lincoln dc600 Service Manual
IDEALARC DC-600
World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel (216) 481-8100
For use with machines having Code Numbers:
9773MSP
9774
9776M
9778M
9779M
9780M
9793MSP
9910M
SVM108-A
August, 1998
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
1
2
3
4
5
6
7
8
9
10
®
SAFETY
i
WARNING
WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK
can kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder or cutter
is on. Do not touch these “hot” parts with your
bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding or
cutting 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.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ting with electrodes which require special ventilation such as
stainless or hard facing (see instructions on container or
MSDS) or on lead or cadmium plated steel and other metals
or coatings which produce highly toxic fumes, keep exposure
as low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In confined
spaces or in some circumstances, outdoors, a respirator may
be required. Additional precautions are also required when
welding on galvanized steel.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or cutting or
observing open arc welding or cutting.
Headshield and filter lens should conform to
ANSI Z87. I standards.
FUMES AND GASES
can be dangerous.
3.a.Welding or cutting may produce fumes and
gases hazardous to health. Avoid breathing
these fumes and gases.When welding,
or cutting keep your head out of the fume.
Use enough
arc to keep
breathing zone. When welding or cut-
ventilation and/or exhaust at the
fumes and gases away from the
1.f.
Maintain the electrode holder, work clamp, welding or cutting
cable and
condition. Replace
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
welding or cutting machine in good, safe operating
damaged insulation.
3.b.
Do not weld or cut in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with
solvent vapors toform phosgene, a highly toxic gas, and
other irritating products.
3.c. Shielding gases used for arc welding or cutting can displace
air and cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.e. Also see item 7b.
IDEALARC DC-600
SAFETY ii
WELDING OR CUTTING
SPARKS can cause fire or
explosion.
4.a.
Remove fire hazards from the welding or cutting area.
prevent the welding or cutting sparks from start-
ing a fire. Remember that welding or cutting sparks and hot
materials from welding or cutting can easily go through small
cracks and openings to adjacent areas. Avoid welding or cutting near hydraulic lines. Have a fire extinguisher readily
available.
4.b. Where compressed gases are to be used at the job site,
special precautions 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.
4.c. When not welding or cutting, make certain no part of the
electrode circuit is touching the work or ground. Accidental
contact can cause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until the
proper 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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
If this is not possible, cover them to
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders containing the correct shielding gas for the process
used and properly operating regulators
designed for the gas and pressure used. All
hoses, fittings, etc. should be suitable for the
application and maintained in good condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
4.f.
Sparks and spatter are thrown from the welding and cutting
arc. Wear oil
heavy shirt, cuffless trousers, high shoes and a cap over
your hair. Wear ear plugs when welding or cutting out of position or in confined places. Always wear safety glasses with
side shields when in a welding or cutting area.
4.g. Connect the work cable to the work as close to the welding
or cutting area as practical. Work cables connected to the
building framework or other locations away from the welding
area increase the possibility of the welding or cutting current
passing through lifting chains, crane cables or other alternate
circuits. This can create fire hazards or overheat lifting
chains or cables until they fail.
4.h. Also see item 7c.
free protective garments such as leather gloves,
FOR ELECTRICALLY
powered equipment.
6.a.Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
IDEALARC DC-600
SAFETY iii
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
7.c.Do not add the fuel near an open flame
welding or cutting arc or when the engine is
running. Stop the engine and allow it to cool
before refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
eliminated.
____________________________________________________
7.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 or
repairing equipment.
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding or
cutting current creates EMF fields around welding or
cutting cables and welding machines
8.b. EMF fields may interfere with some pacemakers, and
welders or cutters having a pacemaker should consult their
physician before welding or cutting.
8.c. Exposure to EMF fields in welding or cutting may have other
health effects which are now not known.
8d. All welders or cutters should use the following procedures in
order to minimize exposure to EMF fields from the welding
or cutting circuit:
8.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding or cutting power source.
____________________________________________________
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
IDEALARC DC-600
SAFETY iv
PRÉCAUTIONS DE SÛRETÉ
Pour
votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles 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 tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du 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.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du 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 approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
IDEALARC DC-600
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety .........................................................................................................................i-iv
Installation ..........................................................................................................Section A
Technical Specifications .......................................................................................... A-2
Safety Precautions .................................................................................................. A-3
Select Proper Location .............................................................................................A-3
Electrical Input Connections ................................................................................... A-4
Reconnect Procedure ............................................................................................. A-5
Output Connections ....................................................................................... A-8 - A-9
Operation ............................................................................................................Section B
Safety Precautions ................................................................................................. B-2
General Description ................................................................................................ B-3
Recommended Processes and Equipment..............................................................B-3
Operational Features and Controls .........................................................................B-3
Design Features and Advantages ...........................................................................B-3
Welding Capability .................................................................................................. B-4
Controls and Settings ..............................................................................................B-5
Operating Steps ...................................................................................................... B-6
Welding Procedure Recommendations .................................................................. B-6
v
