Idealarc DC-600 - Lincoln Electric · welding machine in good, safe operating condition. Replace damaged insulation. 3.g. Never dip the electrode in water for cooling. 3.h. Never

Operator’s Manual

Idealarc™ DC-600

Register your machine: www.lincolnelectric.com/registration

Authorized Service and Distributor Locator: www.lincolnelectric.com/locator

IM642-E | Issue D ate Oct-17

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

10588; 10589; 10590; 10591; 10592;

10593; 10594; 10595; 10596; 10639;

10640; 10641; 10700; 10701; 11071;

11072; 11129; 11130; 11131; 11132;

11133; 11140; 11335; 11336; 11337;

11338; 11339; 11537; 11538; 11539;

11540; 11541; 11568; 12778

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.

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

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

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.

READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glarewith protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work areaAT ALL TIMES.

SPECIAL SITUATIONSDO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.

Additional precautionary measuresPROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 06/15/2016

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel EnginesDiesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and otherreproductive harm.

Gasoline EnginesThe engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or otherreproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. Foradditional 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 AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

1.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flamewelding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel fromvaporizing on contact with hot engine partsand igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes 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 V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

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

SAFETY

Safety 02 of 04 - 06/15/2016

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skin or wet clothing.Wear dry, hole-free gloves to insulate hands.

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

In addition to the normal safety precautions, ifwelding must be performed under electricallyhazardous conditions (in damp locations or whilewearing wet clothing; on metal structures such asfloors, gratings or scaffolds; when in crampedpositions such as sitting, kneeling or lying, if thereis a high risk of unavoidable or accidental contactwith the workpiece or ground) use the followingequipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)ground.

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

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

3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enoughventilation and/or exhaust at the arc to keep fumes and gasesaway from the breathing zone. When welding hardfacing(see instructions on container or SDS) or on leador cadmium plated steel and other metals orcoatings which produce highly toxic fumes, keepexposure as low as possible and within applicableOSHA PEL and ACGIH TLV limits using localexhaust or mechanical ventilation unless exposureassessments indicate otherwise. In confinedspaces or in some circumstances, outdoors, arespirator may also be required. Additionalprecautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 06/15/2016

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions should be used to prevent hazardous situations.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 istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,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 oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

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

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.

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

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

7.f. Valve protection caps should always be in place and hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.

FOR ELECTRICALLYPOWERED EQUIPMENT.

8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

Refer tohttp://www.lincolnelectric.com/safetyfor additional safety information.

SAFETY

Safety 04 of 04 - 06/15/2016

vi vi TABLE OF CONTENTS Page

Installation....................................................................................................... Section A Technical Specifications ............................................................................................. A-1 Safety Precautions ..................................................................................................... A-2 Select Proper Location.................................................................................................A-2 Limit on Stacking................................................................................................... A-2 Stacking.................................................................................................................A-2 Tilting..................................................................................................................... A-2 Electrical Input Connections ....................................................................................... A-3 Fuses and Wire Sizes............................................................................................A-3 Ground Connection ............................................................................................. A-3 Input Power Supply Connections.......................................................................... A-3 Reconnect Procedure ................................................................................................ A-4 Output Connections ................................................................................................... A-7 Electrode, Work and #21 Lead.............................................................................. A-7 Auxiliary Power and Control Connections............................................................. A-8________________________________________________________________________

Operation......................................................................................................... Section B Safety Precautions ............................................................................................... B-1 General Description ............................................................................................. B-2 Recommended Processes and Equipment........................................................... B-2 Design Features and Advantages ........................................................................ B-2 Welding Capability ............................................................................................... B-3 Meaning of Graphical Symbols on Case Front......................................................B-3 Meaning of Graphical Symbols on Rating Plate.................................................... B-4 Meaning of Graphical Symbol for Ground Connection.......................................... B-4 Controls and Settings ....................................................................................B-4, B-5 Auxiliary Power in MS - Receptacle.......................................................................B-6 Overload, Overcurrent and Fault Protection..........................................................B-6 Operating Steps ................................................................................................... B-7 Remote Control of Machine Operation.................................................................. B-7 Welding Procedure Recommendations ............................................................... B-7 Semi-Automatic and Automatic Wire Feeding with a IDEALARC® DC-600 and Wire Feeders.....................................................B-8 NA-3 Automatic Wire Feeder.......................................................................... B-8 NA-5 Automatic Wire Feeder........................................................................ B-10 LN-8 Semi-Automatic Wire Feeder............................................................... B-10 LN-7 & LN-9 Semi-Automatic Wire Feeders................................................. B-10________________________________________________________________________

Accessories.....................................................................................................Section C Wire Feeders and Tractors....................................................................................C-1 Field Installed Options...........................................................................................C-1 Remote Output Control (K775 or K857)..........................................................C-1 Remote Control Adapter Cable (K864)........................................................... C-1 Undercarriages (K817P, K842).......................................................................C-1 Paralleling Kit (K1611-1)................................................................................. C-1 TIG Module (K930-2)...................................................................................... C-1 Factory or Field Installed Options..........................................................................C-1 Multi-Process Switch (K804-1)........................................................................C-1 Connections for Semi-Automatic or Automatic Wire Feeder Control.................... C-3________________________________________________________________________

vii viiTABLE OF CONTENTS Page

Maintenance.................................................................................................... Section D Safety Precautions................................................................................................ D-1 Routine and Periodic Maintenance....................................................................... D-2

Troubleshooting.............................................................................................. Section E Safety Precautions.................................................................................................E-1 How to Use Troubleshooting Guide.......................................................................E-1 Troubleshooting Guide.......................................................................................... E-2

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

Parts List........................................................................................................ parts.lincolnelectric.com

Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

60% Duty Cycle

122/61122/61/49

6149

128/74/6474/56

64140/70

68

A-1INSTALLATION

IDEALARC® DC-600

A-1TECHNICAL SPECIFICATIONS – IDEALARC® DC-600

Volts at Rated Amperes444444

Auxiliary PowerSee the OPERATION section

for Auxiliary Power information by model

Amps600680750

Maximum Open Circuit Voltage72V for 60 HZ models

69V for 50/60 HZ models

Duty Cycle100% Duty Cycle60% Duty Cycle50% Duty Cycle

Output Range70A/13V-780A/44V (CV)90A/24V-780A/44V (CC)

INPUT - THREE PHASE ONLY

OUTPUT

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

RECOMMENDED INPUT WIRE AND FUSE SIZES

StandardVolatge

230/460/60230/460/575/60

460/60575/60

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

440/50/60200/400/50/60

415/50/60

100% Duty Cycle

108/54108/54/43

5443

116/67/5867/51

58128/64

62

50% Duty Cycle

134/67134/67/54

6754

138/80/6980/61

69152/76

73

Input Current at Rated Output

RATED OUTPUT

INPUTVOLTAGE /

FREQUENCY

230460575200220380400415440500

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

175 Amp90 Amp70 Amp

175 Amp175 Amp100 Amp100 Amp100 Amp90 Amp80 Amp

TYPE 75°CGROUND WIRE

IN CONDUITAWG(IEC-MM2) SIZES

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

TYPE 75°CCOPPER WIRE

IN CONDUITAWG(IEC-MM2) SIZES30°C (86°F) Ambient

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

INPUT AMPERERATING ON

NAMEPLATE

1085443

1281166764615851

HERTZ

606060

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

PHYSICAL DIMENSIONSHEIGHT30.75 in781 mm

WIDTH22.25 in567 mm

DEPTH39.0 in

988 mm

WEIGHT522 lbs.237 kg.

A-2INSTALLATION

IDEALARC® DC-600

A-2SAFETY PRECAUTIONSRead entire Installation Section before installingthe IDEALARC® DC-600.

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel shouldinstall this machine.

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

• Do not touch electrically hot parts.

• Always connect the IDEALARC IDEALARC® DC-600 grounding terminal to agood electrical earth ground.

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

__________________SELECT PROPER LOCATIONPlace the welder where clean cooling air can freelycirculate in through the front louvers and out throughthe rear louvers. Dirt, dust or any foreign material thatcan be drawn into the welder should be kept at a mini-mum. Failure to observe these precautions can resultin excessive operating temperatures and nuisanceshut-downs.

LIMIT ON STACKING

STACKING

Three IDEALARC® DC-600 machines can bestacked.

DO NOT stack more than three machines in onegrouping.

DO NOT stack the IDEALARC® DC-600 on anothertype of machine.

Follow these guidelines when stacking:1. Select a firm, level surface capable of sup- porting the total weight of up to three machines (1570 pounds/712 kilograms).

2. Set the bottom machine in place.

3. Stack the second machine on top of it by aligning the two holes in the base rails of the second machine with the two pins on top front of the bottom machine.

4. Repeat process for third machine.

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

FIGURE A.1 - Stacking IDEALARC® DC-600machines

TILTING

The IDEALARC® DC-600 must be placed on a stable,level surface so it will not topple over.

