Operator’s Manual IDEALARC DC600 VRD · 5/16/2018 · ELECTRIC SHOCK CAN KILL. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on

IDEALARC ® DC600 VRD

Operator’s Manual

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10018-A | Issue D ate 11-Aug

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

11598, 11613, 11707, 11725,

Register your machine: www.lincolnelectric.com/register

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

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 SITUATIONS

DO 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 measures

PROTECT 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 - 5/16/2018

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,

or other reproductive harm.• Always start and operate the engine in a

well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

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-ventilated areas or vent the engineexhaust fumes outdoors.

1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact

with hot engine parts and 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 - 5/16/2018

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, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,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 thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions 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 - 5/16/2018

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 to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

IDEALARC® DC-600 VRD

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

ivSAFETYiv

vi vi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications ............................................................................................. A-1Safety Precautions ..................................................................................................... A-2Select Proper Location.................................................................................................A-2

Limit on Stacking ...................................................................................................A-2Stacking.................................................................................................................A-2Tilting .....................................................................................................................A-2

Electrical Input Connections ....................................................................................... A-3Fuses and Wire Sizes............................................................................................A-3Ground Connection .............................................................................................. A-3Input Power Supply Connections...........................................................................A-3

Reconnect Procedure ................................................................................................ A-4Output Connections ................................................................................................... A-5

Electrode, Work and #21 Lead ..............................................................................A-5Auxiliary Power and Control Connections .............................................................A-6

________________________________________________________________________

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

NA-3 Automatic Wire Feeder ..........................................................................B-8NA-5 Automatic Wire Feeder ..........................................................................B-9

________________________________________________________________________

Accessories .....................................................................................................Section CWire Feeders and Tractors....................................................................................C-1Field Installed Options...........................................................................................C-1

Remote Output Control (K775 or K857)..........................................................C-1Remote Control Adapter Cable (K864) ...........................................................C-1Undercarriages (K817P, K842).......................................................................C-1

Factory or Field Installed Options..........................................................................C-1Multi-Process Switch (K804-1)........................................................................C-1

Connections for Semi-Automatic or Automatic Wire Feeder Control ....................C-3________________________________________________________________________

vii viiTABLE OF CONTENTSPage

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Routine and Periodic Maintenance........................................................................D-1

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

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

Parts List ....................................................................................................P-631 Series

60% Duty Cycle

122/61/4968

A-1INSTALLATION


A-1

TECHNICAL SPECIFICATIONS – IDEALARC® DC-600 VRD

Volts at Rated Amperes444444

Auxiliary PowerSee the OPERATION section

for Auxiliary Power information by model

Amps600680750

Maximum Open Circuit Voltage5V for 60 HZ models

5V 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

StandardVoltage

230/460/575/60415/50/60

CODES

11613, 1170711598, 11725

100% Duty Cycle

108/54/4362

50% Duty Cycle

134/67/5473

Input Current at Rated Output

RATED OUTPUT

INPUTVOLTAGE /

FREQUENCY

230460575415

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

175 Amp90 Amp70 Amp100 Amp

TYPE 75°CGROUND WIRE

IN CONDUITAWG(IEC-MM2) SIZES

6 (14)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)6 (14)

INPUT AMPERERATING ON

NAMEPLATE

108544361

HERTZ

606060

50/60

PHYSICAL DIMENSIONSHEIGHT30.75 in781 mm

WIDTH22.25 in567 mm

DEPTH39.0 in

988 mm

WEIGHT525 lbs.238 kg.

A-2INSTALLATION


A-2

SAFETY PRECAUTIONSRead entire Installation Section beforeinstalling the IDEALARC® DC-600 VRD.

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel shouldinstall this machine.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on the equipment.

• Do not touch electrically hot parts.

• Always connect the IDEALARC® DC-600 VRDgrounding terminal to a good electrical earthground.

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

__________________SELECT PROPER LOCATION

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

LIMIT ON STACKING

STACKING

Three IDEALARC® DC-600 VRD machines can bestacked.

DO NOT stack more than three machines in onegrouping.

DO NOT stack the IDEALARC® DC-600 VRD onanother type of machine.

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

the total weight of up to three machines (1570pounds/712 kilograms).

2. Set the bottom machine in place.

3. Stack the second machine on top of it by aligningthe two holes in the base rails of the secondmachine with the two pins on top front of the bot-tom 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-600VRD machines

TILTING

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

STACKING HOLE

STACKING PINS

WARNING

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

• Be sure machine is stable whenlifting.

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

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

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

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

any other machine.------------------------------------------------------------------------

WARNING

A-3INSTALLATION


A-3

ELECTRICAL INPUT CONNECTIONS

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

FIGURE A.2 - Rear Panel

FUSE AND WIRE SIZES

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

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

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

GROUND CONNECTION

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

INPUT POWER SUPPLY CONNECTIONS

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

FIGURE A.4-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.5-Reconnect Panel Board Positions for 230/460/575 VAC Machines

A-4INSTALLATION


A-4

RECONNECT PROCEDURE

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

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

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

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

1. For 415 Single Voltage, see Figure A.4. (S17894)

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

CAUTION

A-5INSTALLATION


A-5

OUTPUT CONNECTIONSSee Table A.1 for recommended IDEALARC® DC-600 VRD cable sizes for combined lengths of electrode andwork cables.

