light will illuminate. If theinput contactor deenergizes the machine in anabnormal situation the pilot light will still illuminate.In this situation it may be necessary to reset themachine by switching the POWER switch to theOFF and then to the ON position. (See Overload,Overcurrent, and Fault Protection Section)

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B-5OPERATIONB-5

IDEALARC DC-600

3. OUTPUT CONTROLThis control provides continuous control of themachines output voltage and current from minimum to maximum (typical full pot range between15 to 44 volts and 90 to 750 amps) as it is rotatedclockwise. Voltage or current control is determined by setting of Mode Switch (CV or CC).

4. OUTPUT TERMINALS ON/REMOTE SwitchWhen this switch is in the REMOTE position, the IDEALARC DC600s output terminalswill be electrically cold until a remote device suchas a wire feeder closes the #2 and #4 circuit in theMSreceptacle or terminal strip (T.S.2). When thisswitch is in the ON position the machinesoutput terminals will be electrically energized allthe time.

5. LOCAL/REMOTE SwitchWhen this switch is set to the LOCAL position, control of the output voltage and current is viathe OUTPUT CONTROL on the IDEALARC DC

600s control panel. When this switch is set to theREMOTE position, control is through aremote source such as a wire feeder via the #75,#76, and #77 leads in the MSreceptacle or terminal strip (T.S.1).

6. Mode SwitchThis switch allows for selecting the weldingprocess to be used:CC STICKfor SMAW and AACCV SUBMERGED ARC for SAWCV INNERSHIELD for FCAW and GMAW

7. 115VAC Duplex Receptacle (60 Hertz Models)This receptacle provides up to 15 amps of 115VAC auxiliary power.

8. 115VAC 15 Amp Circuit BreakerThis breaker protects the 115 VAC auxiliary circuits located in the duplex receptacle, terminalstrip (T.S.2) and MSreceptacle.

9. 42VAC 10 Amp Circuit Breaker

This breaker protects the 42VAC auxiliary circuitslocated in the terminal strip (T.S.2) and MSreceptacle.

10.14 Pin MS-ReceptacleThis connector provides easy connection for a wirefeeder control cable. It provides connections forauxiliary power, output switching, remote outputcontrol, wire feeder voltmeter sense lead andground. Refer to 14 Pin MS Type Receptacle in theInstallation Section for information about the circuits made available at this receptacle.

11.Terminal Strip Cover PanelRotate this panel to gain access to the circuitsmade available at the two terminal strips (T.S.1and T.S.2). These terminal strips contains thesame circuits as the 14 pin MSreceptacle. Thereis a box connector adjacent to this cover for routingleads to the terminal strips.

12.Negative Output Terminal

This output terminal is for connecting a weldingcable. To change welding polarity and for properwelding cable size refer to Electrode and WorkCables in the Installation Section.

13.Positive Output TerminalThis output terminal is for connecting a weldingcable. To change welding polarity and for properwelding cable size refer to Electrode and WorkCables in the Installation Section.

AUXILIARY POWER IN MS-RECEPTACLE42 volt AC auxiliary power, as required for some wirefeeders, is available through the wire feeder MSreceptacle. A 10 amp circuit breaker protects the 42volt circuit from overloads.

IDEALARC DC600 machines can also supply 115volt AC auxiliary power through the wire feeder receptacle. A 15 amp circuit breaker protects the 115 voltcircuit from overloads.

OVERLOAD, OVERCURRENT, AND

FAULT PROTECTION

This welder has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and highambient temperatures. When the welder is subjectedto an overload or loss of cooling, a thermostat willopen. The input contactor will open and remain openuntil the machine cools; the white POWER light staysilluminated. No welding is possible during this cooldown period. The machine will reset automaticallywhen the thermostat cools.

The power source is also protected against overcurrents in the SCR bridge assembly through an electronic protection circuit. This circuit senses currentsover 780 amps on the power source and opens theinput contactor should the overcurrent remain for apredetermined time (the white POWER light stays illuminated). The predetermined time varies with theamount of overcurrent; the greater the overcurrent,the shorter the time. The input contactor will remainopen until the power source is manually started byresetting the POWER ON/OFF toggle switch.