STACKING HOLE

STACKING PINS

WARNING

• Lift only with equipment of ade-quate lifting capacity.

• Be sure machine is stable whenlifting.

• Do not lift this machine using liftbail if it is equipped with a heavyaccessory such as trailer or gascylinder.

FALLING • Do not lift machine if lift bail is EQUIPMENT can damaged.

cause injury. • Do not operate machine while suspended from lift bail.• Do not stack more than three high.• Do not stack the IDEALARC® DC-600 on top of anyother machine.------------------------------------------------------------------------

WARNING

A-3INSTALLATION

IDEALARC® DC-600

A-3ELECTRICAL INPUT CONNECTIONSBefore installing the machine check that the input sup-ply voltage, phase, and frequency are the same as thevoltage, phase, and frequency as specified on thewelder Rating Plate located on the Case BackAssembly. Input power supply entry is through thehole in the Case Back Assembly. See Figure A.2 forthe location of the machine’s input cable entry open-ing, Input Contactor (CR1), and reconnect panelassembly for dual voltage machines.

FIGURE A.2 - Rear Panel

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses ordelay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machinebeing used. They are also called inverse time or ther-mal/magnetic circuit breakers.

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

Use input and grounding wire sizes that meet localelectrical codes or see the Technical Specificationspage in this manual.

GROUND CONNECTION

Ground the frame of the machine. A ground terminal marked with the symbol ( ) is located insidethe Case Back of the machine near the input contac-tor. Access to the Input Box Assembly is at the upperrear of the machine. See your local and national elec-trical codes for proper grounding methods.

INPUT POWER SUPPLYCONNECTIONS

A qualified electrician should connect the input powersupply leads.

1. Follow all national and local electrical codes.

2. Use a three-phase line.

3. Remove Input Access Door at upper rear ofmachine.

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

5. Connect the three-phase AC power supply leadsL1, L2, and L3 to the input contactorterminals in the Input Box Assembly by passingthem thru the three aligned .50” diameter holes inthe baffle and tighten them in the terminal connec-tors. Be sure to close the baffle by inserting thetab into the slot in the baffle. See Figure A.3.

FIGURE A.3 - Input Power SupplyConnections

INPUT SUPPLYCABLE ENTRY

OPENING INPUTCONTACTOR (CR1)

RECONNECTPANEL ASSEMBLY

INPUT POWER SUPPLYCABLE WITH BUSHINGOR BOX CONNECTOR

INPUTCONTACTOR (CR1)

RECONNECTPANEL ASSEMBLY

A-4INSTALLATION

IDEALARC® DC-600

A-4

RECONNECT PROCEDUREMultiple voltage machines are shipped connected tothe highest input voltage listed on the machine’s ratingplate. Before installing the machine, check that theReconnect Panel in the Input Box Assembly is con-nected for the proper voltage.

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

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

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

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

1. For Dual Voltage except 380/500-460/575, seeFigure A.4. (M15009)

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

3. For 380/500-460/575, see Figure A.6. (M15011)

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

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

6. For Voltages not listed, see the Input Connection Diagram pasted on the inside of the Case Back Input Access Door.

L3L2L1

LINK

LINES INPUT

GND H2H1

H3

L3L2L1

LINK

LINES INPUT

H3H1

H2GND

W

V

U

W

V

U

CONTACTOR

CRI

CRI

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

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

CTOR

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION. 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN. 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES. 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS, DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE REMAINING HEX NUTS IN PLACE.

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION. 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CRI CONTACTOR AS SHOWN. 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES. 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.

PILOT TRANSF.

PILOT TRANSF.

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

CAUTION

A-5INSTALLATION

IDEALARC® DC-600

A-5

CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.

CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT

LEAST 600 VOLT INSULATION.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE

INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE

POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUMCLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT


INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,

LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

L3L2L1

LINKS

LINESINPUT

H4H1

H2GND

W

V

UCONTACTOR

CRI

H3

L3L2L1

LINKS

LINESINPUT

H3H1

H2GND

W

V

UCONTACTOR

CRI

H4

L3L2L1

LINKS

LINESINPUT

H2H1

H3GND

W

V

UCONTACTOR

CRI

H4

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT


INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.

INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.

PILOTTRANSF.

PILOTTRANSF.

PILOTTRANSF.

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

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

CONNECTION FOR 380/460 VOLTAGES

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

2. CONNECT H3 LEAD TO CONTACTOR..3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR

AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN

ALL HEX NUTS

L3L2L1

LINK

LINESINPUT

H2

H3GND

W

V

UCONTACTOR

CRI L3L2L1

LINK

LINESINPUT

GNDH2

W

V

U

CRI

CONTACTOR

H1

TAPE

CONNECTION FOR 500/575 VOLTAGESH3

H1

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

2. CONNECT H2 LEAD TO CONTACTOR.3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR

AS SHOWN.4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN

ALL HEX NUTS

TAPE

A-6INSTALLATION

IDEALARC® DC-600

A-6

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

L3L2L1

LINESINPUT

GND

SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.

W

V

UCONTACTOR

CRI

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

A-7INSTALLATION

IDEALARC® DC-600

A-7OUTPUT CONNECTIONSSee Table A.1 for recommended IDEALARC® DC-600 cable sizes for combined lengths of electrode and workcables.

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

at 100% Duty Cycle

Cable SizeParallel CablesCable Length

1/0 (53mm2)2

2

2

Lengths up to 150 ft. (46m)

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

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

ELECTRODE, WORK AND #21 LEAD CONNECTIONS

A. Connect Electrode and Work Leads toOutput Terminals.

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

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

3. Pull out the retractable strain relief loops.

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

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

6. Tighten the output terminal nut with a wrench.

7. Connect the work lead to the other output terminal following steps 4-6.

FIGURE A.9 - Output Terminals.B. Connect #21 Work Sense Lead to Proper

Terminal

There are two work sense lead connection points (+21and -21) on terminal strip (T.S.2) located behind thehinged access panel on the right side of the casefront. See 14 Pin MS Type Receptacle section orTerminal Strip Section for connection procedure.

TERMINAL STRIPS

Terminal strips are available behind the cover on thecase front to connect wire feeder control cables thatdo not have a 14 Pin MS-type connector. These termi-nals supply the connections as shown in the followingTerminal Strip charts. NOTE: There are two worksense lead connection points on the terminal strip.Connect both the work sense lead #21 from the 14 pinconnector and #21 lead of the control cable to “-21”when welding positive polarity or to “+21” when weld-ing negative polarity.

TERMINAL STRIP 1 (T.S.1)

TERMINAL STRIP 2 (T.S.2)

Lead No. Function

75 Output Control 76 Output Control 77 Output Control

Lead No. Function

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

41 42 VAC 4 Trigger Circuit 2 Trigger Circuit 31 115 VAC1

32 115 VAC1

A-8INSTALLATION

IDEALARC® DC-600

A-8AUXILIARY POWER AND CONTROL CONNECTIONS

Located at the left side of the front of the welderbehind a hinged cover is a 115VAC duplex receptaclefor auxiliary power (60 Hertz Models only). On the rightside of the case front is a 14 Pin MS type receptaclefor connection of auxiliary equipment such as wirefeeders. Also, terminal strips with 115VAC and con-nections for auxiliary equipment are located behind thehinged access panel on the right side of the case front.(see Auxiliary Power Table for details)

115VAC DUPLEX RECEPTACLE (60 HERTZMODELS ONLY)

The 115VAC duplex receptacle is protected by a circuitbreaker located on the nameplate. The receptacle is aNEMA 5-15R.

AUXILIARY POWER TABLEVoltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various Models Auxiliary 60 Hz 50/60 Hz Power Models Models Connections

At Duplex 115V 15A No Duplex Receptacle

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

MS-Receptacle 115V 15A 115V 15A pins A & J

MS-Receptacle 42V 10A 42V 10A pins I & K

PIN LEAD NO. FUNCTION

A 32 115 VAC B GND Chassis Connection C 2 Trigger Circuit D 4 Trigger Circuit E 77 Output Control F 76 Output Control G 75 Output Control H 21 Work Sense Connection2

I 41 42 VAC J 31 115 VAC1.

K 42 42 VAC L --- --- M --- --- N --- ---

F = 7 6

G = 7 5

H = 2 1

I = 4 1

J = 3 1

K = 4 2

A = 3 2

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 config-uration for positive welding. If welding negative polarity, connectlead #21 to the “+21” connection point on the terminal strip(T.S.2).

14 PIN MS TYPE RECEPTACLE(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)

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

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

115 VAC is available at receptacle pins A and J (AllModels). A 15 amp circuit breaker protects this circuit.Note that the 42 VAC and 115 VAC circuits are elec-trically isolated from each other.FIGURE A.10 FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE

B-1OPERATION

IDEALARC® DC-600

B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructions

before operating the machine.

ELECTRIC SHOCK can kill.• Do not touch electrically live parts or

electrodes with your skin or wet

clothing.