TABLE A.1IDEALARC® DC-600 VRD 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.6.

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.6 - Output Terminals.

B. Connect #21 Work Sense Lead to ProperTerminal

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

TERMINAL STRIPS

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

TERMINAL STRIP 1 (T.S.1)

TERMINAL STRIP 2 (T.S.2)

Lead No. Function

75 Output Control76 Output Control77 Output Control

Lead No. Function

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

41 42 VAC 4 Trigger Circuit 2 Trigger Circuit 31 115 VAC(1)

32 115 VAC(1)

A-6INSTALLATION


A-6

AUXILIARY POWER AND CONTROL CON-NECTIONS

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 15Amp circuit breaker located on the nameplate. Thereceptacle is a NEMA 5-15R.

AUXILIARY POWER TABLEVoltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various Models

Auxiliary 60 Hz 50/60 HzPower Models ModelsConnections

At Duplex 15A No DuplexReceptacle 115V

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

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

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

PIN LEAD NO. FUNCTION

A 32 115 VAC(3)

B GND Chassis ConnectionC 2 Trigger CircuitD 4 Trigger CircuitE 77 Output ControlF 76 Output ControlG 75 Output Control

H 21 Work Sense Connection(2)

I 41 42 VAC

J 31 115 VAC(3)

K 42 42 VACL --- ---M --- ---N --- ---

F=76

G=75

H=21

I=41

J=31K=42

A=32

B=GND

C=2

D=4

E=77

L N

MF=76

G=75

H=21

I=41

K=42

B=GND

C=2

D=4

E=77

L N

M

(1)115VAC circuit is on all models.

(2)As shipped from the factory Lead #21 from the 14 Pin connectoris connected to “-21” on the terminal strip (T.S.2). This is the con-figuration for positive welding. If welding negative polarity, con-nect lead #21 to the “+21” connection point on the terminal strip(T.S.2).

(3)115VAC is not available at the 14 Pin connector on Codes 11707,11725.

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

Refer to the Figure A.7 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.

On codes 11598 and 11613, 115 VAC is available atreceptacle pins A and J. A 15 amp circuit breaker pro-tects this circuit. (See Figure A.7 for pin allocation).Note that the 42 VAC and 115 VAC circuits are electri-cally isolated from each other.

FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE

Table for Codes 11598, 11613

Auxiliary 60 Hz 50/60 HzPower Models ModelsConnections

At Duplex 15A No DuplexReceptacle 115V

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

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

Table for Codes 11707, 11725

FIGURE A.7

Pin location for Codes 11598, 11613 Pin location for Codes 11707, 11725

B-1OPERATION


B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructionsbefore operating the machine.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts orelectrodes with your skin or wetclothing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.• Do not use AC welder if your cloth-

ing, gloves or work area is damp orif working on, under or inside work-piece.Use the following equipment:-Semiautomatic DC constant volt-age (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, PROTECTYOURSELF & OTHERS.

FUMES AND GASES can bedangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust at the arc, or both, tokeep fumes and gases from your breathing zoneand general area.

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

• Do not weld near flammable material.

• Do not weld, cut or gouge on contain-ers which have held flammable materi-al.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional Safety Guidelinesdetailed in the beginning of this manual.

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

WARNING

B-2OPERATIONB-2


GENERAL DESCRIPTIONThe IDEALARC® DC-600 VRD includes a proprietary design which isavailable in certain arc welding power sources such as the DC 600and 400. This internal circuitry applies a high frequency, low voltagesignal through the Electrode and Work terminals, while disabling theoutput of the power source. The OCV ( open circuit voltage) duringthis period is less than 2 Volts RMS at 70kHz. When an Electrode toWork load of 100 ohms or less is applied, the output of the powersource is enabled, allowing normal welding operation. When the out-put load is removed, within 0.3 seconds, the output is again disabledreducing the OCV to less than 2 Volts RMS

The IDEALARC® DC-600 VRD is an SCR controlled three phasewelding and cutting power source. It uses a single range potentiome-ter to control:

• Submerged Arc Semi-Automatic or Automatic Welding• 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 VRD has a three-position Welding ModeSwitch to enable the user to operate in one of three modes:• Constant Current (CC) Stick also used for Air Carbon Arc Cutting

Process (AAC)• Constant Voltage (CV) Submerged Arc• Constant Voltage (CV) Innershield (also used for FCAW/GMAW)

Two VRD models are available:• Domestic - 230/460/575V 60 Hertz model• Export-415V 50/60 Hertz model

The optional Multi-Process Switch allows the user to switch betweensemi-automatic or automatic welding and stick welding or air/carbonarc cutting without disconnecting the wire feeder equipment control,electrode, and work leads.

RECOMMENDED PROCESSES AND EQUIPMENT

The IDEALARC® DC-600 VRD is designed for GMAW (MIG), FCAW,and submerged arc (SAW) within the capacity of the machine. It canalso be used for stick welding (SMAW) and for air carbon arc (AAC)cutting with carbon rods up to 3/8" diameter.The IDEALARC® DC-600 VRD is provided with a three position modeswitch that selects CV Innershield, CV Submerged Arc, or CC Stick.