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REMOTE CONTROL OF MACHINEOPERATION

The toggle switch on the control panel labeledRemote Panel gives the operator the option of controlling the machine output from a remote location. Ifin the Remote position a wire feeder with remote control capabilities or a remote control device such as a

K775 must be connected to terminals 75, 76, and 77.Refer to Accessories Section for wire feeder remoteinformation.

WELDING PROCEDURERECOMMENDATIONS

Select Welding Mode Switch position based on type ofwelding to be done.

1. Innershi eld Welding (FCAW)/M IG (GMAW)Welding: Use the CV INNERSHIELD mode.

2. Submerged Arc Welding (SAW): Use the CVSUBMERGED ARC mode. If performing highspeed welding, switch between the CVSubmerged Arc and the CV Innershield mode anduse the mode that produces the best weldingresults.

3. Air/Carbon Arc Cutting (AAC) / Stick Welding(SMAW) / High Current, Large Puddle SubmergedArc Welding (SAW): Use the CC STICK mode.When the IDEALARC DC600 is used forAir/Carbon Arc cutting, the OUTPUT CONTROL

potentiometer should be set to "9" initially. Basedon the size of the carbon being used or theprocess, turn the potentiometer to a lower settingas required by the process. You can use carbonrods up to 3/8" in diameter at currents as high as750 amps with excellent arc control. The welderprotection circuit protects the machine fromextremely high short circuiting pulses.

SEMI-AUTOMATIC ANDAUTOMATIC WIRE FEEDING WITHTHE IDEALARC DC-600 AND WIRE

FEEDERS

When using the IDEALARC DC600 with semiautomatic or automatic wire feeding equipment and forstick welding or air/carbon arc cutting, it is recommended that the optional MULTIPROCESS SWITCHbe used. This switch permits you to easily change thepolarity of the connected wire feeding equipment orswitch to stick welding or air/carbon arc cutting.

B-6OPERATIONB-6The power source circuitry is protected from faults onleads 75, 76, or 77. If any of these leads are connected to either the positive or negative output leads, theIDEALARC DC600 will either shut down completely(input contactor opens and white POWER light staysilluminated), or will operate at minimum output thuspreventing any damage to the IDEALARC DC600. IfIDEALARC DC600 shuts down, it must be manuallystarted by resetting the POWER ON/OFF toggleswitch.

OPERATING STEPS

The following procedures are for using the IDEALARC DC600 in the local control mode of operation. For remote control of the machine, see theRemote Control of Machine Operation section.

Before operating the machine, make sure you have allmaterials needed to complete the job. Be sure youare familiar with and have taken all possible safety

precautions before starting work. It is important thatyou follow these operating steps each time you usethe machine.

1. Turn on the main AC power supply to themachine.

2. Connect the #21 work lead to either + or on terminal strip (T.S.2).

3. Set the Welding Mode switch to welding processbeing used:

CC STICK (for SMAW and AAC)

CV SUBMERGED ARC (for SAW)

CV INNERSHIELD (for FCAW and GMAW)

4. Turn the POWER ON/OFF Toggle Switch to theON position

The white pilot light glows.

The fan starts.

5. Set OUTPUT CONTROL Potentiometer to desiredvoltage or current.

6. Set the OUTPUT TERMINALS switch to eitherON ( output terminals energized) or REMOTE(output terminals energized when #2 and #4closed by remote device such as wire feeder)

7. Make the weld.

IDEALARC DC-600

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To adjust the Open Circuit Voltage Control to get thebest starting performance, make repeated startsobserving the NA-3 voltmeter.

When the voltmeter pointer swings smoothly up tothe desired arc voltage, without undershooting orovershooting the desired arc voltage, the OpenCircuit Voltage Control is set properly.

If the voltmeter pointer overshoots the desired volt-age and then returns back to the desired voltage, theOpen Circuit Voltage Control is set too high. Thiscan result in a bad start where the wire tends to"Blast off."

If the voltmeter pointer hesitates before coming up tothe desired voltage, the Open Circuit Voltage Controlis set too low.This can cause the electrode to stub.

4. Start and make the weld.

Cold starts. For cold starts, be sure the work piece is

clean and the electrode makes positive contact withthe work piece.

Hot "On the Fly" starts. For hot starts, travel shouldbegin before the wire contacts the work piece.

ARC STRIKING WITH IDEALARC DC-600 AND THENA-3 START BOARD

When electrical strikeouts exceed 1 3/4 (44.4mm) anNA-3 Start Board may be required to improve arc strik-ing.