• Insulate yourself from the work and

ground.

• Always wear dry insulating gloves.

• Do not use AC welder if your cloth-

ing, gloves or work area is damp or if

working on, under or inside work-

piece.

Use the following equipment:

-Semiautomatic DC constant voltage

(wire) welder.

-DC manual (stick) welder.

-AC welder with reduced voltage control.

• Do not operate with panels removed.

• Disconnect input power before servicing.

------------------------------------------------------------------------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 general area.

WELDING, CUTTING and GOUG-ING SPARKS can cause fire orexplosion.• Do not weld near flammable material.

• Do not weld, cut or gouge on contain-

ers which have held flammable materi-

al.

ARC RAYS can burn.• Wear eye, ear, and body protection.

Observe additional Safety Guidelines

detailed in the beginning of this manual.

WARNING

B-2OPERATIONB-2

IDEALARC® DC-600

GENERAL DESCRIPTIONThe IDEALARC® DC-600 is an SCR controlled threephase welding and cutting power source. It uses asingle range potentiometer to control:

• Submerged Arc Semi-Automatic or AutomaticWelding

• Open Arc Semi-Automatic or Automatic Welding• Stick Welding• Air/Carbon Arc Cutting (Carbon Rod Sizes up to

3/8” Diameter)

The IDEALARC® DC-600 has a three-posit ionWelding Mode Switch to enable the user to operate inone of three modes:

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

FCAW/GMAW)

Three models are available:

• Domestic - al l 60 Hertz models except230/460/575V.

• Canadian-230/460/575V 60 Hertz models• Export-50/60 Hertz models

The optional Multi-Process Switch allows the user toswitch between semi-automatic or automatic weldingand stick welding or air/carbon arc cutting without dis-connecting the wire feeder equipment control, elec-trode,and work leads.

RECOMMENDED PROCESSES ANDEQUIPMENTThe IDEALARC® DC-600 is designed for GMAW(MIG), FCAW, and submerged arc (SAW) within thecapacity of the machine. It can also be used for stickwelding (SMAW) and for air carbon arc (AAC) cuttingwith carbon rods up to 3/8" diameter.

The IDEALARC® DC-600 is provided with a threeposition mode switch that selects CV Innershield, CVSubmerged Arc, or CC Stick.

The IDEALARC® DC-600 can be easily connected towire feeding equipment, including:

• Semi-automatic wire feeders LN-7, LN-7 GMA,LN-742, LN-8, LN-9, LN-9 GMA, LN- 10, LN-15LN-23P, LN-25, and DH-10.

• Automatic wire feeders NA-3, NA-5, and NA-5R.• Tractors LT-56 and LT-7

DESIGN FEATURES AND ADVANTAGES• Excellent arc characteristics for optimum constant

voltage submerged arc and Innershield weldingperformance.

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

• Output Control Potentiometer that provides easysingle range continuous control.

• Output Control Switch that provides simple switch-ing from local to remote control.

• Output Terminals Switch to energize output termi-nals either local or remote.

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

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

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

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

on 60 Hertz models, circuit breaker protected.• Multi-functional terminal strip for easy connection

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

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

• Thermostatically protected power source.• Electronic protection circuit to protect power

source against overloads.• Input line voltage compensation to provide an

essentially constant output.• SCR electronically controlled welder output pro-

vides extra long life, especially for highly repetitivewelding applications.

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

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

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

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

B-3OPERATIONB-3

IDEALARC® DC-600

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

MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONTInput POWER ON/OFF Switch

SYMBOL MEANING

ON

OFF

INPUT POWER

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

Always indicates POWER ON/OFFswitch is in ON position.

Pilot Light

OUTPUT CONTROL

OUTPUT VOLTAGEAND CURRENT

Clockwise Increase of OutputVoltage and Current

TERMINALS ON/REMOTE Switch

OUTPUT TERMINALSENERGIZED

Remote Control of Output Terminals(Energized or Non-Energized)

LOCAL/REMOTE SwitchSYMBOL MEANING

Control Of Output Voltage andCurrent is Via IDEALARC® DC-600's

Control Dial

Remote Control of Output Voltageand Current

MODE SwitchCC 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 BreakerCircuit Breaker (two breakers: 15Afor 115V circuit and 10A for 42V

circuit)

CONTROLS AND SETTINGSAll operator controls and adjustments are located onthe Case Front Assembly of the IDEALARC® DC-600.See Figure B.1 for the location of each control.

FIGURE B.1 - CONTROL PANEL KEYS

1

2

3

4

5 6

7

8

9

10

DC-600

1312

7

5

11

2

1

49863

10

B-4OPERATION

IDEALARC® DC-600

B-4

3 Phase transformer with rectifiedDC output

Line Connection

Three Phase Input Power

Designates welder complies withNational Electrical ManufacturersAssociation requirements EW 1Class I with 100% duty cycle at600Amps output.

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

1. Input POWER ON/OFF Switch This toggle switch turns the machine on or off.

Putting the switch in the ON “ ” position ener-gizes the machine’s input contactor applying inputpower to the machine. Switching the switch to theOFF “ ” position de-energizes the input con-tactor.

2. POWER Light When the POWER switch is in the ON position the

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

B-5OPERATIONB-5

IDEALARC® DC-600

3. OUTPUT CONTROL This control provides continuous control of the

machine’s output voltage and current from mini-mum to maximum (typical full pot range between15 to 44 volts and 90 to 750 amps) as it is rotatedclock-wise. Voltage or current control is deter-mined by setting of Mode Switch (CV or CC).

4. OUTPUT TERMINALS ON/REMOTE Switch When this switch is in the REMOTE “ ” posi-

tion, the IDEALARC® DC-600’s output terminalswill be electrically “cold” until a remote device suchas a wire feeder closes the #2 and #4 circuit in theMS-receptacle or terminal strip (T.S.2). When thisswitch is in the ON “ ” position the machine’soutput terminals will be electrically energized allthe time.

5. LOCAL/REMOTE Switch When this switch is set to the LOCAL “ “ posi-

tion, control of the output voltage and current is viathe OUTPUT CONTROL on the IDEALARC® DC-600’s control panel. When this switch is set to theREMOTE “ ” position, control is through aremote source such as a wire feeder via the #75,#76, and #77 leads in the MS-receptacle or termi-nal strip (T.S.1).

6. Mode Switch This switch allows for selecting the welding

process to be used: CC STICK-for SMAW and AAC CV SUBMERGED ARC- for SAW CV INNERSHIELD- for FCAW and GMAW

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

VAC auxiliary power.

8. 115VAC 15 Amp Circuit Breaker This breaker protects the 115 VAC auxiliary cir-

cuits located in the duplex receptacle, terminalstrip (T.S.2) and MS-receptacle.

9. 42VAC 10 Amp Circuit Breaker This breaker protects the 42VAC auxiliary circuits

located in the terminal strip (T.S.2) and MS-recep-tacle.

10.14 Pin MS-Receptacle This connector provides easy connection for a wire

feeder control cable. It provides connections forauxiliary power, output switching, remote outputcontrol, wire feeder voltmeter sense lead andground. Refer to 14 Pin MS Type Receptacle in theInstallation Section for information about the cir-cuits made available at this receptacle.

11.Terminal Strip Cover Panel Rotate this panel to gain access to the circuits

made available at the two terminal strips (T.S.1and T.S.2). These terminal strips contains thesame circuits as the 14 pin MS-receptacle. Thereis a box connector adjacent to this cover for routingleads to the terminal strips.

12.Negative Output Terminal This output terminal is for connecting a welding

cable. To change welding polarity and for properwelding cable size refer to Electrode and WorkCables in the Installation Section.

13.Positive Output Terminal This output terminal is for connecting a welding

cable. 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 MS-receptacle. A 10 amp circuit breaker protects the 42volt circuit from overloads.

IDEALARC® DC-600 machines can also supply 115volt AC auxiliary power through the wire feeder recep-tacle. A 15 amp circuit breaker protects the 115 voltcircuit from overloads.

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

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

REMOTE CONTROL OF MACHINEOPERATIONThe toggle switch on the control panel labeled“Remote - Panel” gives the operator the option of con-trolling the machine output from a remote location. Ifin the Remote position a wire feeder with remote con-trol capabilities or a remote control device such as aK775 must be connected to terminals 75, 76, and 77.Refer to Accessories Section for wire feeder remoteinformation.

WELDING PROCEDURE RECOMMENDATIONSSelect Welding Mode Switch position based on type ofwelding to be done.

1. Innershield Welding (FCAW)/MIG (GMAW)Welding: Use the CV INNERSHIELD mode.

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

3. Air/Carbon Arc Cutting (AAC) / Stick Welding(SMAW) / High Current, Large Puddle SubmergedArc Welding (SAW): Use the CC STICK mode.When the IDEALARC® DC-600 is used forAir/Carbon Arc cutting, the OUTPUT CONTROLpotentiometer should be set to "9" initially. Basedon the size of the carbon being used or theprocess, turn the potentiometer to a lower settingas required by the process. You can use carbonrods up to 3/8" in diameter at currents as high as750 amps with excellent arc control. The welderprotection circuit protects the machine fromextremely high short circuiting pulses.