Accessories........................................................................................................Section C
Accessories.....................................................................................................C-2 - C-8
Maintenance........................................................................................................Section D
Safety Precautions ...................................................................................................D-2
Routine and Periodic Maintenance ..........................................................................D-3
3-D Exploded View...................................................................................................D-4
Theory of Operation...........................................................................................Section E
Power Supply Operation ..................................................................................E-2 - E-4
SCR Operation .........................................................................................................E-5
Troubleshooting and Repair..............................................................................Section F
How To Use Troubleshooting Guide .........................................................................F-2
PC Board Troubleshooting Procedures....................................................................F-3
Troubleshooting Guide..................................................................................F-4 – F-52
Electrical Diagrams............................................................................................Section G
Parts Manual..............................................................................................................P-282
IDEALARC DC-600
TABLE OF CONTENTS
- INSTALLATION SECTION -
INSTALLATION ......................................................... Section A
Technical Specifications ................................................ A-2
Safety Precautions ........................................................ A-3
Select Proper Location....................................................A-3
Stacking ....................................................................A-3
Tilting.........................................................................A-3
Electrical Input Connections ......................................... A-4
Fuses and Wire Sizes ...............................................A-4
Ground Connection ................................................. A-4
Input Power Supply Connections..............................A-4
Reconnect Procedure ................................................... A-5
Output Connections ...................................................... A-8
Electrode and Work Leads........................................A-8
Connection for Wire Feeder Control .........................A-9
Connection for Stick Welding and Air Carbon Arc ....A-9
SECTION A-1
IDEALARC DC-600
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - IDEALARC DC-600
INPUT - THREE PHASE ONLY
Standard Voltage
208/230/416/460/575/3/60 125/113/63/57/45
Input Current at Rated Output
RATED OUTPUT
Duty Cycle
AMPS
V
olts at Rated Amps
100%
60%
50%
Mode
Constant Current
Constant Voltage
Input Voltage /
Frequency
208/60
230/60
416/60
460/60
575/60
600
680
750
OUTPUT
Current
Range
90 to 850 Amps
70 to 850 Amps
Maximum Open
Circuit Voltage
72 VDC
55 VDC
115 VAC, 8 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
Fuse
(Super Lag)
or Breaker Size
175
175
100
90
80
Input Ampere
Rating on
Nameplate
125
113
63
57
45
Type 75
Copper Wire in
Conduit AWG
(IEC) Sizes
2 (35mm
2 (35mm2)
6 (16mm2)
6 (16mm2)
6 (16mm2)
o
C
2
)
44
44
44
Auxiliary Power
Type 75
Copper Ground
Wire in Conduit
AWG (IEC) Sizes
6 (16 mm2)
6 (16 mm2)
8 (10 mm2)
8 (10 mm2)
8 (10 mm2)
o
C
Height
30.75 in.
(781 mm.)
IDEALARC DC-600
PHYSICAL DIMENSIONS
Width
22.25 in.
(567 mm.)
Depth
39.0 in.
(988 mm.)
Weight
522 lbs.
(237 kg.)
INSTALLATION
A-3
Read entire Installation Section before installing
the IDEALARC DC-600.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel should install
this machine.
• Turn the input power OFF at the
disconnect switch or fuse box before
working on the equipment.
• Do not touch electrically hot parts.
• Always connect the IDEALARC
DC-600 grounding terminal to a good electrical earth ground.
• Set the IDEALARC DC-600 Power ON/OFF PUSH BUTTON to
OFF position when connecting power cord to input power.
__________________
DO NOT stack the IDEALARC DC-600 on another 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 (1570 pounds/712 kilograms).
2. Set the bottom machine in place.
3. Stack the second machine on top of it by
aligning the two holes in the base rails of the
second machine with the two pins on top front
of the bottom machine.
4. Repeat process for third machine.
NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
Figure A.1.
SELECT PROPER LOCATION
Place the IDEALARC DC-600 where clean air can
freely circulate in through the front intake and out
through the rear louvers. Dirt, dust, or any foreign
material that can be drawn into the machine should be
kept at a minimum. Not following these precautions
can result in the nuisance shutdown of the machine
because of excessive operating temperatures.
STACKING
Three IDEALARC DC-600 machines can be stacked.
DO NOT stack more than three machines in one
grouping.
STACKING HOLE
STACKING PINS
FIGURE A.1 - Stacking IDEALARC DC-600
machines
TILTING
The IDEALARC DC-600 must be placed on a
stable, level surface so it will not topple over.
IDEALARC DC-600
A-4
Y
INSTALLATION
ELECTRICAL INPUT CONNECTIONS
Before installing the machine, check that the input supply voltage, phase, and frequency are the same as the
machine’s voltage, phase, and frequency as specified
on the machine’s rating plate on the Case Front
Assembly Control Panel. Input power supply entry is
through the hole in the Case Back Assembly. See
Figure A.2 for the location of the machine’s input cable
entry opening, Input Contactor (CR1), and reconnect
panel assembly for dual voltage machines.
FIGURE A.2 - Rear Panel
INPUT SUPPLY
CABLE ENTRY
OPENING
CONTACTOR (CR1)
INPUT
RECONNECT
PANEL ASSEMBLY
GROUND CONNECTION
Ground the frame of the machine. A ground
terminal marked with the symbol ( ) is located inside
the Case Back of the machine near the input contactor.
Access to the Input Box Assembly is at the upper rear
of the machine. See your local and national electrical
codes for proper grounding methods.
INPUT POWER SUPPLYCONNECTIONS
A qualified electrician should connect the input power
supply leads.
1. Follow all national and local electrical codes.
2. Follow Input Supply Connection Diagram located
on the inside of the machine.
3. Use a three-phase line.
4. Remove Input Access Door at upper rear of
machine.
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or thermal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in “nuisance” tripping caused by inrush current even when
machine is not being used for welding at high output
currents.
Use input and grounding wire sizes that meet local
electrical codes or see the Technical Specifications
page in this manual.
5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
terminals in the Input Box Assembly. See Figure
A.3.
INPUT
CONTACTOR (CR1)
INPUT POWER SUPPLY
CABLE WITH BUSHING
OR BOX CONNECTOR
RECONNECT
PANEL ASSEMBL
FIGURE A.3 - Input Power Supply
Connections
IDEALARC DC-600
RECONNECT PROCEDURE
Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine’s rating
plate. Before installing the machine, check that the
Reconnect Panel in the Input Box Assembly is connected for the proper voltage.
To reconnect a multiple voltage machine to a different
voltage, remove input power and change the position
of the reconnect board on the Reconnect Panel.
Follow The Input Connection Diagram located on the
inside of Case Back Input Access Door. These connection diagrams for the following codes are listed
below.
1. For codes 9773MSP, 9910M, 9776M, 9780M, see
Figure A.4.
CAUTION
Failure to follow these instructions can cause immediate failure of components within the machine.