The IDEALARC® DC-600 VRD can be easily connected to wire feed-ing equipment, including:• Semi-automatic wire feeders LN-7*, LN-7 GMA*, LN-742, LN-8*,

LN-9*, LN-9 GMA*, LN- 10, LN-15 LN-23P, LN-25, and DH-10.• Automatic wire feeders NA-3*, NA-5*, and NA-5R*.• Tractors LT-56* and LT-7*

*The 14-pin MS receptacle on codes 11707 and 11725 does not provide115VAC for these feeders; 115VAC must be obtained from terminalstrip.

DESIGN FEATURES AND ADVANTAGES

• No large output mechanical contactors or Solid State switches suchas SCRʼs, etc; are added to the Electrode to Work output circuit.

• “Tamper Resistant” design. Circuitry is built into power source, notan exterior package which could easily be tampered with.

• No reduction of power source output rating. This feature does notaffect the rating of the power source.

• Self diagnostics upon machine power up. Indicator lights are test-ed.

• Green lamp on when weld voltage is less than 30 volts. If weld volt-age exceeds 30 volts, Green lamp turns off and Red lamp turns on.

• Output is disabled if OCV > 50 volts is sensed.• Excellent arc characteristics for optimum constant voltage sub-

merged arc and Innershield welding performance.• A control circuit designed to provide good starting for a large variety

of processes and procedures.• Output Control Potentiometer that provides easy single range con-

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

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

remote.• White neon pilot light to confirm that the Input Contactor is ener-

gized.• 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 mod-

els, 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 acci-

dentally coming into contact with the output terminals and labeled "+ " and " - " for easy identification.

• Thermostatically protected power source.• Electronic protection circuit to protect power source against over-

loads.• Input line voltage compensation to provide an essentially constant

output.• SCR electronically controlled welder output provides extra long life,

especially for highly repetitive welding applications.• Solid state 2 and 4 circuit for extra long life.• Two circuit solid state control system provides maximum perfor-

mance 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 dam-

age.• Easily removed case side, even when stacked.• Outdoor operation because enclosure is designed with air intake

louvers that keep dripping water from entering the unit. Transformer,SCR Bridge and choke have special corrosion resistant paint foradded protection.

B-3OPERATIONB-3


WELDING CAPABILITYThe IDEALARC® DC-600 VRD has the following Output and Duty Cycle based on operation for a 10 minute period: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).

Indicates main Transformer is operating.

Pilot Light

OUTPUT CONTROL

OUTPUT VOLTAGEAND CURRENT

Clockwise Increase of OutputVoltage and Current

TERMINALS ON/REMOTE Switch

OUTPUT TERMINALSENERGIZED

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

LOCAL/REMOTE Switch

SYMBOL MEANING

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

VRD's Control Dial

Remote Control of Output Voltageand Current

MODE Switch

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

CV SUBMERGED ARC:Constant Voltage Submerged

Arc Welding (SAW)

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

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

Output Terminal Connections

Positive Output Terminal

Negative Output Terminal

WARNING Identification

Warning Identification

Circuit Breaker

Circuit Breaker (two breakers: 15A for115V circuit and 10A for 42V circuit)

Thermal Protection Light

On when power source exceeds nor-mal operating temperature.

CONTROLS AND SETTINGSAll operator controls and adjustments are located onthe Case Front Assembly of the IDEALARC® DC-600VRD. 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 VRD

1312

7

5

11

2

1

4

9863

10

15

14

B-4OPERATION


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 SwitchThis toggle switch turns the machine on or off.Putting the switch in the ON “ ” position ener-gizes the machineʼs input contactor applying inputpower to the machine. Switching the switch to theOFF “ ” position de-energizes the input con-tactor.

2. POWER LightWhen the POWER switch is in the ON position themachineʼs white POWER light will illuminate. If theinput contactor de-energizes the machine in anabnormal situation the pilot light will turn off. In thissituation it may be necessary to reset the machineby switching the POWER switch to the OFF andthen to the ON posit ion. (See Overload,Overcurrent, and Fault Protection Section)

B-5OPERATIONB-5


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

4. OUTPUT TERMINALS ON/REMOTE SwitchWhen this switch is in the REMOTE “ ” posi-tion, the IDEALARC® DC-600 VRDʼs output termi-nals will be electrically “cold” until a remote devicesuch as a wire feeder closes the #2 and #4 circuitin the MS-receptacle or terminal strip (T.S.2).When this switch is in the ON “ ” position themachineʼs output terminals will be electricallyenergized all the time.

5. LOCAL/REMOTE SwitchWhen this switch is set to the LOCAL “ “ posi-tion, control of the output voltage and current is viathe OUTPUT CONTROL on the IDEALARC® DC-600 VRDʼs control panel. When this switch is setto the REMOTE “ ” position, control isthrough a remote source such as a wire feeder viathe #75, #76, and #77 leads in the MS-receptacleor terminal strip (T.S.1).

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

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

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

9. 42VAC 10 Amp Circuit BreakerThis breaker protects the 42VAC auxiliary circuitslocated in the terminal strip (T.S.2) and MS-recep-tacle.