SEMI-AUTOMATIC ANDAUTOMATIC WIRE FEEDING WITHTHE IDEALARC® DC-600 AND WIREFEEDERSWhen using the IDEALARC® DC-600 with semi-auto-matic or automatic wire feeding equipment and forstick welding or air/carbon arc cutting, it is recom-mended that the optional MULTI-PROCESS SWITCHbe used. This switch permits you to easily change thepolarity of the connected wire feeding equipment orswitch to stick welding or air/carbon arc cutting.

B-6OPERATIONB-6The power source circuitry is protected from faults onleads 75, 76, or 77. If any of these leads are connect-ed to either the positive or negative output leads, theIDEALARC® DC-600 will either shut down completely(input contactor opens and white POWER light staysilluminated), or will operate at minimum output thuspreventing any damage to the IDEALARC® DC-600. IfIDEALARC® DC-600 shuts down, it must be manuallystarted by resetting the POWER ON/OFF toggleswitch.

OPERATING STEPSThe following procedures are for using the IDE-ALARC® DC-600 in the local control mode of opera-tion. For remote control of the machine, see theRemote Control of Machine Operation section.

Before operating the machine, make sure you have allmaterials needed to complete the job. Be sure youare familiar with and have taken all possible safetyprecautions before starting work. It is important thatyou follow these operating steps each time you usethe machine.

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

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

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

• CC STICK (for SMAW and AAC) • CV SUBMERGED ARC (for SAW) • CV INNERSHIELD (for FCAW and GMAW)

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

• The white pilot light glows. • The fan starts.

5. Set OUTPUT CONTROL Potentiometer to desiredvoltage or current.

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

7. Make the weld.

IDEALARC® DC-600

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

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

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

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

4. Start and make the weld.

• Cold starts. For cold starts, be sure the work piece isclean and the electrode makes positive contact withthe work piece.

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

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

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

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

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

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

4. Turn the Start Board Timer to maximum.

5. Set Start Board current and voltage control.

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

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

B-7OPERATIONB-7

IDEALARC® DC-600

NA-3 AUTOMATIC WIRE FEEDER

1. Set the IDEALARC® DC-600 LOCAL/REMOTESwitch to REMOTE. Set the OUTPUT TERMINALSswitch to REMOTE. NOTE: Later model NA-3 auto-matic wire feeders are capable of cold starts whenthe NA-3 Mode switch is in the CV or CC mode posi-tion. Some earlier models are capable of cold start-ing only in the CC mode position. Cold startingenables you to inch the wire down to the work, auto-matically stop, and automatically energize the fluxhopper valve.

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

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

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

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

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

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

1. Cut the electrode to a sharp point.

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

NOTE: The open circuit voltage of the IDEALARC® DC-600 varies from approximately 16volts to 56 volts in the CV INNERSHIELD or CVSUBMERGED ARC modes. The open circuit voltageis constant in the CC STICK mode.

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

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

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

When using the IDEALARC® DC-600 with the NA-5wire feeder, set the controls on the IDEALARC® DC-600 as follows for the best performance:

1. Turn OFF main AC input power supply to the IDE-ALARC® DC-600.

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

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

4. Set the IDEALARC® DC-600LOCAL/REMOTE Switch to REMOTE.

5. Set the IDEALARC® DC-600 OUTPUT TERMI-NALS switch to REMOTE.

6. Set the IDEALARC® DC-600 WELDING MODESWITCH to the position that matches the weldingprocess being used.

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

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

B-8OPERATIONB-8

IDEALARC® DC-600

NOTE: These Start Board current and voltage set-tings result in a start up current that is lower thanthe NA-3 current setting and approximately equalwith the NA-3 voltage setting for the desired weld-ing procedure.

6. Establish the correct arc striking procedure withthe NA-3 Start Board timer set at maximum.

• For the best starting performance, the NA-3 OpenCircuit Voltage Control and Voltage Control set-ting should be the same. Set the Inch SpeedControl for the slowest inch speed possible.

• To adjust the Open Circuit Voltage Control to getthe best starting performance, make repeatedstarts observing the NA-3 voltmeter.

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

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

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

• Set NA-3 Start Board current and voltage asclose to the welding procedure current and volt-age as possible.

NOTE: The Start Board current and voltageshould be as close as possible to the welding pro-cedure current and voltage, while still getting sat-isfactory starts.

• Set the start time to as low a time as possible while still getting satisfactory starts.

7. Start and make the weld.

C-1ACCESSORIESC-1

IDEALARC® DC-600

WIRE FEEDERS AND TRACTORSThe IDEALARC® DC-600 can be used to power anyof the following Lincoln Wire Feeders and Tractors:

Semi-Automatic Wire Feeders:DH-10 LN-9 LN-7 LN-9 GMA LN-7 GMA LN-23P LN-742 LN-25 LN-8 LN-10

Automatic Wire Feeders:NA-3 NA-5RNA-5

Tractors: LT-7 LT-56

FIELD INSTALLED OPTIONSRemote Output Control (K775 or K857with K864 Adapter)

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

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

Remote Control Adapter Cable (K864)

A "V" cable 12" (.30 m) long to connect a K857Remote Control (6-pin connector) with an LN-7 wire-feeder (14-pin connector) and the machine (14-pinconnector). If a remote control is used alone the wire-feeder connection is then not used.

Undercarriages (K817P, K842)

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

Paralleling Kit (K1611-1)

Permits paralleling of two IDEALARC® DC-600's forwelding currents of up to 1200 amps, 100% dutycycle.

Tig Module (K930-2)

Portable high frequency generator for AC/DC TIGwelding.

FACTORY OR FIELD INSTALLEDOPTIONS

Multi-Process Switch (K804-1)

The MULTI-PROCESS SWITCH gives you the abilityto:• Switch between "stick welding or air/carbon arc

cutting" and using a semi-automatic or automaticwire feeder.

• Change the polarity of a semi-automatic or auto-matic wire feeder without changing any electricalcable connections.

See Figure C.1FIGURE C.1 - MULTI-PROCESS SWITCH

STRAIGHT PLUG (14 PIN)

TO POWER SOURCE

CABLE RECEPTACLE (6 SOCKET)

CABLE RECEPTACLE (14 SOCKET)

TO: K857 REMOTE CONTROL

TO: LN-7 WIRE FEEDERS – +

WIREFEEDERCABLES

STICK ORAIR/CARBONARC CABLES

STICK ORAIR

CARBON ARC

+

-

C-2ACCESSORIESC-2

IDEALARC® DC-600

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

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

Follow these steps to install the MULTI-PROCESSSWITCH:

1. Confirm that the IDEALARC® DC-600 POWERON/OFF switch is in the OFF position.

2. Disconnect main AC input power to the IDE-ALARC® DC-600.

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

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

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

6. Connect the control leads from the MULTI-PROCESS SWITCH to terminals #2 and #4 onthe IDEALARC® DC-600's terminal strip.

7. Connect the right cable from the MULTI-PROCESS SWITCH (facing the front of themachine) to the IDEALARC® DC-600 positive (+)output terminal. See Figure C.2.

FIGURE C.2 - MULTI-PROCESS SWITCHCABLE CONNECTIONS.

8. Connect the left cable from the MULTI-PROCESSSWITCH (facing the front of the machine) to theIDEALARC® DC-600 negative (-) output terminal.See Figure C.2.

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

• Insert the wire feeder electrode and work cablesthrough the strain relief loop on the left side of theIDEALARC® DC-600 (facing the front of themachine).

• Connect the wire feeder electrode and workcables to the electrode and work terminals on the left side of the MULTI-PROCESSSWITCH.

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


WORKCABLE

WORK

ELECTRODES

21-21+ 41 4 2 31 32 75 76 77

TERMINALSTRIP COVER

BOX CONNECTOR

POSITIVE (+)OUTPUT

STUD– +

NEGATIVE (–)OUTPUT

STUD

ELECTRODECABLE

WORKCABLE

ELECTRODECABLE

JUMPER (IF NEEDEDSEE INSTRUCTIONS)

+

CONTROLLEADS

STICK AIR/CARBONARC WELDINGEQUIPMENT

WIREFEEDER

C-3ACCESSORIESC-3

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

• Insert the electrode and work cables through thestrain relief loop on the right side (facing the frontof the machine) of the IDEALARC® DC-600.

• Connect the electrode cable to the "Positive" ter-minal on the right side of the MULTI-PROCESSSWITCH.

• Connect the work cable to the "Negative" terminalon the right side of the MULTI-PROCESSSWITCH.

NOTE: The instructions above are for connectingthe stick polarity positive. To change the polarity,turn the IDEALARC® DC-600 OFF, and reversethe cables.