__________________
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
LINES
INPUT
L3
L2
L1
GND
H3
W
V
CONTACTOR
U
H1
PILOT
TRANSF.
CRI
H2
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
2.
LEAST 600 VOLT INSULATION.
CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
3.
THE CRI CONTACTOR AS SHOWN.
CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
4.
MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
5.
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
REMAINING HEX NUTS IN PLACE.
2. For code 9778M, see Figure A.5.
3. For code 9779M, see Figure A.6.
4. For code 9774, see Figure A.7.
5. For code 9793MSP, see Figure A.8.
6. For codes not listed, see the Input Connection
Diagram pasted on the inside of the Case
Back Input Access Door.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
LINES
INPUT
L3
L2
L1
GND
H2
W
V
CTOR
U
H1
CRI
PILOT
TRANSF.
H3
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
2.
LEAST 600 VOLT INSULATION.
CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
3.
THE CRI CONTACTOR AS SHOWN.
CONNECT TERMINAL M A RKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
4.
MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
5.
FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines
A-6
LINES
INPUT
LINKS
LINES
INPUT
LINKS
L3
L2
L1
GND
L3
L2
L1
GND
H4
H3
INSTALLATION
CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)
W
V
CONTACTOR
U
H1
W
V
CONTACTOR
U
H1
CRI
PILOT
TRANSF.
CRI
PILOT
TRANSF.
H3
H2
CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.
H4
H2
CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE
POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUM
CLEARANCE TO THE LINKS. INSTA LL AND TIGHTEN ALL OF TH E HEX NUTS.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL M A RKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,
LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
LINES
INPUT
LINKS
L3
L2
L1
GND
H2
W
V
CONTACTOR
U
H1
CRI
PILOT
TRANSF.
H4
H3
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL M A RKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines
CONNECTION FOR 380/460 VOLTAGES
H2
LINES
INPUT
GND
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN
ALL HEX NUTS
L3
L2
L1
H1
H3
W
V
CONTACTOR
U
CRI
TAPE
LINK
CONNECTION FOR 500/575 VOLTAGES
H3
GND
L3
L2
L1
H1
LINES
INPUT
1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS
H2
CRI
W
V
CONTACTOR
U
TAPE
LINK
FIGURE A.6-Reconnect Panel Board Positions for 380/460, 500/575 VAC Machines
IDEALARC DC-600
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. 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.
LINES
INPUT
L3
L2
L1
GND
W
V
CONTACTOR
U
CRI
FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines
FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines
A-8
INSTALLATION
OUTPUT CONNECTIONS
See Table A.1 for recommended IDEALARC DC-600 cable sizes for combined lengths of electrode and work
cables.
TABLE A.1
IDEALARC DC-600 Cable Sizes for Combined Lengths of Electrode and Work Cable (Copper)
at 100% Duty Cycle
Cable SizeParallel CablesCable Length
Lengths up to 150 ft. (46m)
Connect Electrode and Work Leads to Output
Terminals.
1. Set the ON/OFF PUSH BUTTON to OFF.
2. Locate the retractable strain relief loops directly
below the output terminals in the lower right and
lower left corners of the Case Front Assembly.
See Figure A.9.
3. Pull out the retractable strain relief loops.
1/0 (53mm
2
2
2/0 (67mm
3/0 (85mm
2
)2
2
)150 ft.(46m) to 200 ft (61m)
2
)200 ft.(61m) to 250 ft.(76m)
4. Insert the electrode lead through the loop directly
below the desired polarity (positive or negative).
Pull through enough cable to reach the output
terminals.
5. Connect electrode lead to the desired terminal
(positive/negative).
6. Tighten the output terminal nut with a wrench.
7. Connect the work lead to the other output
terminal following steps 4-6.
IDEALARC DC-600
FIGURE A.9 - Output Terminals.
Connection For Semi-Automatic or Automatic
Wire Feeder Control
NOTE: See the ACCESSORIES Section of this manual for specific instructions on connecting the following
semi-automatic and automatic wire feeders:
• LN-7
• LN-8
• LN-9
Semi-Automatic Wire Feeders
}
1. Set ON/OFF PUSH BUTTON to OFF.
2. Locate and open the hinged access door on the
Front Case Assembly.
3. If necessary, disconnect all wire feeder control
cable connections from the DC-600 terminal strip.
4. Remove the leads from the unit by pulling them
through and out of the strain relief loops.
• NA-3
• NA-5
•LT-7
• LT-56
Connection for Stick Welding and Air/Carbon
Arc Cutting Operation
Automatic Wire Feeders
}
Tractors
}
WARNING
THE OUTPUT TERMINALS ARE ENERGIZED AT ALL
TIMES WHEN THE IDEALARC DC-600 IS CONNECTED FOR STICK WELDING AND AIR/CARBON
ARC CUTTING.
__________________
5. Connect a jumper wire from terminal #2 to terminal
#4 on the terminal strip.
6. Set the Welding Mode Switch to the VV position for
both stick welding and air/carbon arc cutting.
NOTE: To use the IDEALARC DC-600 for both stick
welding / air/carbon arc cutting, AND semi-automatic /
automatic welding, the optional Multi-Process Switch
(K804) must be used. See the ACCESSORIES
Section of this manual for instructions on installing and
using the Multi-Process Switch. When the MultiProcess Switch is not used, all control, work, and electrode leads from semi-automatic or automatic wire
feeders must be disconnected from the IDEALARC
DC-600 before connecting the machine for stick welding or air/carbon arc cutting.