10. 14 Pin MS-ReceptacleThis connector provides easy connection for awire feeder control cable. It provides connectionsfor auxiliary power, output switching, remote out-put control, wire feeder voltmeter sense lead andground. Refer to 14 Pin MS Type Receptacle inthe Installation Section for information about thecircuits made available at this receptacle.

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

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

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

14. VRD LightsWhen VRD is active, in CC mode, these lightsilluminate based on the stud voltage while weld-ing. The green light will be on when the weldingvoltage is under 30 volts and the red light light willturn on when the voltage is 30 volts or greater.

15. Thermal Protection Light (Only on Codes11707 and 11725)An amber light on the machine control panel indi-cates when either of the two protective ther-mostats has opened. Output power will be dis-abled temporarily. Thermostat will automaticallyreset when the machine cools to an acceptableoperating temperature.

AUXILIARY POWER IN MS-RECEP-TACLE

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

On Codes 11598 and 11613, IDEALARC® DC-600VRD machines supply 115 volt AC auxiliary powerthrough the wire feeder receptacle. A 15 amp circuitbreaker protects the 115 volt circuit from overloads.

Whenever the CC welding mode is selected andpower is turned on, or power is on and the weldingmode is changed from Constant Voltage (CV) toConstant Current (CC), the VRD circuitry performs aself test for approximately five seconds. For one sec-ond the input contactor and the cooling fan will turnon, then off. With welding inhibited, the studs will beexamined. Both VRD lights will be on to indicate thatthe machine is in self test mode.

After passing the self test, only the green light remainson and the machine is ready to weld. If the test fails,both lights will remain on and welding remains inhibit-ed. This could be caused by the stick electrode hold-er being shorted to work, or if an across the arc wirefeeder, such as the LN 25, is connected to the powersource.

To use a system with sense leads in CC mode on aVRD model, disconnect the feederʼs work sense leadprior to the self test. After passing the self test, recon-nect the work sense lead.

• In CC mode, the VRD will reduce the output voltageregardless of the position of the “TERMINALSON/REMOTE” Switch.

• The voltmeter will display zero volts until the elec-trode contacts the work and establishes the weldingarc.

NOTE:Under normal circumstances, the machine will neverbe able to exceed 49 volts while not welding. If,under abnormal circumstances, the output voltagewere to exceed 49 volts while not welding, the VRDturns the output off. The green light would be onbecause the voltage would be zero and the pilot lightwill be off, but establishing an arc would not be pos-sible. The machineʼs “POWER ON/OFF” Switchmust be cycled off, then back on, to restore normaloperation.

B-6OPERATIONB-6

OVERLOAD, OVERCURRENT, ANDFAULT PROTECTION

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

The power source is also protected against overcur-rents in the SCR bridge assembly through an elec-tronic protection circuit. This circuit senses currentsover 780 amps on the power source and opens theinput contactor should the overcurrent remain for apredetermined time (the white POWER light also turnsoff).

The predetermined time varies with the amount ofovercurrent; the greater the overcurrent, the shorterthe time. The input contactor will remain open untilthe power source is manually started by resetting thePOWER ON/OFF toggle switch.

For codes 11707 and above.The power source is protected against overvoltagewhen not welding in CC mode. If the protection circuitsenses voltage in excess of 49V at the studs when nowelding is taking place, the POWER light will turn off.The input contactor will open up and remain open untilthe power source is manually restarted by toggling theON/OFF switch.

The power source circuitry is protected from faults onleads 75, 76, or 77. If any of these leads are connect-ed to either the positive or negative output leads, theIDEALARC® DC-600 VRD will either shut down com-pletely (input contactor opens and white POWER lightturns off), or will operate at minimum output thus pre-venting any damage to the IDEALARC® DC-600 VRD.If IDEALARC® DC-600 VRD shuts down, it must bemanually started by resetting the POWER ON/OFFtoggle switch.

VRD (VOLTAGE REDUCTIONDEVICE) OPERATION

The VRD electronic circuitry is designed to reduce theOCV of the power source in the Constant Current(CC) Stick welding mode only. The operation of themachine with the VRD is slightly different than theoperation of a standard machine. The followingdescribes the machine operation with the VRDinstalled in the DC600.


REDONONOFFOFF

GREENONOFFONOFF

Power source is in self test mode.Output voltage is greater than 30 V.Output voltage is less than 30 V.Power source is in CV mode.

LED STATUSLED STATUS

B-7OPERATIONB-7

The Lincoln VRD circuit meets the requirements ofAS1674.2-2007, Safety in welding and all iedprocesses - Electrical, for Category C environments.Category C environments include coffer dams,trenches, mines, in rain, etc.

The Lincoln VRD circuit also meets recommendationof ANSI Z49.1- 2005, Safety in Welding, Cutting andAllied Processes, for use in electrically hazardousconditions ( in damp locations or while wearing wetclothing; on metal structures such as floors, gratingsor scaffolds; when in cramped positions such as sit-ting, kneeling or lying, if there is a high risk ofunavoidable or accidental contact with the workpieceor ground ).

OPERATING STEPS

The following procedures are for using the IDE-ALARC® DC-600 VRD in the local control mode ofoperation. 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.

CV MODE

1. Connect the #21 work lead to either + or - on termi-nal strip (T.S.2).

2. Turn on the main AC power supply to the machine.3. Set the Welding Mode switch to welding process

being used:• 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 and the fan starts.