NOTE: When it is not necessary to have separateground cables for stick and semi-automatic orautomatic welding, connect a jumper from theMULTI-PROCESS SWITCH "Work" terminal tothe MULTI-PROCESS SWITCH "negative" termi-nal. See Figure C.2.

To operate the MULTI-PROCESS SWITCH, refer tothe operating instructions on the switch nameplate.

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

1. Set the IDEALARC® DC-600 ON/OFF switch toOFF.

2. Set the IDEALARC® DC-600 LOCAL/REMOTEswitch to REMOTE.


4. Set the IDEALARC® DC-600 MODE switch to thewelding process being used.

5. Refer to the proper connection diagram in the DIA-GRAMS section for more information.

IDEALARC® DC-600

ROUTINE AND PERIODIC MAINTENANCE1. Disconnect input AC power supply lines to the

machine before performing periodic maintenance,tightening, cleaning, or replacing parts.

Perform the following daily:

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

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

3. Inspect the electrode cables for any slits or punctures in the cable jacket, or any condition thatwould affect the proper operation of the machine.

Perform Periodically:

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

• Main transformer and choke.

• Electrode and work cable connections.

• SCR rectifier bridge and heat sink fins.

• Control board.

• Firing board.

• Fan Assembly. NOTE: The fan motor has sealed bearings which

require no maintenance.

D-1MAINTENANCED-1

IDEALARC® DC-600

SAFETY PRECAUTIONS

ELECTRIC SHOCK CANKILL.Only qualified personnel shouldperform this maintenance.

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

Do not touch electrically hot parts.

WARNING

E-1TROUBLESHOOTINGE-1

IDEALARC® DC-600

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

CAUTION

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

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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

__________________________________________________________________________

WARNING

ELECTRIC SHOCK can kill.Have an electrician install and ser-vice this equipment. Turn the inputpower OFF at the fuse box beforeworking on equipment. Do not touchelectrically hot parts.


IDEALARC® DC-600

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

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

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

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

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

• Remove your body’s staticcharge before opening the static-shielding bag. Wear an anti-staticwrist strap. For safety, use a 1Meg ohm resistive cord connect-ed to a grounded part of theequipment frame.

• If you don’t have a wrist strap,touch an unpainted, grounded,part of the equipment frame.Keep touching the frame to pre-vent static build-up. Be sure notto touch any electrically live partsat the same time.

• Tools which come in contact with the P.C. Boardmust be either conductive, anti-static or static-dis-sipative.

• Remove the P.C. Board from the static-shieldingbag and place it directly into the equipment. Don’tset the P.C. Board on or near paper, plastic orcloth which could have a static charge. If the P.C.Board can’t be installed immediately, put it back inthe static-shielding bag.

• If the P.C. Board uses protective shorting jumpers,don’t remove them until installation is complete.

• If you return a P.C. Board to The Lincoln ElectricCompany for credit, it must be in the static-shield-ing bag. This will prevent further damage andallow proper failure analysis.

4. Test the machine to determine if the failure symp-tom has been corrected by the replacement PCboard.

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

NOTE: Allow the machine to heat up so that all electri-cal components can reach their operating tem-perature.

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

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

• If the original problem is recreated by the substitu-tion of the original board, then the PC board wasthe problem. Reinstall the replacement PC boardand test the machine.

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

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

PC BOARD TROUBLESHOOTING PROCEDURES

ATTENTIONStatic-SensitiveDevicesHandle only atStatic-SafeWorkstations

Reusable ContainerDo Not Destroy

WARNING


IDEALARC® DC-600

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

PROBLEMS(SYMPTOMS)

Major Physical or ElectricalDamage is Evident

The Machine is dead- The Inputcontactor does not operate.

POSSIBLECAUSE

Contact the Lincoln Electric ServiceDept. 1-(888)-953-3877.

1. Check for blown or missingfuses in input lines.

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

3. Power ON/OFF switch may bedefective

RECOMMENDEDCOURSE OF ACTION

OUTPUT PROBLEMS


CAUTION

Observe all Safety Guidelines detailed throughout this manual


IDEALARC® DC-600


CAUTION

PROBLEMS(SYMPTOMS)

Input contactor (CR1) chatters.

Variable or sluggish welding arc.

Output Control Pot. not functioningin “LOCAL” control.

No output control in “REMOTE”control.

115VAC duplex receptacle notworking. (60HZ machines only)

POSSIBLECAUSE

1. The input line voltage may below. Check all three phases.

2. Make sure input line voltagematches machine rating andthe reconnect panel is connect-ed correctly for the line voltage.

1. Poor electrode or work lead con-nection

2. Welding cables too small.

3. Welding current or voltage toolow.

1. LOCAL/REMOTE Switch (S3)faulty or in wrong position.

2. Faulty OUTPUT CONTROL Pot.

1. LOCAL/REMOTE Switch (S3)faulty or in wrong position.

2. Faulty Remote Control Unit.

1. 115VAC Circuit Breaker tripped.


OUTPUT PROBLEMS




IDEALARC® DC-600


CAUTION


PROBLEMS(SYMPTOMS)

Machine input contactor operatesbut machine has no weldoutput.Fan runs and pilot lightglows.

POSSIBLECAUSE

1. Place OUTPUT TERMINALSwitch to “ON”, or install ajumper from #2 to #4 onmachine terminal strip. Ifmachine weld output isrestored the problem is in thewire feeder or control cable.

2. If remote control is not beingused make certain theLOCAL/REMOTE SWITCH(SW3) is in the "Local" position.

3. Check 42V Circuit Breaker inthe front panel.Reset if neces-sary.

4. Check for loose or faulty weldcable connections.

5. Trigger circuit not working.


OUTPUT PROBLEMS



IDEALARC® DC-600


CAUTION


PROBLEMS(SYMPTOMS)

Machine has maximum weld out-put and no control.

POSSIBLECAUSE

1. LOCAL/REMOTE Switch (S3)in wrong position.

2. LOCAL/REMOTE Switch (S3)is faulty, or an open lead goingto the LOCAL/REMOTE Switch(S3).


OUTPUT PROBLEMS



IDEALARC® DC-600


CAUTION


PROBLEMS(SYMPTOMS)

Machine has minimum output andno control.

The machine does not have maxi-mum weld output.

POSSIBLECAUSE

1. If a remote control unit is NOTconnected to the terminal strip#75, #76, and #77 terminals, or isnot connected to the 14 pin MSreceptacle the LOCAL/REMOTESWITCH must be in the "Local"position.

2. If a remote control cable is con-nected to terminals #75, #76 and#77 or is connected to the 14 pinMS receptacle the leads may be"shorted" to the positive weld out-put.

3. Make certain the Three Phaseinput voltage is correct andmatches the machine rating andthe reconnect panel.

1. Check all Three-Phase inputlines at the DC600. Make sureinput voltages match machinerating and reconnect panel.

2. Put LOCAL/REMOTE SWITCH(SW3) in "LOCAL" position. Ifproblem is solved then checkremote control unit or wirefeeder.

3. Check for loose welding cableconnections.


OUTPUT PROBLEMS



IDEALARC® DC-600


CAUTION


PROBLEMS(SYMPTOMS)

Machine shuts off (input contactordrops out) when the welder outputterminals are made electrically"hot".(#2 to #4 closure at terminal strip.)or OUTPUT TERMINALS switchis in ON position.

The DC600 will NOT shut off whenthe Power Switch is turned toOFF.

POSSIBLECAUSE

1. Remove all welding cables andcontrol cables from the DC 600.Jumper #2 to #4 at the terminalstrip or set OUTPUT TERMI-NALS switch to ON position. Ifthe machine does NOT shut offand normal open circuit voltageis present at the welder outputterminals the problem is exter-nal to the DC600. Either theremote leads #75, #76 or #77are grounded to the negativeoutput cable or there is a shorton the welding output terminals.

2. If the machine still shuts offwhen all control and weldingcables are removed then theproblem is internal to the DC-600.

1. Contact your local LincolnAuthorized Field ServiceFacility.


OUTPUT PROBLEMS



IDEALARC® DC-600


CAUTION


PROBLEMS(SYMPTOMS)

The weld output terminals arealways electrically "hot".

POSSIBLECAUSE

1. Remove any external leadshooked to #2 and #4 on the ter-minal strip or any connectionsto the 14 pin MS connector.Set OUTPUT TERMINALSswitch to the OFF position. Ifthe problem disappears thefault is in the control cable orwire feeder.

2. If some open circuit voltage ispresent (over 3VDC.) after per-forming Step #1. then the prob-lem is within the IDEALARC®DC-600.


OUTPUT PROBLEMS



IDEALARC® DC-600


CAUTION


PROBLEMS(SYMPTOMS)

Poor arc starting when the IDE-ALARC® DC-600 is in the CVSub-Arc or CV Innershield Modes.