When the NA-3 Start Board is used to improve arc strik-ing, use the following procedures:1. Set start t ime at 0.

2. Set NA-3 start current and start voltage at mid-range.

3. Set the NA-3 output current and voltage to the prop-er settings for the welding procedure to be used.

4. Turn the Start Board Timer to maximum.

5. Set Start Board current and voltage control.

Set the Start Board current control to 1 1/2 dial num-bers below that set on the NA-3 current control.

Set the Start Board voltage control equal with theNA-3 voltage control setting.

B-7OPERATIONB-7

IDEALARC DC-600

NA-3 AUTOMATIC WIRE FEEDER

1. Set the IDEALARC DC-600 LOCAL/REMOTESwitch to REMOTE. Set the OUTPUT TERMINALSswitch to REMOTE. NOTE: Later model NA-3 auto-matic wire feeders are capable of cold starts whenthe NA-3 Mode switch is in the CV or CC mode posi-tion. Some earlier models are capable of cold start-

ing only in the CC mode position. Cold startingenables you to inch the wire down to the work, auto-matically stop, and automatically energize the fluxhopper valve.

2. Set the IDEALARC DC-600 welding mode switchfor the desired process: CV SUBMERGED ARC, CVINNERSHIELD mode or CC STICK mode.

3. Set the NA-3 mode Switch Position to either CV orCC to match the IDEALARC DC-600 mode select-ed in step 2.

4. Refer to the NA-3 operators manual for instructionson how to use the NA-3 in conjunction with the IDE-ALARC DC-600.

5. Follow the following guidelines for good arc strikingdetailed below for each welding mode.

GOOD ARC STRIKING GUIDELINES FOR THE NA-3WITH THE IDEALARC DC-600 IN THE CVINNERSHIELD, CV SUBMERGED ARC OR CC STICKWELDING MODES.

Following are some basic arc striking techniques thatapply to all wire feed processes. Using these proceduresshould provide trouble-free starting. \These proceduresapply to single, solid wires and Innershield wires.

1. Cut the electrode to a sharp point.

2. Set the NA-3 Open Circuit Voltage Control to thesame dial setting as the Arc Voltage Control. If this isa new welding procedure, a good starting point is toset the Open Circuit Voltage Control to # 6.

NOTE: The open circuit voltage of theIDEALARC DC-600 varies from approximately 16volts to 56 volts in the CV INNERSHIELD or CV

SUBMERGED ARC modes. The open circuit voltageis constant in the CC STICK mode.

3. Run a test weld. Set proper current, voltage, andtravel speed.

For the best starting performance, the NA-3 OpenCircuit Voltage Control and Voltage Control settingshould be the same. Set the Inch Speed Control forthe slowest inch speed possible.

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IDEALARC DC-600 POWER SOURCESETTING WHEN CONNECTED TO NA-5WIRE FEEDER

When using the IDEALARC DC600 with the NA5wire feeder, set the controls on the IDEALARC DC600 as follows for the best performance:

1. Turn OFF main AC input power supply to the IDEALARC DC600.

2. Connect the electrode cables to terminal polarityto be used.

3. Connect the #21 work lead (on T.S.2) to thesame polarity as the work cable connection.

4. Set the IDEALARC DC600

LOCAL/REMOTE Switch to REMOTE.

5. Set the IDEALARC DC600 OUTPUT TERMINALS switch to REMOTE.

6. Set the IDEALARC DC600 WELDING MODESWITCH to the position that matches the weldingprocess being used.

For submerged arc welding, set WELDING MODESWITCH to CV SUBMERGED ARC position.

For all open arc welding processes set WELDINGMODE SWITCH to CV INNERSHIELD position.

B-8OPERATIONB-8

IDEALARC DC-600

NOTE: These Start Board current and voltage settings result in a start up current that is lower thanthe NA3 current setting and approximately equalwith the NA3 voltage setting for the desired welding procedure.

6. Establish the correct arc striking procedure withthe NA3 Start Board timer set at maximum.

For the best starting performance, the NA3 OpenCircuit Voltage Control and Voltage Control setting should be the same. Set the Inch SpeedControl for the slowest inch speed possible.

To adjust the Open Circuit Voltage Control to getthe best starting performance, make repeatedstarts observing the NA3 voltmeter.