5. Set OUTPUT CONTROL Potentiometer to desiredvoltage.

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

7. Make the weld.

CC MODE

1. Connect the #21 work lead to either + or - on termi-nal strip (T.S.2).

2. Turn on the main AC power supply to the machine.

3. Set the Welding Mode switch to welding processbeing used:• CC STICK (for SMAW and AAC)

4. Turn the POWER ON/OFF Toggle Switch to the“ON” position:• The white pilot light glows and the fan starts for 1

second.• The machine continues the 5 second pretest indi-

cated by both red and green VRD lights glowing.When the red light turns off, the pilot light turns onand the fan restarts, the machine is ready.

5. Set OUTPUT CONTROL Potentiometer to desiredcurrent.

6. Set the OUTPUT TERMINALS switch to either“ON” ( output terminals active) or “REMOTE” (out-put terminals active when #2 and #4 is closed byremote device such as wire feeder).

7. Make the weld.

REMOTE CONTROL OF MACHINEOPERATION

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

WELDING PROCEDURE RECOMMENDATIONS

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

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

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


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 VRD 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 VRD varies from approximately16 volts to 56 volts in the CV INNERSHIELD or CVSUBMERGED ARC modes. The open circuit voltageis essentially zero 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.

• 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.

B-8OPERATIONB-8


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 VRD 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 VRD ANDWIRE FEEDERS

When using the IDEALARC® DC-600 VRD with semi-automatic or automatic wire feeding equipment andfor stick 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.

To use a feeder with sense leads in CC mode on theIDEALARC® DC-600 VRD, disconnect the feederʼswork sense lead prior to the VRD self test. Reconnectthe work sense lead after passing the self test.

NA-3 AUTOMATIC WIRE FEEDER

1. Set the IDEALARC® DC-600 VRD 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 and when welding in positive polarity only. Someearlier models are capable of cold starting only in theCC mode position. Cold starting enables you to inchthe wire down to the work, automatically stop, andautomatically energize the flux hopper valve.

2. Set the IDEALARC® DC-600 VRD welding modeswitch for the desired process: CV SUBMERGEDARC, CV INNERSHIELD mode or CC STICK mode.

3. Set the NA-3 mode Switch Position to either CV orCC to match the IDEALARC® DC-600 VRD modeselected 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 VRD.

B-9OPERATIONB-9


ARC STRIKING WITH IDEALARC® DC-600 VRD ANDTHE NA-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.

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 comingup to the desired voltage, the Open CircuitVoltage Control is set too low. This can cause theelectrode 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.

IDEALARC® DC-600 VRD POWERSOURCE SETTING WHEN CONNECTEDTO NA-5 WIRE FEEDER

When using the IDEALARC® DC-600 VRD with theNA-5 wire feeder, set the controls on the IDEALARC®

DC-600 VRD as follows for the best performance:

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

2. Connect the electrode cables to terminal polarityto be used. NOTE: Cold starting is only availiablein positive polarity.

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

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

5. Set the IDEALARC® DC-600 VRD OUTPUT TER-MINALS switch to REMOTE.

6. Set the IDEALARC® DC-600 VRD WELDINGMODE SWITCH to the position that matches thewelding process being used.

• For submerged arc welding, set WELDINGMODE SWITCH to CV SUBMERGED ARC posi-tion.

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

C-1ACCESSORIESC-1


WIRE FEEDERS AND TRACTORS

The IDEALARC® DC-600 VRD can be used to powerany of the following Lincoln Wire Feeders andTractors:

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

*Codes 11707 and 11725 only provide 115VAC for these feeders at the ter-minal strip.

FIELD INSTALLED OPTIONS

Remote Output Control (K775 or K857with K864 Adapter)

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

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

Remote Control Adapter Cable (K864)

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

Undercarriages (K817P, K842)

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

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 cut-ting" and using a semi-automatic or automatic wirefeeder.

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

See Figure C.1

FIGURE C.1 - MULTI-PROCESS SWITCH

S T R A I G H T P L U G ( 1 4 P I N )

TO P O W E R S O U R C E

C A B L E R E C E P TA C L E ( 6 S O C K E T )

C A B L E R E C E P TA C L E ( 1 4 S O C K E T )

TO : K 8 5 7 R E M O T E C O N T R O L

TO : L N - 7 W I R E F E E D E R S

– +

WIREFEEDERCABLES

STICK ORAIR/CARBONARC CABLES

STICK ORAIR

CARBONARC

+

-

C-2ACCESSORIESC-2


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 VRDPOWER ON/OFF switch is in the OFF position.

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

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 VRD's terminal strip.

7. Connect the right cable from the MULTI-PROCESS SWITCH (facing the front of themachine) to the IDEALARC® DC-600 VRD posi-tive (+) 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 VRD negative (-) output ter-minal. 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 VRD (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 VRD.

• 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 VRD OFF, andreverse the 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 VRD ON/OFF switchto OFF.

2. Set the IDEALARC® DC-600 VRDLOCAL/REMOTE switch to REMOTE.


4. Set the IDEALARC® DC-600 VRD MODE switch tothe welding process being used.

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


ROUTINE AND PERIODIC MAINTENANCE

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

Perform the following daily:

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

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

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

Perform Periodically:

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

• Main transformer and choke.