Machine has output but trips offimmediately when wire feed unittrigger is activated

POSSIBLECAUSE

1. Make sure the proper weldingprocedures are being used.(wire feed speed , arc voltageand wire size)

2. Check weld cables for loose orfaulty connections.

1. Remove output cables fromIDEALARC® DC-600. If prob-lem is resolved check for exter-nal short between weldiongcables. Also check controlcable (#75, #76, & #77) forgrounds or shorts.


WELDING PROBLEMS



IDEALARC® DC-600


CAUTION


PROBLEMS(SYMPTOMS)

Poor arc characteristics in allprocesses.

POSSIBLECAUSE

1. Check for the correct input volt-ages on the three- phase inputlines at the IDEALARC® DC-600.

2. Make sure the proper weldingprocedures are being used. (wirefeed speed, arc voltage and wiresize).

3. Check the welding cables forloose or faulty connections.


WELDING PROBLEMS


PC BOARD TROUBLESHOOTING GUIDEFIRING P.C. BOARD

1. All 10 LED’s must be ON when the POWERSOURCE is turned “ON” and the trigger circuit* isclosed.

2. LED’s 7, 8, and 9 indicate AC power being suppliedto the P.C. board from auxiliary windings on themain transformer (T1). If a LED is not “ON”, turn themachine off and unplug P5 from the firing board.Turn the machine back on and check the followingvoltages:

3. If all voltages are present, turn power off, and plugP5 back into J5. Turn power back on. If LED’s arestill “OUT”, replace Firing PCB.

4. If voltages were not present then check the wiringback to the auxiliary windings for a possible open.

5. LED 10 senses when trigger circuit* is closed.Close trigger circuit, LED10 should be on be “ON”.Open trigger circuit, LED 10 should be “OFF”. IfLED does not come “ON”, check to make sureleads 2,4, or 41 are not broken.

6. LED’s 1 through 6 indicate gate signals are beingsent to the main SCR’s 1 through 6 respectively. IfLED 5 (located on Control Board) is “ON”, alongwith LED’s 7, 8, and 9 (on Firing PCB), and LED’s 1through 6 are “OFF”, check to make sure lead 231between Control board and Firing board is not bro-ken

7. If any one of LED’s 1 through 6 are “OFF” andLED’s 7, 8, and 9 are “ON”, replace the Firing PCB.

PC BOARD TROUBLESHOOTING GUIDECONTROL P.C. BOARD

1. LED 1 indicates AC input voltage necessary to gen-erate the DC supply voltages is present. These volt-ages power the Control board circuitry. If LED 1 isnot “ON” when machine POWER is “ON”, checkleads 255, 256, X1, and X2 for broken connection.


IDEALARC® DC-600



CAUTION

Voltage across leads 255 and 256 should beapproximately 115VAC. Check voltage across sec-ondary winding of the control transformer (T2) whichsupplies leads 255 and 256. Measure +16VDC fromTEST POINTS “A” to “C” and -10VDC from TESTPOINTS “A” to “J” on Control board.

2. LED 2 indicates welder output voltage is being sup-plied to the control circuit. LED 2 will be “ON”brightly in CC STICK mode with trigger circuit*closed and no load. (LED 2 diminishes in bright-ness as output voltage is reduced). If LED 2 is not“ON”, look for open connection in lead 222 circuit.

3. LED 3 indicates power is being applied to FAULTPROTECTION RELAY (CR2). LED 3 will be “ON”when machine POWER is “ON”. LED 3 goes “OUT”when CR2 drops out which turns off the INPUTCONTACTOR (CR1). When LED 3 goes out, LED 4comes “ON”. See step 3.

4. LED 4 indicates an overload or fault condition; LEDshould not be on. If this LED comes “ON”, theINPUT CONTACTOR (CR1) will turn off and the redPOWER light stays illuminated. This was do toeither a short across output, or a current draw inexcess of 780A, or leads 75, 76, or 77 grounded tonegative output lead. Remove short or reduce out-put current or eliminate ground. Welder must bereset by turning POWER ON/OFF switch to “OFF”and then back to “ON”. If no short or loads above780A exists or no ground, replace Control PCB.

5. LED 5 indicates DC control voltage (which suppliesFiring board) is present. LED 5 will be “ON” in CVINNERSHIELD mode with trigger circuit* closed,CONTROL POT at minimum, and no load. (LED 5diminishes in brightness as output voltage isincreased). Replace P.C. board if LED 5 did not go“ON”.

6. LED 6 indicates trigger circuit* condition. LED 6“ON” indicates trigger circuit is closed. LED 6 “OFF”indicates trigger circuit is open. If LED 6 does notcome “ON”, when trigger circuit closed, look foropen connections in the 2 & 4 circuit and in leads290 and 291.

TRIGGER CIRCUIT is closed by any of the following:• Wire feeder’s trigger is closed. • A jumper is placed across 2 & 4 on terminal stripT.S.2. or across pins C & D in 14 pin connector.

• OUTPUT TERMINAL switch is in the “ON” position.

LED that was off

789

Check AC voltage between pins specified,it should be approximately 32VAC .P5 pins 15 & 16 (wires 203,204)P5 pins 7 & 8 (wires 205,206)P5 pins 5 & 6 (wires 207,208)


IDEALARC® DC-600



CAUTION

CHECKING POWER ON/OFF SWITCH (S1)

1. Turn off the machine input power (" o "position).SW1 has 115 volts across it when the input poweris connected.

2. Isolate the switch to be tested by removing all co-nnecting leads.

3. Check to make sure the switch is making open andclosed connections with a V.O.M. meter. Put ohmmeter on X1 scale. The meter should read zeroresistance with switch " I " and infinite with switch " o "

4. Put the ohmmeter on X1K scale and measure theresistance between the terminal and the case of themachine (touch a self-tapping screw). Readingshould be infinite.

5. If either step (3) or step (4) fails, replace the switch.

CHECKING OUTPUT CONTROL RHEO-STAT ON MACHINE (R1)

1. Turn machine off (" o " position).2. Remove the screws from the hinged control panel

and open the panel.

3. Turn the LOCAL/REMOTE CONTROL switch to"REMOTE".

4. With an ohmmeter on X1K, connect it to lead 236and 237 on R1.

5. Exercise caution to avoid damaging rheostat tabs.

6. Rotate the OUTPUT voltage control rheostat. Theresistance reading should be from around zero to10K ohms. Check the resistance reading betweenthe two outer tabs on the rheostat (leads 236 and75). The reading must be 10K "10% ohms. Noreading will indicate an open rheostat and a lowreading will indicate a shorted or partially shortedrheostat; in either case, replace.

CONNECTING REMOTE OUTPUTCONTROL RHEOSTAT TO THE MACHINE

Extreme caution must be observed when installing orextending the wiring of a remote control. Improperconnection of this unit can lead to loss of controland/or poor welding. Only the green lead can andshould be grounded to the machine case. Whenextending the standard remote control, make sure theleads are the same and the splice is waterproof. Bevery careful not to ground the cable when in use anddon't let the lugs touch against the case.

CHECKING REMOTE OUTPUT CONTROLRHEOSTAT

Disconnect the remote output control and connect anohmmeter across 75 and 76 and rotate the rheostat inthe remote control. The resistance reading should gofrom zero to 10K ohms. Repeat with ohmmeter across77 and 76 with same results. Connect ohmmeteracross 75 and 77. The reading should be 10K "10%ohms. A lower reading will indicate a shorted or par-tially shorted rheostat. A very high reading will indicatean open rheostat. In either of the last two cases,replace rheostat. Check cable for any physical dam-age.

F-1DIAGRAMSF-1

IDEALARC® DC-600

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F-2DIAGRAMSF-2

IDEALARC® DC-600

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F-3DIAGRAMSF-3

IDEALARC® DC-600

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ne o

f the

enc

losur

e pa

nels.

If t

he d

iagra

m is

illeg

ible,

writ

e to

the

Serv

ice D

epar

tmen

t for

a re

place

men

t. G

ive th

e eq

uipm

ent c

ode

num

ber.

F-4DIAGRAMSF-4

IDEALARC® DC-600

NOTE

: Th

is dia

gram

is fo

r ref

eren

ce o

nly.

It m

ay n

ot b

e ac

cura

te fo

r all m

achin

es co

vere

d by

this

man

ual.

The

spec

ific d

iagra

m fo

r a p

artic

ular c

ode

is pa

sted

inside

the

mac

hine

on o

ne o

f the

enc

losur

e pa

nels.

If t

he d

iagra

m is

illeg

ible,

writ

e to

the

Serv

ice D

epar

tmen

t for

a re

place

men

t. G

ive th

e eq

uipm

ent c

ode

num

ber.

IDEALARC® DC-600

F-5DIAGRAMSF-5

S2

0409

1-28

-94

CO

NN

EC

TIO

N O

F L

N-7

42

TO

TH

E C

V-6

55

, D

C-6

55

OR

DC

-60

0 P

OW

ER

SO

UR

CE

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

ELEC

TRO

DE

CAB

LE

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

ELI

NC

OLN

TO W

OR

K

LN-7

42W

IRE

FEED

ER

Powe

r Sou

rce

befo

re c

onne

cting

the

wire

feed

er.