When the voltmeter pointer swings smoothly up tothe desired arc voltage, without undershooting orovershooting the desired arc voltage, the OpenCircuit Voltage Control is set properly.

If the voltmeter pointer overshoots the desiredvoltage and then returns back to the desired voltage, the Open Circuit Voltage Control is set toohigh. This can result in a bad start where the wiretends to "Blast off."

If the voltmeter pointer hesitates before coming upto the desired voltage, the Open Circuit VoltageControl is set too low. This can cause the electrode to stub.

Set NA3 Start Board current and voltage as

close to the welding procedure current and voltage as possible.

NOTE: The Start Board current and voltageshould be as close as possible to the welding procedure current and voltage, while still getting satisfactory starts.

Set the start time to as low a time as possiblewhile still getting satisfactory starts.

7. Start and make the weld.

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C-1ACCESSORIESC-1

IDEALARC DC-600

WIRE FEEDERS AND TRACTORS

The IDEALARC DC600 can be used to power anyof the following Lincoln Wire Feeders and Tractors:

SemiAutomatic Wire Feeders:DH10 LN9LN7 LN9 GMA

LN7 GMA LN23PLN742 LN25LN8 LN10

Automatic Wire Feeders:NA3 NA5RNA5

Tractors:LT7 LT56

FIELD INSTALLED OPTIONS

Remote Output Control (K775 or K857with K864 Adapter)

An optional remote out control is available. TheK775 is the same remote control that is used on otherLincoln power sources. The K775 consist of a controlbox with 28 feet (8.5mm) of four conductor cable. Thisconnects to terminals 75,76, and 77 on the terminalstrip (T.S.1) and the case grounding screw so markedwith the symbol on the machine. These terminals are located behind the hinged cover on the case

front. This control will give the same control as theoutput control on the machine.

The K857 is similar to the K775, except the K857 hasa 6pin MSstyle connector. The K857 requires aK864 adapter cable which connects to the 14pin connector on the case front.

Remote Control Adapter Cable (K864)

A "V" cable 12" (.30 m) long to connect a K857Remote Control (6pin connector) with an LN7 wirefeeder (14pin connector) and the machine (14pinconnector). If a remote control is used alone the wirefeeder connection is then not used.

Undercarriages (K817P, K842)

For easy moving of the machine, optional undercarriages are available with polyolefin wheels (K817P) ora platform undercarriage (K842) with mountings fortwo gas cylinders at rear of welder.

Paralleling Kit (K1611-1)

Permits paralleling of two IDEALARC DC600's forwelding currents of up to 1200 amps, 100% dutycycle.

Tig Module (K930-2)

Portable high frequency generator for AC/DC TIGwelding.

FACTORY OR FIELD INSTALLEDOPTIONS

Multi-Process Switch (K804-1)

The MULTIPROCESS SWITCH gives you the abilityto: Switch between "stick welding or air/carbon arc

cutting" and using a semiautomatic or automaticwire feeder.

Change the polarity of a semiautomatic or automatic wire feeder without changing any electricalcable connections.

See Figure C.1

FIGURE C.1 - MULTI-PROCESS SWITCH

STRAIGHT PLUG (14 PIN )TO PO WE R SO UR CE

CABLE RECEPTACLE (6 SOCKET )

CABLE RECEPTACLE (14 SOCKET )

TO : K8 57 RE MO TE CO NT RO L

TO : LN -7 WI RE FE ED ER S +

WIREFEEDERCABLES

STICK ORAIR/CARBONARC CABLES

STICK OR-AIR-

CARBON-ARC

+

-

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C-2ACCESSORIESC-2

IDEALARC DC-600

The MULTIPROCESS SWITCH has two sets of output terminals. You connect the wire feeder unit cablesto the set of terminals on the left side of the box andthe stick or air/carbon arc cables to the set of terminals on the right side (facing the front of the machine)as shown in Figure C.1. The output terminals are protected against accidental contact by hinged covers.

When the MULTIPROCESS SWITCH is in the "Stickor Air/Carbon Arc" position, only those terminals areenergized. The wire feeder nozzle or gun and electrode are not electrically "hot" when in this mode.