• Electrode and work cable connections.

• SCR rectifier bridge and heat sink fins.

• Control board.

• Firing board.

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

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

D-1MAINTENANCED-1


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


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.



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

1. Determine to the best of your technical ability thatthe P.C. board is the most likely component caus-ing the failure symptom.

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

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

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

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

• If you donʼt have a wrist strap,touch an unpainted, grounded,part of the equipment frame.Keep touching the frame to pre-vent static build-up. Be sure notto touch any electrically live partsat the same time.

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

• Remove the P.C. Board from the static-shieldingbag and place it directly into the equipment. Donʼtset the P.C. Board on or near paper, plastic orcloth which could have a static charge. If the P.C.Board canʼt be installed immediately, put it back inthe static-shielding bag.

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

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

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

NOTE: It is desirable to have a spare (known good)P.C. board available for P.C. 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 P.C. board and substituteit with 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.

P.C. BOARD TROUBLESHOOTING PROCEDURES

ATTENTIONStatic-SensitiveDevicesHandle only atStatic-SafeWorkstations

Reusable ContainerDo Not Destroy

WARNING

E-3TROUbLESHOOTINGE-3


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

PRObLEMS(SYMPTOMS)

Major Physical or ElectricalDamage is Evident

The Machine is dead- The Inputcontactor does not operate.

POSSIbLECAUSE

Contact the Lincoln Electric ServiceDept. (216) 383-2531 or 1-888-935-3877

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.

4. Rectifier bridge may be defec-tive.

5. VRD P.C. board may be defec-tive.

RECOMMENDEDCOURSE OF ACTION

OUTPUT PRObLEMS


CAUTION

Observe all Safety Guidelines detailed throughout this manual




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






CAUTION


PROBLEMS(SYMPTOMS)

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

Red and Green lights do not comeon for approximately 5 secondswhen switching to or powering upin CC mode.

Both red and green lights stay onin CC mode well past the 5 secondpretest time.

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.

6. If machine functions properly in CV modes but not in CC mode, check for loose connections at VRD P.C. board.

1. Check for faulty mode switch.

2. Check for loose connections atVRD P.C. board.

3. Possible bad VRD P.C. Board.

1. Check to make sure output isnot shorted (electrode touchingwork).

2. If using an across the arc WireFeeder, remove the clamp fromthe output stud until after the 5second pretest is complete.

3. Uncoil output cables.


OUTPUT PROBLEMS





CAUTION


PROBLEMS(SYMPTOMS)

Machine has maximum weld out-put and no control.

VRD passes self test and greenlight is on, but machine will notWeld.

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).

1. Too much cable inductance.

• Uncoil output cables, shortencable length, or wrap work andelectrode cables together.

2. Too much cable.

• Maximum cable length (workand electrode) is approximately300 feet.

3. Buildup on stick electrode.Clean or replace electrode.

4. Possible shorted bridge rectifier,if pilot light is off.

5. Fault detected after self test.Cycle power to reset machine.


OUTPUT PROBLEMS





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





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





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 VRD.


OUTPUT PROBLEMS





CAUTION


PROBLEMS(SYMPTOMS)

Poor arc starting when the IDE-ALARC® DC-600 VRD 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 VRD. Ifproblem is resolved check forexternal short between weldingcables. Also check controlcable (#75, #76, & #77) forgrounds or shorts.


WELDING PROBLEMS





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-600VRD.

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


P.C. BOARD TROUBLESHOOTING GUIDEFIRING P.C. BOARD

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

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

3. If all voltages are present, turn power off, and plugP5 back into J5. Turn power back on. If LEDʼs arestill “OUT”, replace Firing P.C.B.

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

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

6. LEDʼs 1 through 6 indicate gate signals are beingsent to the main SCRʼs 1 through 6 respectively. IfLED 5 (located on Control Board) is “ON”, alongwith LEDʼs 7, 8, and 9 (on Firing P.C.B), and LEDʼs1 through 6 are “OFF”, check to make sure lead231 between Control board and Firing board isnot broken

7. If any one of LEDʼs 1 through 6 are “OFF” andLEDʼs 7, 8, and 9 are “ON”, replace the FiringP.C.B.

P.C. 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.





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 P.C.B.

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

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

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

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

LED that was off

789

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





CAUTION

CHECKING POWER ON/OFF SWITCH (S1)

1. Turn off the machine input power (" o "position).

SW1 has 115 volts across it when the input poweris connected.

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

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

" o "

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

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

CHECKING OUTPUT CONTROL RHEO-STAT ON MACHINE (R1)

1. Turn machine off (" o " position).

2. Remove the screws from the hinged control paneland open the panel.

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

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

5. Exercise caution to avoid damaging rheostat tabs.

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

CONNECTING REMOTE OUTPUTCONTROL RHEOSTAT TO THE MACHINE

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

CHECKING REMOTE OUTPUT CONTROLRHEOSTAT

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

P.C. BOARD TROUBLESHOOTING GUIDEVRD P.C. BOARD

1. LEDʼs 4 and 5 indicate power being supplied to theP.C. board from the 42 volt winding on the maintransformer (T1), but only when the machine is inCC mode. If LED 4 and 5 are not “ON” while in CCmode, turn the machine off, check the wiring backto the 42V transformer winding and check the modeswitch. If the LEDʼs are on when the machine is inCV mode then a wiring error exists. (For Codes11598, 11613 only)

2. With the power on, change mode switch from CV toCC. LED 2 must be ON for the initial 5 seconds,and then LED 3 should turn “ON”. LED 3 indicatesthat the machine is ready to weld. LED 3 also indi-cates when 48V has been exceeded by turning“OFF” until the power is cycled.