TABLE OF CONTENTS
- OPERATION SECTION -
OPERATION ....................................................................... Section B
Safety Precautions ................................................................. B-2
General Description ............................................................... B-3
Recommended Processes and Equipment..............................B-3
Operational Features and Controls .........................................B-3
Design Features and Advantages ...........................................B-3
Welding Capacity ................................................................... B-4
Controls and Settings ..............................................................B-5
Operating Steps ..................................................................... B-6
Remote Control of Machine Operation.....................................B-6
Welding Procedure Recommendations ...................... B-6 Ñ B-9
Semi-Automatic and Automatic Wire Feeding
with a DC-600 and Wire Feeders.............................................B-7
NA-3 Automatic Wire Feeder.............................................B-7
NA-5 Automatic Wire Feeder.............................................B-9
LN-8 Semi-Automatic Wire Feeder....................................B-9
LN-7 & LN-9 Semi-Automatic Wire Feeders......................B-9
SECTION B-1
IDEALARC DC-600
OPERATING INSTRUCTIONS
Read and understand entire section before operating machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating
gloves.
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
GENERAL DESCRIPTION
The IDEALARC DC-600 is an SCR controlled three
phase welding and cutting power source. It uses a single range potentiometer to control:
OPERATIONAL FEATURES AND
CONTROLS
The IDEALARC DC-600 comes with the following
standard controls:
• Submerged Arc Semi-Automatic or Automatic
Welding
• Open Arc Semi-Automatic or Automatic Welding
• Stick Welding (Standard on All Machines)
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to
3/8” Diameter)
The IDEALARC DC-600 has a three-position Welding
Mode Switch to enable the user to operate in one of
three modes:
• Constant Voltage (CV) Innershield
• Constant Voltage (CV) Submerged Arc
• Variable Voltage (VV - Constant Current)
Submerged Arc
The IDEALARC DC-600 can be easily connected to
wire feeding equipment, including:
• Semi-automatic wire feeders LN-7, LN-8, and
LN-9
• Automatic wire feeders NA-3 and NA-5
• Tractors LT-56 and LT-7
The optional Multi-Process Switch allows the user to
switch between semi-automatic or automatic welding
and stick welding or air/carbon arc cutting without disconnecting the wire feeder equipment control, electrode, and work leads.
• ON/OFF PUSH BUTTON
• OUTPUT CONTROL POTENTIOMETER
• OUTPUT CONTROL SWITCH (Remote or
Machine Control)
• WELDING MODE SWITCH
• CONTROL CIRCUIT POLARITY SWITCH
• POWER SOURCE PILOT LIGHT
• DC AMMETER (OPTIONAL)
• DC VOLTMETER (OPTIONAL)
DESIGN FEATURES AND
ADVANTAGES
The following list of design features will help you
understand the machine’s total capabilities and how
you can take advantage of them to get maximum use
of your machine.
• Excellent arc characteristics for optimum constant
voltage submerged 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 continuous control.
• Output Control Switch that provides simple switching from local to remote control.
• Red neon pilot light to confirm that the Input
Contactor is energized.
RECOMMENDED PROCESSES AND
EQUIPMENT
The IDEALARC DC-600 is recommended for the following welding or cutting processes within its output
capacity of 70 amps to 850 amps in the Constant
Voltage mode and 90 amps to 850 amps in the
Variable Voltage (Constant Current) mode:
• Submerged Arc Semi-Automatic or Automatic
Welding
• Open Arc Semi-Automatic or Automatic Welding
• Stick Welding (Standard on All Machines)
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to
3/8” Diameter)
• Auxiliary power source to provide 115-volt AC
power (1000 VA) to wire feeding equipment.
• Multi-functional terminal strip for easy connection
of wire feeding control cables and switching
between CV Innershield and CV Submerged Arc
welding when using the Dual Process or Dual
Procedure Kits.
• Recessed output terminals to avoid any person or
object from accidentally coming into contact with
the output terminals and labeled positive and negative for easy identification.
• Thermostatically protected power source.
• Electronic protection circuit to protect power
source against overloads.
• Input line voltage compensation to provide an
essentially constant output.
• SCR electronically controlled welder output provides extra long life, especially for highly repetitive
welding applications.
• Three circuit solid state control system provides
maximum performance and circuit protection.
• Low profile case provides maximum use of space.
• Convenient access to all controls.
• Output lead strain relief loops to prevent terminal
and cable damage.
• Easily removed case side, even when stacked.
• Outdoor operation because enclosure is designed
with air intake louvers that keep dripping water
from entering the unit. Transformer, SCR bridge,
and choke have special corrosion resistant paint
for added protection.
_____________________________________
WELDING CAPABILITY
The IDEALARC DC-600 has the following duty cycle ratings:
If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal
operating temperature.
Duty Cycle
50%
(Based on 10 min.)
60%
(Based on 10 min.)
100%
Amps Volts Hertz
750
680
600
44
44
44
50/60
50/60
50/60
_____________________________________
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the Case Front Assembly of the IDEALARC DC-600. See
Figure B.1 for the location of each control.
AMMETER
(optional)
5.
CONTROL CIRCUIT
VOLTMETER
8.
(optional)
5
4
3
2
1
2.
POLARITY SWITCH
FIGURE B.1 - CONTROL PANEL KEYS
1. ON/OFF PUSH BUTTON: This push button turns
the machine ON or OFF.
2. OUTPUT CONTROL POTENTIOMETER: This
control provides tapered, continuous control of the
machine output. The control can be rotated from
minimum to maximum while machine is under load
to adjust the machine output.
WELDING MODE
3. 4.7.
SWITCH
6
7
8
9
10
OUTPUT CONTROL
SWITCH
ON/OFF
1.
PUSH
BUTTON
POWER
6.
SOURCE
PILOT
LIGHT
OUTPUT CONTROL
POTENTIOMETER
5. CONTROL CIRCUIT POLARITY SWITCH: This
toggle switch is used to set power source voltage
sensing polarity to match the polarity to which the
electrode is connected to the machine. This provides the correct polarity at the terminal strip for
correct operation of the automatic wire feeding
equipment powered by the auxiliary power from
the power source.