Turn

off

(0) t

he p

ower

swi

tch

on th

e W

elding

AND

14-

PIN

CAB

LE P

LUG

, R

EAR

VIE

WAN

D 1

4-PI

N C

ABLE

PLU

G,

FRO

NT

VIEW

K=4

2

C=2

D=4

E=77

F=76

G=7

5

H=2

1I=41

K=4

2

I=41 H

=21

G=7

5

F=76

E=77

D=4

C=2

PIN C D E F G H I K

42412175767742

LEAD

42V

AC42

V AC

WO

RK

OU

TPU

T C

ON

TRO

LO

UTP

UT

CO

NTR

OL

OU

TPU

T C

ON

TRO

LTR

IGG

ER C

IRC

UIT

TRIG

GER

CIR

CU

IT

(SEE

APP

RO

PRIA

TE W

IRIN

G D

IAG

RAM

)

FUN

CTI

ON

FUN

CTI

ON

S AR

E LI

STED

FO

R R

EFER

ENC

EO

NLY

AN

D E

ACH

MAY

OR

MAY

NO

T B

EPR

ESEN

T IN

YO

UR

EQ

UIP

MEN

T.

14-S

OC

KET

BO

X R

ECEP

TAC

LE,

FRO

NT

VIEW

14-S

OC

KET

BO

X R

ECEP

TAC

LE,

REA

R V

IEW

LN-7

42IN

PUT

CAB

LEAS

SEM

BLY

N.C

. PI

NS

NO

T LI

STED

AR

E N

OT

CO

NN

ECTE

D

ON

CAB

LE.

N.A

. W

ELD

ING

CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

A

ND

DU

TY C

YCLE

OF

APPL

ICAT

ION

.N

.B.

DIA

GR

AM S

HO

WS

ELEC

TRO

DE

POSI

TIVE

. TO

C

HAN

GE

POLA

RIT

Y, T

UR

N P

OW

ER "

OFF

",

REV

ERSE

ELE

CTR

OD

E AN

D W

OR

K C

ABLE

S AT

P

OW

ER S

OU

RC

E AN

D S

ET W

IRE

FEED

ER

VO

LTM

ETER

PO

LAR

ITY

SWIT

CH

ON

PO

WER

S

OU

RC

E TO

PR

OPE

R P

OLA

RIT

Y.

N.D

. IF

USI

NG

K58

9-1,

REM

OTE

CO

NTR

OL

KIT

,

SET

PO

WER

SO

UR

CE

CO

NTR

OL

SWIT

CH

T

O "

REM

OTE

" PO

SITI

ON

.

N.D

.

F-6DIAGRAMSF-6

IDEALARC® DC-600

N.C

. Ta

pe u

p bo

lted

conn

ectio

n if

lead

#21

is e

xten

ded.

N.D

. Co

nnec

t the

con

trol c

able

gro

und

lead

to th

e fra

me

term

inal

mar

ked

nea

r the

pow

er s

ourc

e te

rmin

al s

trip.

The

pow

er

s

ourc

e gr

ound

ing

term

inal

(mar

ked

and

loca

ted

near

the

pow

er

s

ourc

e in

put p

ower

con

nect

ions

) mus

t be

prop

erly

conn

ecte

d to

ele

ctric

al g

roun

d pe

r the

pow

er s

ourc

e op

erat

ing

man

ual.

N.E

. If

an o

ptio

nal r

emot

e vo

ltage

con

trol i

s us

ed, c

onne

ct it

to

this

term

inal s

trip.

N.

A. W

eldi

ng c

able

s m

ust b

e of

pro

per c

apac

ity fo

r the

cur

rent

and

du

ty c

ycle

of i

mm

edia

te a

nd fu

ture

app

licat

ions

. Se

e LN

-7

Ope

ratin

g M

anua

l for

pro

per s

izes.

N.

B. I

f LN-

7 is

equi

pped

with

a m

eter

kit,

ext

end

LN-7

con

trol c

able

su

itabl

e fo

r the

inst

alla

tion.

An

S165

86-[L

ENG

TH] r

emot

e

volta

ge s

ensin

g w

ork

lead

may

be

orde

red

for t

his

purp

ose.

Co

nnec

t it d

irect

ly to

the

wor

k pi

ece

inde

pend

ent o

f the

wel

ding

w

ork

cabl

e co

nnec

tion.

For

con

veni

ence

, thi

s ex

tend

ed #

21 le

ad

shou

ld b

e ta

ped

to th

e w

eldi

ng w

ork

lead

. (If

the

leng

th o

f

wel

ding

wor

k ca

ble

is sh

ort,

less

than

25

feet

, and

con

nect

ions

ca

n be

exp

ecte

d to

be

relia

ble,

then

con

trol c

able

lead

#21

doe

s

not n

eed

to b

e ex

tend

ed a

nd c

an b

e di

rect

ly co

nnec

ted

to

term

inal

#21

on

the

term

inal

stri

p. N

ote

that

this

is no

t the

pr

efer

red

conn

ectio

n be

caus

e it

adds

erro

r to

the

LN-7

vol

tmet

er

Abo

ve d

iagra

m sh

ows e

lectro

de co

nnec

ted p

ositiv

e. T

o ch

ange

pola

rity,

turn

pow

er o

ff, re

verse

the e

lectro

de an

d wo

rk lea

ds at

the p

ower

414

231

3275

7677

NEG

ATIV

EPO

SITI

VE

32 31 2 4 GND 21

N.A.

N.D.

ELEC

TRO

DE

CAB

LETO

WIR

E FE

ED U

NIT

TO W

OR

K

POW

ER S

OU

RC

E

N.E.

N.F

.

re

adin

g.)

N.F

. If

lead

#21

is to

be

conn

ecte

d to

the

term

inal s

trip,

con

nect

to th

e #2

1 te

rmina

l tha

t mat

ches

work

pol

arity

. Th

is c

onne

ctio

n m

ust b

e ch

ange

d wh

enev

er th

e ele

ctro

de p

olar

ity is

ch

ange

d.

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

LN-7

TO

INPU

T C

ABLE

PLU

G

LN-7

CO

NTR

OL

CAB

LE

21-

21

FOR

CONT

ROL

CABL

EW

ITH

14 P

INM

S-TY

PEPL

UG C

ONN

ECTO

R

OR

FOR

CONT

ROL

CABL

EW

ITH

TERM

INAL

STR

IPLE

AD C

ONN

ECTO

RS

CO

NTRO

L CA

BLE

S2

2976

sour

ce an

d po

sition

the s

witch

on w

ire fe

eder

(if eq

uippe

d )

to p

rope

r pola

rity.

Also

refer

to no

te N.

F.

N.B.

& N

.C.

14-P

INRE

CEPT

ACLE

lead

#21

from

con

trol c

able

with

term

inal

stri

p co

nnec

tors

or f

rom

14-

pin

rece

ptac

le u

sing

#14

AWG

or l

arge

r ins

ulat

ed w

ire p

hysic

ally

21+

REM

OTE

VO

LTAG

E SE

NSI

NG

LEA

D

10-3

0-98

F

N.G

.

N.G

. Illu

stra

tion

does

not

nec

essa

rily

repr

esen

t act

ual p

ositi

on o

f

fo

r mor

e inf

orm

atio

n.

CO

NN

EC

TIO

N O

F L

N-7

TO

TH

E C

V-6

55

, D

C-6

55

OR

DC

-60

0 P

OW

ER

SO

UR

CE

ap

prop

riate

out

put s

tuds

. Ref

er to

pow

er s

ourc

e op

erat

ing m

anua

l

For p

rope

r set

ting

of s

witc

hes

on p

ower

sou

rce,

see

pow

er s

ourc

e op

erat

ing

man

ual.

F-7DIAGRAMSF-7

IDEALARC® DC-600

N.C

. Ta

pe u

p bo

lted

conn

ectio

n if

lead

#21

is e

xten

ded.

N.D

. Co

nnec

t the

con

trol c

able

gro

und

lead

to th

e fra

me

term

inal

mar

ked

near

the

pow

er s

ourc

e te

rmin

al s

trip.

The

pow

er

s

ourc

e gr

ound

ing

term

inal

(mar

ked

and

loca

ted

near

the

pow

er

s

ourc

e in

put p

ower

con

nect

ions

) mus

t be

prop

erly

conn

ecte

d to

ele

ctric

al g

roun

d pe

r the

pow

er s

ourc

e op

erat

ing

man

ual.

N.

A. W

eldi

ng c

able

s m

ust b

e of

pro

per c

apac

ity fo

r the

cur

rent

and

Abo

ve d

iagra

m sh

ows e

lectro

de co

nnec

ted p

ositiv

e. T

o ch

ange

pola

rity,

turn

pow

er o

ff, re

verse

the e

lectro

de an

d wo

rk lea

ds at

the p

ower

NEG

ATIV

EPO

SITI

VE

32 31 2 4 GND 21

N.A.