3. When LED 3 is “ON”, LED 1 should then turn “ON”when the electrode touches the work.

F-1DIAGRAMSF-1


NO

TE

:T

his

diag

ram

is fo

r re

fere

nce

only

. It

may

not

be

accu

rate

for

all m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a

part

icul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pane

ls.

If th

e di

agra

m is

ille

gibl

e, w

rite

to th

e S

ervi

ce D

epar

tmen

t for

a r

epla

cem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.

F-2DIAGRAMSF-2


NO

TE

:T

his

diag

ram

is fo

r re

fere

nce

only

. It

may

not

be

accu

rate

for

all m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a

part

icul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pane

ls.

If th

e di

agra

m is

ille

gibl

e, w

rite

to th

e S

ervi

ce D

epar

tmen

t for

a r

epla

cem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.

F-3DIAGRAMSF-3


NO

TE

:T

his

diag

ram

is fo

r re

fere

nce

only

. It

may

not

be

accu

rate

for

all m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a

part

icul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pane

ls.

If th

e di

agra

m is

ille

gibl

e, w

rite

to th

e S

ervi

ce D

epar

tmen

t for

a r

epla

cem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.

F-4DIAGRAMSF-4


NO

TE

:T

his

diag

ram

is fo

r re

fere

nce

only

. It

may

not

be

accu

rate

for

all m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a

part

icul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pane

ls.

If th

e di

agra

m is

ille

gibl

e, w

rite

to th

e S

ervi

ce D

epar

tmen

t for

a r

epla

cem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.


F-5DIAGRAMSF-5

S

2040

9

1-28

-94

CO

NN

EC

TIO

N O

F L

N-7

42 T

O T

HE

DC

-600

VR

D P

OW

ER

SO

UR

CE

Onl

y qu

alif

ied

pers

ons

shou

ld in

stal

l, us

e or

serv

ice

this

mac

hine

.

ELECTRODE

CABLE

-+

14

PIN

AMPHENOL

PO

WE

R S

OU

RC

E

LIN

CO

LN

TO

WORK

LN

-74

2W

IRE

FE

ED

ER

Pow

er S

ourc

e be

fore

con

nect

ing

the

wir

e fe

eder

.

Turn

off

(0)

the

pow

er s

wit

ch o

n th

e W

eldi

ng

AND

14-P

IN CABLE

PLUG,

REAR

VIEW

AND

14-P

IN CABLE

PLUG,

FRONT

VIEW

K=42

C=2

D=4

E=77

F=76

G=75

H=21I=41

K=42

I=41 H=21

G=75

F=76

E=77

D=4

C=2

PIN C D E F G H I K

42

41

21

75767742

LEAD

42V

AC

42V

AC

WORK

OUTPUT

CONTROL

OUTPUT

CONTROL

OUTPUT

CONTROL

TR

IGGER

CIRCU

IT

TR

IGGER

CIRCU

IT

(SEE

APPROPR

IATE

WIR

ING

DIAGRAM)

FUNCT

ION

FUNCT

IONS

ARE

LISTED

FOR

REFERENCE

ONLY

AND

EACH

MA

Y OR

MA

Y NOT

BE

PRESENT

IN

YOUR

EQU

IPMENT.

14-SOCKET

BOX

RECEPTACLE,

FRONT

VIEW

14-SOCKET

BOX

RECEPTACLE,

REAR

VIEW

LN-742

INPUT

CABLE

ASSEMBLY

N.C.

PINS

NOT

LISTED

ARE

NOT

CONNECTED

ON

CABLE.

N.A.

WELD

ING

CABLE

MUST

BE

SIZED

FOR

CURRENT

AND

DUT

Y C

YCLE

OF

APPL

ICAT

ION.

N.B.

DIAGRAM

SHOWS

ELECTRODE

POS

ITIVE.

TO

CHANGE

POLAR

ITY, TURN

POWER

"OFF",

REVERSE

ELECTRODE

AND

WORK

CABLES

AT

POWER

SOURCE

AND

SET

WIRE

FEEDER

VOL TMETER

POLAR

ITY

SW

ITCH

ON

POWER

SOURCE

TO

PROPER

POLAR

ITY.

N.D.

IF

US

ING

K589-1, REMOTE

CONTROL

KIT,

SET

POWER

SOURCE

CONTROL

SW

ITCH

TO

"REMOTE" POS

ITION.

N.D.

F-6DIAGRAMSF-6


N.C.

Tape up

bolted connectio

n if

lead

#21

is e

xtended.

N.D.

Connect

the

control

cab

le ground

lead

to the fram

e term

inal

marked

near

the

pow

er source term

inal

strip.