3. WELDING MODE SWITCH: This toggle switch is
used to select the proper welder performance
characteristics for the process being used. There
are three modes: CV (Constant Voltage)
Innershield, CV (Constant Voltage) Submerged
Arc, and VV (Variable Voltage) CC (Constant
Current) Submerged Arc.
4. OUTPUT CONTROL SWITCH: This toggle switch
is used to switch between "Output Control at DC600" for local control of machine output and
"Output Control Remote" for remote control of
machine output.
6. POWER SOURCE PILOT LIGHT: The red neon
light glows when the power source input contactor
is energized.
7. AMMETER: An optional ammeter is
available.
8. VOLTMETER: An optional voltmeter is
available.
OPERATING STEPS
The following procedures are for using the IDEALARC DC-600 in the local control mode of operation.
For remote control of the machine, see the Remote
Control of Machine Operation section.
Before operating the machine, make sure you have all
materials needed to complete the job. Be sure you are
familiar with and have taken all possible safety precautions before starting work. It is important that you
follow these operating steps each time you use the
machine.
REMOTE CONTROL OF MACHINE
OPERATION
The toggle switch on the control panel labeled “Output
Control at DC-600” — “Output Control Remote” gives
the operator the option of controlling the machine output from a remote location. If in the Remote position a
wire feeder with remote control capabilities or a remote
control device such as a K775 must be connected to
terminals 75, 76, and 77. Refer to Accessories Section
for wire feeder remote information.
1. Turn on the main AC power supply to the machine.
2. Set the CONTROL CIRCUIT POLARITY SWITCH
to the appropriate position.
- Set toggle to "Electrode Negative" position if the
electrode is connected to the negative (-) output
terminal.
- Set toggle to "Electrode Positive" position if the
electrode is connected to the positive (+) output
terminal.
3. Set the WELDING MODE SWITCH to welding
process being used.
- CV Innershield
- CV Submerged Arc
- VV (CC)
4. Push the ON/OFF PUSH BUTTON to the ON position
- The red neon light glows.
- The fan starts.
5. Set Output Control Potentiometer to desired voltage or current.
6. Make the weld (NOTE: Terminal #2 and #4 must
be connected together to energize the machine
output).
WELDING PROCEDURE
RECOMMENDATIONS
Select Welding Mode Switch position based on type of
welding to be done.
1. Innershield Welding/Other Open Arc Processes:
Use the CV Innershield mode.
2. Submerged Arc Welding: Use the CV Submerged
Arc mode. If performing high speed welding,
switch between the CV Submerged Arc and the CV
Innershield mode and use the mode that produces
the best welding results.
3. Air/Carbon Arc Cutting / Stick Welding / High
Current, Large Puddle Submerged Arc Welding:
Use the VV (CC) mode. When the IDEALARC DC600 is used for Air/Carbon Arc cutting, the OUTPUT CONTROL POTENTIOMETER should be set
to "9" initially. Based on the size of the carbon
being used or the process, turn the potentiometer
to a lower setting as required by the process. You
can use carbon rods up to 3/8" in diameter at currents as high as 750 amps with excellent arc control. The welder protection circuit protects the
machine from extremely high short circuiting pulses.
OPERATION
B-7
SEMI-AUTOMATIC AND
AUTOMATIC WIRE FEEDING WITH
A IDEALARC DC-600 AND WIRE
FEEDERS
When using the IDEALARC DC-600 with semi-automatic or automatic wire feeding equipment and for
stick welding or air/carbon arc cutting, it is recommended that the optional MULTI-PROCESS SWITCH
be used. This switch permits you to easily change the
polarity of the connected wire feeding equipment or
switch to stick welding or air/carbon arc cutting.
NA-3 AUTOMATIC WIRE FEEDER
1. Set the DC-600 Output Control Switch to Remote.
NOTE: Later model NA-3 automatic wire feeders
are capable of cold starts when the NA-3 Mode
switch is in the CV or VV(CC) mode position.
Some earlier models are capable of cold starting
only in the VV(CC) mode position. Cold starting
enables you to inch the wire down to the work,
automatically stop, and automatically energize the
flux hopper valve.
2. Set the DC-600 welding mode switch for the
desired process: CV Submerged Arc, CV
Innershield mode or VV(CC) mode.
3. Set the NA-3 mode Switch Position to either CV or
VV(CC) to match the DC-600 mode selected in
step 2.
4. Refer to the NA-3 operators manual for instructions on how to use the NA-3 in conjunction with
the DC-600.
5. Follow the following guidelines for good arc striking
detailed below for each welding mode.
GOOD ARC STRIKING GUIDELINES FOR THE NA-3
WITH THE IDEALARC DC-600 IN THE CV
INNERSHIELD, CV SUBMERGED ARC OR VV(CC)
WELDING MODES.
2. Set the NA-3 Open Circuit Voltage Control to the
same dial setting as the Arc Voltage Control. If this
is a new welding procedure, a good starting point
is to set the Open Circuit Voltage Control to # 6.
NOTE: The open circuit voltage of the
IDEALARC DC-600 varies from approximately 16
volts to 56 volts in the CV Innershield or CV
Submerged Arc modes. The open circuit voltage is
constant in the VV(CC) mode.
3. Run a test weld. Set proper current, voltage, and
travel speed.
a. For the best starting performance, the NA-
3 Open Circuit Voltage Control and Voltage
Control setting should be the same. Set the
Inch Speed Control for the slowest inch speed
possible.
b. To adjust the Open Circuit Voltage Control to
get the best starting performance, make
repeated starts observing the NA-3 voltmeter.
When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
overshooting the desired arc voltage, the Open
Circuit Voltage Control is set properly.
If the voltmeter pointer overshoots the desired voltage and then returns back to the desired voltage,
the Open Circuit Voltage Control is set too high.
This can result in a bad start where the wire tends
to "Blast off."
If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit Voltage
Control is set too low. This can cause the electrode to stub.
4. Start and make the weld.
a. Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes positive contact with the work piece.