Follow these steps to install the MULTIPROCESSSWITCH:

1. Confirm that the IDEALARC DC600 POWERON/OFF switch is in the OFF position.

2. Disconnect main AC input power to the IDEALARC DC600.

3. Open the terminal strip hinged cover located onthe Case Front Assembly.

4. The MULTIPROCESS SWITCH is mounted tothe case front with four 1/4 selftapping screws.The screw holes are 13.8 apart side to side and4.5 apart top to bottom, Run one of the 1/4screws part way in and out of the screw holes toopen them up. Make sure that the two sleevedcontrol leads do not get pinched when hangingthe switch; route them out the side to the right ofthe switch. Support the switch in position and start

the four screws, then tighten them.

5. Route the MULTIPROCESS SWITCH controlleads through the strainrelief box connectors andinto the terminal strip. Connect wire feeder controlcable as specified in specific connection diagramand make other terminal strip connections asspecified on the connection diagram for theLincoln wire feeder being used.

6. Connect the control leads from the MULTIPROCESS SWITCH to terminals #2 and #4 onthe IDEALARC DC600's terminal strip.

7. Connect the r ight cable from the MULTIPROCESS SWITCH (facing the front of themachine) to the IDEALARC DC600 positive (+)output terminal. See Figure C.2.

FIGURE C.2 - MULTI-PROCESS SWITCH

CABLE CONNECTIONS.

8. Connect the left cable from the MULTIPROCESSSWITCH (facing the front of the machine) to theIDEALARC DC600 negative () output terminal.See Figure C.2.

9. Connect the wire feeder electrode and workcables. See Figure C.2.

Insert the wire feeder electrode and work cables

through the strain relief loop on the left side of theIDEALARC DC600 (facing the front of themachine).

Connect the wire feeder electrode and workcables to the electrode and workterminals on the left side of the MULTIPROCESSSWITCH.

10. Connect wire feeder control cable and make otherterminal strip connections as specified on theconnection diagram for the Lincoln wire feederbeing used.


WORKCABLE

WORK

ELECTRODES

2121+ 41 4 2 31 32 75 76 77

TERMINALSTRIP COVER

BOXCONNECTOR

POSITIVE (+)OUTPUT

STUD +

NEGATIVE ()OUTPUT

STUD

ELECTRODECABLE

WORKCABLE

ELECTRODECABLE

JUMPER (IF NEEDEDSEE INSTRUCTIONS)

+

CONTROLLEADS

STICK AIR/CARBONARC WELDINGEQUIPMENT

WIREFEEDER

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C-3ACCESSORIESC-3

12. Connect stick or air/carbon arc electrode and workcable. See Figure C.2.

Insert the electrode and work cables through thestrain relief loop on the right side (facing the frontof the machine) of the IDEALARC DC600.

Connect the electrode cable to the "Positive" terminal on the right side of the MULTIPROCESSSWITCH.

Connect the work cable to the "Negative" terminalon the right side of the MULTIPROCESSSWITCH.

NOTE: The instructions above are for connectingthe stick polarity positive. To change the polarity,turn the IDEALARC DC600 OFF, and reversethe cables.

NOTE: When it is not necessary to have separateground cables for stick and semiautomatic orautomatic welding, connect a jumper from theMULTIPROCESS SWITCH "Work" terminal tothe MULTIPROCESS SWITCH "negative" terminal. See Figure C.2.

To operate the MULTIPROCESS SWITCH, refer tothe operating instructions on the switch nameplate.

CONNECTIONS FOR SEMI-AUTO-MATIC OR AUTOMATIC WIRE FEED-ER CONTROL

1. Set the IDEALARC DC600 ON/OFF switch toOFF.

2. Set the IDEALARC DC600 LOCAL/REMOTEswitch to REMOTE.


4. Set the IDEALARC DC600 MODE switch to thewelding process being used.

5. Refer to the proper connection diagram in the DIAGRAMS section for more information.

IDEALARC DC-600

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ROUTINE AND PERIODICMAINTENANCE

1. Disconnect input AC power supply lines to themachine before performing periodic maintenance,tightening, cleaning, or replacing parts.

Perform the following daily:

1. Check that no combustible materials are in thewelding or cutting area or around the machine.

2. Remove any debris, dust, dirt, or materials thatcould block the air flow to the machine for cooling.

3. Inspect the electrode cables for any sl i ts or

punctures in the cable jacket, or any condition thatwould affect the proper operation of the machine.