The

pow

er

source

grounding

terminal

(marked

and

located near

the

pow

er

source

input power

connections) must be

properly connected to

electrical

ground per the power

source operating manua

l.

N.E.

If an

optiona

l rem

ote vo

ltage

control

is used,

connect

it to

this

term

inal

strip.

N.A.

Welding

cab

les must be

of proper

capacity

for

the

current

and

duty cycle of

immediate

and

future applications.

See

LN-7

Operatin

g Manua

l for

proper sizes.

N.B.

If LN

-7 is

equipped with

a meter

kit,

extend LN

-7 control

cab

le

suitable for the instal

latio

n. A

n S16586-

[LENGTH

] remote

voltage

sensing

work

lead

may

be ordered for this

purpose.

Connect

it directly

to the work piece independent of

the

welding

work cable connectio

n. For

convenience, this

extended #21

lead

should be

taped

to the welding

work

lead.

(If

the

length

of

welding

work cable is

short,

less

than 25

feet,

and

connections

can

be expected

to be

reliable,

then contro

l cab

le le

ad #21

does

not

need to

be extended

and

can

be direct

ly connected

to

terminal

#21

on the term

inal

strip.

Note that

this is

not

the

preferred

connection because it adds

error

to the LN

-7 voltmeter

Abo

ve diagram

sho

ws electro

de con

nected

positive. To

cha

nge po

larity,

turn

pow

er off,

reverse the electro

de and

work

lead

s at

the po

wer

414

231

3275

7677

NEGAT

IVE

POS

ITIVE

32 31 2 4 GND

21

N.A.

N.D.

ELECTRODE

CABLE

TO

WIRE

FEED

UN

IT

TO

WORK

POWER

SOURCE

N.E.

N.F.

reading.)

N.F.

If le

ad #21

is to

be conn

ected to

the term

inal

strip,

con

nect

to th

e #2

1 term

inal

that

matches

work po

larity.

This

con

nection must b

e chan

ged whe

never the

electrode

polarity

is

chan

ged.

Only

qua

lifie

d pe

rson

s sh

ould

inst

all,

use

or

serv

ice

this

mac

hine

.

Do n

ot o

pera

te w

ith c

over

s re

mov

ed.

Disc

onne

ct p

ower

sou

rce

befo

re

serv

icin

g.

Do n

ot to

uch

elec

trica

lly li

ve p

arts

.LN-7

TO

INPUT

CABLE

PLUG

LN-7

CONTROL

CABLE

21-

21

FOR

CONTROL CABLE

WITH

14 P

INMS-T

YPE

PLU

G CONNECTOR

OR

FOR

CONTROL CABLE

WITH

TERM

INAL STR

IP

LEAD

CONNECTORS

CONTROL CABLE

S22

976

source

and

position

the sw

itch on

wire

feed

er (if e

quippe

d )

to prope

r polarity. A

lso refer to no

te N.F.

N.B. &

N.C.

14-P

IN

RECEPTA

CLE

lead

#21

from

control

cab

le with

terminal

strip

connectors or

from

14-pin

receptacle using #14 AWG

or

larger

insu

lated wire physical

ly

21+

REMOTE

VOLTAGE

SENS

ING

LEAD

10-30-98

F

N.G.

N.G.

Illustratio

n does

not

necessari

ly represent

actua

l position

of

for more inform

ation.

CO

NN

EC

TIO

N O

F L

N-7

TO

TH

E D

C-6

00 V

RD

PO

WE

R S

OU

RC

E

ap

prop

riate

outpu

t studs. R

efer

to pow

er source op

erating man

ual

For

proper setting of

switches on

pow

er source,

see power

source operating manua

l.

F-7DIAGRAMSF-7


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

DC

-60

0 V

RD

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


F-9DIAGRAMSF-9


F-10DIAGRAMSF-10


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

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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

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

remove fumes from breathing zone.

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

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

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

teur pour ôter les fumées des zonesde travail.

� Vermeiden Sie das Einatmen vonSchweibrauch!

� Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

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

remover fumo da zona respiratória.

� Turn power off before servicing.

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

� Débranchez le courant avant l’entre-tien.

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

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

serviço.� Não toque as partes elétricas nuas.

� Do not operate with panel open orguards off.

� No operar con panel abierto oguardas quitadas.

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

� Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

� Mantenha-se afastado das partesmoventes.

� Não opere com os paineis abertosou guardas removidas.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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

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

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

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

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

� Insulate yourself from work andground.

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

� Aislese del trabajo y de la tierra.

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

� Isolez-vous du travail et de la terre.

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

� Isolieren Sie sich von denElektroden und dem Erdboden!

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

� Isole-se da peça e terra.

� Keep flammable materials away.

� Mantenga el material combustiblefuera del área de trabajo.

� Gardez à l’écart de tout matérielinflammable.

� Entfernen Sie brennbarres Material!

� Mantenha inflamáveis bem guarda-dos.

� Wear eye, ear and body protection.

� Protéjase los ojos, los oídos y elcuerpo.

� Protégez vos yeux, vos oreilles etvotre corps.

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

� Use proteção para a vista, ouvido ecorpo.

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •

Documents

Operator’s Manual IDEALARC DC600 VRD · 5/16/2018 · ELECTRIC SHOCK CAN KILL. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on