Following are some basic arc striking techniques that
apply to all wire feed processes. Using these procedures should provide trouble-free starting. These procedures apply to single, solid wires and Innershield
wires.
1. Cut the electrode to a sharp point.
b. Hot "On the Fly" starts. For hot starts, travel
should begin before the wire contacts the work
piece.
IDEALARC DC-600
B-8
OPERATION
ARC STRIKING WITH IDEALARC DC-600 AND THE
NA-3 START BOARD
When electrical strikeouts exceed 1 3/4Ó (44.4mm) an
NA-3 Start Board may be required to improve arc striking.
When the NA-3 Start Board is used to improve arc
striking, use the following procedures:
1. Set start time at 0.
2. Set NA-3 start current and start voltage at midrange.
3. Set the NA-3 output current and voltage to the
proper settings for the welding procedure to be
used.
4. Turn the Start Board Timer to maximum.
5. Set Start Board current and voltage control.
a. Set the Start Board current control to 1 1/2 dial
numbers below that set on the NA-3 current
control.
b. Set the Start Board voltage control equal with
the NA-3 voltage control setting.
NOTE: These Start Board current and voltage settings result in a start up current that is lower than
the NA-3 current setting and approximately equal
with the NA-3 voltage setting for the desired welding procedure.
6. Establish the correct arc striking procedure with
the NA-3 Start Board timer set at maximum.
a. For the best starting performance, the NA-3
Open Circuit Voltage Control and V oltage
Control setting should be the same. Set the
Inch Speed Control for the slowest inch speed
possible.
b. To adjust the Open Circuit V oltage Control to
get the best starting performance, make
repeated starts observing the NA-3 voltmeter .
When the voltmeter pointer swings smoothly up to
the desired arc voltage, without undershooting or
overshooting the desired arc voltage, the Open
Circuit Voltage Control is set properly .
If the voltmeter pointer overshoots the desired voltage and then returns back to the desired voltage,
the Open Circuit V oltage Control is set too high.
This can result in a bad start where the wire tends
to "Blast of f."
If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit V oltage
Control is set too low . This can cause the electrode to stub.
c. Set NA-3 Start Board current and voltage as
close to the welding procedure current and
voltage as possible.
NOTE: The Start Board current and voltage
should be as close as possible to the welding procedure current and voltage, while still getting satisfactory starts.
IDEALARC DC-600
d. Set the start time to as low a time as possible
while still getting satisfactory starts.
7. Start and make the weld.
OPERATION
B-9
IDEALARC DC-600 POWER SOURCE
SETTING WHEN CONNECTED TO NA-5
WIRE FEEDER
When using the IDEALARC DC-600 with the NA-5 wire
feeder, set the controls on the IDEALARC DC-600 as
follows for the best performance:
1. Turn OFF main AC input power supply to the IDEALARC DC-600.
2. Connect the electrode cables to terminal polarity to
be used.
3. Set the CONTROL CIRCUIT POLARITY SWITCH
to the same polarity as the electrode cable connection.
4. Set the OUTPUT CONTROL SWITCH to
REMOTE.
5. Set the IDEALARC DC-600 WELDING MODE
SWITCH to the position that matches the welding
process being used.
LN-8 SEMI-AUTOMATIC WIRE FEEDER
To use the LN-8 Semi-Automatic Wire Feeder with
IDEALARC DC-600
1. Set the IDEALARC DC-600 WELDING MODE
SWITCH to either CV Innershield mode or CV
Submerged Arc mode depending on the welding
process being used.
2. Set the IDEALARC DC-600 OUTPUT
CONTROL SWITCH to the REMOTE position.
3. Set the LN-8 W elding Mode Switch to the CV position. The LN-8 Welding Mode Switch is located on
the variable voltage (CC) board.
4. Refer to the LN-8 Operator Õs Manual for instructions on how to use the LN-8.
LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
FEEDERS OR OTHER CONSTANT WIRE
FEEDERS
a. For submerged arc welding, set WELDING
MODE SWITCH TO CV SUBMERGED ARC
position.
b. For all open arc welding processes set WELD-
ING MODE SWITCH TO CV INNERSHIELD
position.
To use the LN-7, LN-9, or other constant wire feed
speed semi-automatic wire feeders with IDEALARC
DC-600
1. Set the IDEALARC DC-600 WELDING MODE
SWITCH to either CV Innershield mode or CV
Submerged Arc mode depending on the welding
process being used.
NOTE: These semi-automatic wire feeders cannot
be used in the VV(CC) mode.
2. Set the IDEALARC DC-600 OUTPUT
CONTROL SWITCH.
a. LN-7: Use either an optional K775 Remote
Control Box Assembly or set the
IDEALARC DC-600 OUTPUT CONTROL
SWITCH in the Local position.
b. LN-9: Refer to the LN-9 Operator Õs Manual for
instructions of how to use the LN-9.
IDEALARC DC-600
TABLE OF CONTENTS
- ACCESSORIES SECTION -
ACCESSORIES .................................................................. Section C
Accessories.....................................................................C-2
Multi-Process Switch ......................................................C-2
Undercarriage .................................................................C-4
Meters .............................................................................C-4
Connections for Wire Feeder Control .............................C-5
NA-3..........................................................................C-5
NA-5..........................................................................C-6
LN-8 or LN-9 .............................................................C-7
LN-7 ..........................................................................C-8
Section C-1
IDEALARC DC-600
C-2
ACCESSORIES
OPTIONS/ACCESSORIES
¥ Multi-Process Switch (K804)
¥ Remote Control Box Assembly (K775)
¥ Undercarriages (K817, K817R, K842)
Semi-Automatic and Automatic Wire Feeders
¥ LN-7
¥ LN-8
¥ LN-9
¥ NA-3
¥ NA-5
Semi-Automatic Wire Feeders
}
Automatic Wire Feeders
}
MULTI-PROCESS SWITCH
The MULTI-PROCESS SWITCH gives you the ability
to:
¥ Switch between "stick welding or air/carbon arc
cutting" and using a semi-automatic or automatic
wire feeder .