Perform Periodically:

Clean the inside of the machine with low pressure airstream. Clean the following parts.

Main transformer and choke.

Electrode and work cable connections.

SCR rectifier bridge and heat sink fins.

Control board.

Firing board.

Fan Assembly.NOTE: The fan motor has sealed bearings whichrequire no maintenance.

D-1MAINTENANCED-1

IDEALARC DC-600

SAFETY PRECAUTIONS

ELECTRIC SHOCK CANKILL.

Only qualified personnel shouldperform this maintenance.

Turn the input power OFF at the disconnectswitch or fuse box before working on this equip-ment.

Do not touch electrically hot parts.

WARNING

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E-1TROUBLESHOOTINGE-1

IDEALARC DC-600

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the threestep procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled PROBLEM (SYMPTOMS). This column describes possible symptoms

that the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled POSSIBLE CAUSE liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact your

local Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

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ELECTRIC SHOCK can kill.Have an electrician install and ser-vice this equipment. Turn the inputpower OFF at the fuse box before

working on equipment. Do not touchelectrically hot parts.


IDEALARC DC-600

CAUTION: Sometimes machine failures appear to bedue to PC board failures. These problems can sometimes be traced to poor electrical connections. Toavoid problems when troubleshooting and replacingPC boards, please use the following procedure:

1. Determine to the best of your technical ability thatthe PC board is the most likely component causingthe failure symptom.

2. Check for loose connections at the PC board toassure that the PC board is properly connected.

3. If the problem persists, replace the suspect PCboard using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform thefollowing procedures:

P.C. Board can be damaged by static electricity.

Remove your bodys staticcharge before opening the staticshielding bag. Wear an antistatic

wrist strap. For safety, use a 1Meg ohm resistive cord connected to a grounded part of theequipment frame.

If you dont have a wrist strap,touch an unpainted, grounded,part of the equipment frame.Keep touching the frame to prevent static buildup. Be sure notto touch any electrically live partsat the same time.

Tools which come in contact with the P.C. Boardmust be either conductive, antistatic or staticdissipative.

Remove the P.C. Board from the staticshieldingbag and place it directly into the equipment. Dontset the P.C. Board on or near paper, plastic orcloth which could have a static charge. If the P.C.Board cant be installed immediately, put it back inthe staticshielding bag.

If the P.C. Board uses protective shorting jumpers,dont remove them until installation is complete.

If you return a P.C. Board to The Lincoln ElectricCompany for credit, it must be in the staticshielding bag. This will prevent further damage and

allow proper failure analysis.

4. Test the machine to determine if the failure symptom has been corrected by the replacement PCboard.

NOTE: It is desirable to have a spare (known good)PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5. Remove the replacement PC board and substitute itwith the original PC board to recreate the originalproblem.

If the original problem does not reappear by substituting the original board, then the PC board was notthe problem. Continue to look for bad connectionsin the control wiring harness, junction blocks, andterminal strips.

If the original problem is recreated by the substitution of the original board, then the PC board wasthe problem. Reinstall the replacement PC boardand test the machine.

6. Always indicate that this procedure was followedwhen warranty reports are to be submitted.

NOTE: Following this procedure and writing on thewarranty report, INSTALLED AND SWITCHED PCBOARDS TO VERIFY PROBLEM, will help avoiddenial of legitimate PC board warranty claims.

PC BOARD TROUBLESHOOTING PROCEDURES

ATTENTIONStatic-SensitiveDevicesHandle only atStatic-SafeWorkstations

ReusableContainerDo Not Destroy

WARNING

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IDEALARC DC-600

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

PROBLEMS(SYMPTOMS)

Major Physical or ElectricalDamage is Evident

The Machine is dead The Inputcontactor does not operate.

POSSIBLECAUSE

Contact the Lincoln Electric ServiceDept. (216) 3832531 or 1800

8339353 (WELD)

1. Check for blown or missingfuses in input lines.

2. Check the three phase inputline voltage at the machine.The input voltage must matchthe rating plate and reconnectpanel.

3. Power ON/OFF switch may bedefective

RECOMMENDEDCOURSE OF ACTION

OUTPUT PROBLEMS


CAUTION

Observe all Safety Guidelines detailed throughout this manual

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IDEALARC DC-600


CAUTION

PROBLEMS

(SYMPTOMS)

Input

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