N.D.

ELEC

TRO

DE

CAB

LETO

WIR

E FE

ED U

NIT

TO W

OR

K

POW

ER S

OU

RC

E

N.E.

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

CAB

LE

21

FOR

CONT

ROL

CABL

EW

ITH

14 P

INM

S-TY

PEPL

UG C

ONN

ECTO

R

OR

FOR

CONT

ROL

CABL

EW

ITH

TERM

INAL

STR

IPLE

AD C

ONN

ECTO

RS

CO

NTRO

L CA

BLE

S2

2977

sour

ce an

d po

sition

the s

witch

on w

ire fe

eder

(if eq

uippe

d )

to p

rope

r pola

rity.

Also

refer

to no

te N.

F.

N.B.

& N

.C.

14-P

INRE

CEPT

ACLE

ABC

N.E

. If

usin

g an

old

er L

N-8

cont

rol c

able

: con

nect

lead

#75

to #

75 o

nte

rmin

al s

trip,

con

nect

lead

#76

to #

76 o

n te

rmin

al s

trip,

con

nect

lead

#77

to #

77 o

n th

e te

rmin

al s

trip.

the

#21

term

inal t

hat m

atch

es w

ork

polar

ity. T

his c

onne

ctio

n m

ust b

e c

hang

ed w

hene

ver t

he e

lectro

de p

olar

ity is

cha

nged

.

N.G

. If

lead

#21

is to

be

conn

ecte

d to

the

term

inal s

trip,

con

nect

to

N.F.

The

LN-

9 vo

ltage

con

trol j

umpe

rs m

ust b

e co

nnec

ted

as fo

llow

s(re

fer t

o LN

-9 O

pera

ting

Man

ual):

Whi

te ju

mpe

r on

volta

ge b

oard

to p

in "S

" .Bl

ue ju

mpe

r on

volta

ge b

oard

(lat

er u

nits

onl

y),

or o

n st

art b

oard

(ear

lier u

nits

), to

pin

"B".

rem

ote

volta

ge s

ensin

g w

ork

lead

may

be

orde

red

for t

his

purp

ose.

N.B.

Ext

end

lead

#21

from

con

trol c

able

with

term

inal

stri

p co

nnec

tors

or

fro

m 1

4-pi

n re

cept

acle

usin

g #1

4 AW

G o

r lar

ger i

nsul

ated

wire

du

ty c

ycle

of i

mm

edia

te a

nd fu

ture

app

licat

ions

.

Con

nect

it d

irect

ly to

the

wor

k pi

ece

keep

ing

it el

ectri

cally

con

veni

ence

, thi

s ex

tend

ed #

21 le

ad s

houl

d be

tape

d to

the

wel

ding

wor

k le

ad.

(If th

e le

ngth

of w

ork

lead

circ

uit i

s

s

hort,

and

con

nect

ions

can

be

expe

cted

to b

e re

liabl

e, th

en

c

ontro

l cab

le le

ad #

21 d

oes

not n

eed

to b

e ex

tend

ed a

nd c

an b

e

d

irect

ly co

nnec

ted

to te

rmin

al #

21 o

n th

e te

rmin

al s

trip.

Not

e

t

hat t

his

is no

t the

pre

ferre

d co

nnec

tion

beca

use

it ad

ds e

rror

sep

arat

e fro

m th

e w

eldi

ng w

ork

lead

circ

uit a

nd c

onne

ctio

n. F

or

to

the

wire

feed

er v

oltm

eter

read

ing.

)

phy

sical

ly su

itabl

e fo

r the

inst

alla

tion.

An

S165

86-[L

ENG

TH]

TO L

N-8

OR

LN

-9

CO

NTR

OL

N.F

.IN

PUT

CAB

LE P

LUG

414

231

3275

7677

N.E.

N.G

.21-21+

REM

OTE

VO

LTAG

E SE

NSI

NG

LEA

D

10-3

0-98

F

N.H

. Ill

ustr

atio

n do

es n

ot n

eces

saril

y re

pres

ent a

ctua

l pos

ition

of a

ppro

pria

te

out

put s

tuds

. Ref

er to

pow

er s

ourc

e in

stru

ctio

n m

anua

l for

mor

e in

fo.

N.H.

CO

NN

EC

TIO

N O

F L

N-8

OR

LN

-9 T

O T

HE

CV

-65

5,

DC

-65

5 O

R D

C-6

00

PO

WE

R S

OU

RC

E

For p

rope

r set

ting

of s

witc

hes

on p

ower

sou

rce,

see

pow

er s

ourc

e op

erat

ing

man

ual.

F-8DIAGRAMSF-8

IDEALARC® DC-600

F-9DIAGRAMSF-9

IDEALARC® DC-600

F-10DIAGRAMSF-10

IDEALARC® DC-600

S2

2980

ELEC

TRO

DE

CAB

LE

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

E TO W

OR

K

AND

14-

PIN

CAB

LE P

LUG

, R

EAR

VIE

WAN

D 1

4-PI

N C

ABLE

PLU

G,

FRO

NT

VIEW

K=4

2

I=41 H

=21

D=4

C=2

PIN B C D E F

75767742

LEAD

42V

AC42

V AC

TRIG

GER

CIR

CU

IT

(SEE

APP

RO

PRIA

TE W

IRIN

G D

IAG

RAM

)

FUN

CTI

ON

FUN

CTI

ON

S AR

E LI

STED

FO

R R

EFER

ENC

EO

NLY

AN

D E

ACH

MAY

OR

MAY

NO

T B

EPR

ESEN

T IN

YO

UR

EQ

UIP

MEN

T.

14-S

OC

KET

BO

X R

ECEP

TAC

LE,

FRO

NT

VIEW

14-S

OC

KET

BO

X R

ECEP

TAC

LE,

REA

R V

IEW

N.C

. PI

NS

NO

T LI

STED

AR

E N

OT

CO

NN

ECTE

D

ON

CAB

LE.

N.A

. W

ELD

ING

CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

A

ND

DU

TY C

YCLE

OF

APPL

ICAT

ION

.

G21

H41

I42

J

MF=

76E=

77

G=7

5NL

A

B=G

ND

K=4

2

I=41

H=2

1

D=4C

=2

J

MF=

76E=

77G

=75

NL

A

B=G

ND

9 PI

NAM

PHEN

OL

K

GN

DC

HAS

SIS

CO

NN

ECTI

ON

WO

RK

OU

TPU

T C

ON

TRO

LO

UTP

UT

CO

NTR

OL

OU

TPU

T C

ON

TRO

L

TRIG

GER

CIR

CU

IT

Only

quali

fied p

erson

s sho

uld in

stall,

use o

rse

rvice

this

mach

ine.

Do no

t ope

rate w

ith co

vers

remov

ed.

Disco

nnec

t pow

er so

urce b

efore

servi

cing.

Do no

t tou

ch el

ectric

ally l

ive pa

rts.

N.D

. IF

LEA

D #

21 IS

TO

BE

CO

NN

ECTE

D T

O T

HE

T

ERM

INAL

STR

IP, C

ON

NEC

T TO

TH

E #2

1

TER

MIN

AL T

HAT

MAT

CH

ES W

OR

K P

OLA

RIT

Y.

TH

IS C

ON

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NOTES

IDEALARC® DC-600

WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Do not touch electrically live parts orelectrode with skin or wet clothing.

l Insulate yourself from work andground.

l No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

l Isolieren Sie sich von denElektroden und dem Erdboden!

l Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

l Isole-se da peça e terra.

l Keep flammable materials away.

l Mantenga el material combustiblefuera del área de trabajo.

l Gardez à l’écart de tout matérielinflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem guarda-dos.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y elcuerpo.

l Protégez vos yeux, vos oreilles etvotre corps.

l Tragen Sie Augen-, Ohren- und Kör-perschutz!

l Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

l Keep your head out of fumes.l Use ventilation or exhaust to

remove fumes from breathing zone.

l Los humos fuera de la zona de res-piración.

l Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

l Gardez la tête à l’écart des fumées.l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

l Vermeiden Sie das Einatmen vonSchweibrauch!

l Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Turn power off before servicing.

l Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

l Débranchez le courant avant l’entre-tien.

l Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

l Não opere com as tampas removidas.l Desligue a corrente antes de fazer

serviço.l Não toque as partes elétricas nuas.

l Do not operate with panel open orguards off.

l No operar con panel abierto oguardas quitadas.

l N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

l Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

l Mantenha-se afastado das partesmoventes.

l Não opere com os paineis abertosou guardas removidas.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.

Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.

Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

TABLE OF CONTENTSINSTALLATIONOPERATIONACCESSORIESMAINTENANCETROUBLE SHOOTINGWIRING DIAGRAMDIMENSION PRINT

Documents

Idealarc DC-600 - Lincoln Electric · welding machine in good, safe operating condition. Replace damaged insulation. 3.g. Never dip the electrode in water for cooling. 3.h. Never