¥ Change the polarity of a semi-automatic or auto-
matic wire feeder without changing any electrical
cable connections.
See Figure C.1
The MULTI-PROCESS SWITCH has two sets of output
terminals. You connect the wire feeder unit cables to
the set of terminals on the left side of the box and the
stick or air/carbon arc cables to the set of terminals on
the right side (facing the front of the machine) as
shown in Figure C.1.
When the MULTI-PROCESS SWITCH is in the "Stick
or Air/Carbon Arc" position, only those
terminals are energized. The wire feeder nozzle or
gun and electrode are not electrically "hot" when in this
mode.
Follow these steps to install the MUL TI-PROCESS
SWITCH:
1. Confirm that the IDEALARC DC-600 ON/OFF
PUSH BUTTON is in the OFF position.
2. Disconnect main AC input power to the IDEALARC DC-600.
3. Open the terminal strip access door located on the
Case Front Assembly.
4. Remove the two front, middle screws that secure
the two side panels of the machine. See Figure
C.2.
POSITIVE
NEGATIVE
Ð
WIRE
FEEDER
CABLES
STICK OR
AIR
CARBON
ARC
+
STICK OR
AIR/CARBON
ARC CABLES
FIGURE C.1 - MULTI-PROCESS SWITCH
REMOVE SCREWS
TO MOUNT
MULTI-PROCESS
SWITCH
POSITIVE
NEGATIVE
Ð
STICK OR
AIR
CARBON
ARC
+
FIGURE C.2 - SIDE PANEL REMOVAL
IDEALARC DC-600
ACCESSORIES
C-3
5. Attach the MUL TI-PROCESS SWITCH bracket
across the front of the machine with the flange
down. Use the long, self-tapping screws and lock
washers provided. The bracket should be on the
outside of the side panel. See Figure C.3.
NOTE: If the machine does not have any holes in
the front of the machine, use the switch template
and drill two .153" diameter holes.
6. Position the MUL TI-PROCESS SWITCH at the
front of the machine. See Figure C.3.
MULTI-
BRACKET
PROCESS
SWITCH
CONTROL
LEADS
SELF TAPPING
SCREWS
(DRILL .153"
HOLE IF
NEEDED)
8. Connect the control leads from the MUL TIPROCESS SWITCH to terminals #2 and #4 on the
IDEALARC DC-600's terminal strip.
9. Position the MUL TI-PROCESS SWITCH flush with
the front of the machine about 2" lower than the
bracket. Slide the switch straight up to the bracket.
10. Check that the bottom of the switch is hooked
behind the top of the bottom louver .
11. Connect the right cable from the MUL TIPROCESS SWITCH (facing the front of the
machine) to the IDEALARC DC-600 positive (+)
output terminal. See Figure C.4.
TERMINAL
STRIP
21 4 2 31 32
75 76 77 80 81
CONTROL
LEADS
MULTIPROCESS
SWITCH
WIRE FEED
CONTROL
CABLE
FIGURE C.3 - ATTACHING THE MULTIPROCESS SWITCH BRACKET.
7. Route the MUL TI-PROCESS SWITCH control
leads through the strain-relief box connectors and
into the terminal strip. The wire feeder control
cable is routed through the strain-relief box connector also. See Figure C.3.
NEGATIVE (Ð)
OUTPUT
STUD
ELECTRODE
CABLE
WIRE
FEEDER
WORK
CABLE
Ð
WORK
ELECTRODES
JUMPER (IF NEEDED
SEE INSTRUCTIONS)
+
ELECTRODE
+
POSITIVE (+)
OUTPUT
STUD
CABLE
STICK AIR/CARBON
ARC WELDING
EQUIPMENT
WORK
CABLE
FIGURE C.4 - MULTI-PROCESS SWITCH
CABLE CONNECTIONS.
12. Connect the left cable from the MUL TI-PROCESS
SWITCH (facing the front of the machine) to the
IDEALARC DC-600 negative (-) output terminal.
See Figure C.4.
IDEALARC DC-600
C-4
ACCESSORIES
13. Connect the wire feeder electrode and work
cables. See Figure C.4.
a. Insert the wire feeder electrode and work
cables through the strain relief loop on the left
side of the IDEALARC DC-600 (facing the front
of the machine).
b. Connect the wire feeder electrode and work
cables to the electrode and work
terminals on the left side of the MUL TIPROCESS SWITCH.
NOTE: When using Dual Process Kits K317 or
K318, connect the electrode and work cables to
these terminals instead of the power source output
terminals. See connection diagrams for details.
14. Connect wire feeder control cable to the terminal
strip of the IDEALARC DC-600.
NOTE: Connect the control cable ground lead to
the frame terminal marked ( ).
NOTE: See the connection diagram for the wire
feeder being used for connection instructions.
15. Connect stick or air/carbon arc electrode and work
cable. See Figure C.4.
NOTE: The instructions above are for connecting
the stick polarity positive. To change the polarity ,
turn the IDEALARC DC-600 OFF, and reverse the
cables.
NOTE: When it is not necessary to have separate
ground cables for stick and semi-automatic or
automatic welding, connect a jumper from the
MULTI-PROCESS SWITCH "Work" terminal to the
MULTI-PROCESS SWITCH "negative" terminal.
See Figure C.4.
To operate the MUL TI-PROCESS SWITCH, refer to
the operating instructions on the switch nameplate.
UNDERCARRIAGE (K817, K817R,
K842)
The IDEALARC DC-600 is designed for use with the
Lincoln K817, K817R, or K842 Undercarriage.
Complete installation instructions are included with the
undercarriage. When any of the undercarriages are
installed, the IDEALARC DC-600 lift bail is no longer
functional. Do not attempt to lift the machine with the
undercarriage attached. The undercarriage is
designed for moving the machine by hand only .
Mechanized towing can lead to injury and/or damage
to the IDEALARC DC-600.
a. Insert the electrode and work cables through
the strain relief loop on the right side (facing
the front of the machine) of the IDEALARC
DC-600.
b. Connect the electrode cable to the "Positive"
terminal on the right side of the MUL TIPROCESS SWITCH.
c. Connect the work cable to the "Negative" ter-
minal on the right side of the MUL TIPROCESS SWITCH.
METERS
Optional factory-installed voltmeter and ammeter are
available.
IDEALARC DC-600
ACCESSORIES
C-5
CONNECTIONS FOR SEMI-AUTOMATIC OR AUTOMATIC WIRE
FEEDER CONTROL
1. Set the ON/OFF PUSH BUTTON to OFF.
2. Locate and open the hinged access door on the
Front Case Assembly.
3. Insert control cable through the strain relief box
connector and pull enough cable through to reach
the terminal strip.
4. Connect the automatic wire feeder control cable to
the terminal strip. See corresponding connection
diagram in this Section of the manual, or the
instructions included with the wire feeder .
5. Connect the wire feeder grounding wire to the
chassis ground screw marked with the symbol ( ).
NOTE: The IDEALARC DC-600 Auxiliary Power
Circuit supplies 1 15-volt AC power to the wire feeding equipment. The circuit has a 1000 volt ampere
rating. An 8-amp slow blow fuse on the machineÕ s
control panel protects the auxiliary power supply
from excessive overloads.
CONNECTING THE NA-3 IDEALARC DC-600
1. Disconnect main AC input power to the IDEALARC
DC-600.
2. Set IDEALARC DC-600 ON/OFF PUSH BUTTON
to OFF.
NA 3 WIRE
FEEDER
CONTROL
CABLE
TO
AUTOMATIC
CONTROL
BOX
77
76
75
21 4 2 31 32
Ð
NEGATIVE
TO WORK
75 76 77 80 81
+
POSITIVE
ELECTRODE
CABLE TO
AUTOMATIC
EQUIPMENT
32
31
2
4
21
GND
FIGURE C.5 - NA-3 WIRE FEEDER
CONNECTION TO THE IDEALARC DC-600
5. Extend wire feeder control cable lead # 21 so it can
be connected directly to the work piece.
a. Make a bolted connection using AWG #14 or
larger insulated wire. Tape the bolted connection with insulating tape.
b. An S-16586- X remote voltage sensing work
lead is available for this purpose.
c. Keep the # 21 lead electrically separate from
the work cable circuit and connection.
d. Tape the # 21 lead to work cable for ease of
use.
NOTE: The connection diagram shown in Figure C.5
shows the electrode connected for positive polarity . To
change polarity:
3. Connect the wire feeder control cable leads to the
IDEALARC DC-600 terminal strip as shown in
Figure C.5.
4. Connect the wire feeder control cable ground lead
to the frame terminal marked ( ).
NOTE: The IDEALARC DC-600 must be properly
grounded.
a. Set the IDEALARC DC-600 ON/OFF PUSH
BUTTON to OFF
b. Move the electrode cable to the Negative (-)
output terminal
c. Move the work cable to the Positive (+) output
terminal.
d. Set the IDEALARC DC-600 CONTROL CIR-
CUIT POLARITY SWITCH to NEGATIVE.
e. Reverse the leads at the back of the ammeter
and voltmeter on the wire feeder automatic
control box.
IDEALARC DC-600
C-6
ACCESSORIES
CONNECTING THE NA-5 TO THE
IDEALARC DC-600
NOTE: For optimum performance use the NA-5 with
IDEALARC DC-600 codes 8288 and above.
1. Disconnect main AC input power to the IDEALARC
DC-600.
2. Set the IDEALARC DC-600 ON/OFF PUSH
BUTTON to OFF.
3. Connect the wire feeder control cable leads to the
IDEALARC DC-600 terminal strip as shown in
Figure C.6.
LN8 OR LN 9
WIRE
FEEDER
CONTROL
CABLE
TO INPUT
CABLE
C
B
A
21 4 2 31 32
Ð
NEGATIVE
TO WORK
75 76 77 80 81
+
POSITIVE
ELECTRODE
CABLE TO WIRE
FEEDER
32
31
GND
2
4
21
5. Extend wire feeder control cable lead # 21 so it can
be connected directly to the work piece.
a. Make a bolted connection using AWG #14 or
larger insulated wire. Tape the bolted connection with insulating tape.
b. An S-16586- X remote voltage sensing work
lead is available for this purpose.
c. Keep the # 21 lead electrically separate from
the work cable circuit and connection.
d. Tape the # 21 lead to work cable for ease of
use.
6. Connect NA-5 wire feeder control jumpers on
Voltage Control Board. See NA-5 Operator's
Manual.
a. Connect red jumper on V oltage Control Board
to pin "S."
b. Connect white jumper on V oltage Control
Board to pin "B."
NOTE: The connection diagram shown in Figure C.6
shows the electrode connected for positive polarity . To
change polarity:
a. Set the IDEALARC DC-600 ON/OFF PUSH
BUTTON to OFF.
FIGURE C.6 - NA-5 WIRE FEEDER CONNECTION TO THE IDEALARC DC-600
NOTE: If using a K215 control cable, connect control cable leads #75, #76, and #77 to the matching
#75, #76, and #77 terminals on the terminal strip of
the IDEALARC DC- 600.
4. Connect the wire feeder control cable ground lead
to the frame terminal marked ( ).
NOTE: The IDEALARC DC-600 must be properly
grounded.
b. Move the electrode cable to the Negative (-)
output terminal.
c. Move the work cable to the Positive (+) output
terminal.
d. Set the IDEALARC DC-600 CONTROL
CIRCUIT POLARITY SWITCH to NEGATIVE.
NOTE: For proper NA-5 operation, the electrode
cables must be secured under the clamp bar on the left
side of the NA-5 Control Box.
IDEALARC DC-600
Loading...