Lincoln Electric IM10018 User Manual

IM10018-A

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IDEALARC ®DC-600 VRD

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and 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.

August, 2011

11598, 11613, 11707, 11725

DC-600 VRD

Equipped with VRD (VOLTAGE REDUCTION DEVICE)
See Operation Section for an explanation.

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

IEC 60974-1
IP23

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

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

____________________________________________________

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

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
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.

____________________________________________________

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 or repairing equipment.

____________________________________________________

1.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.

___________________________________________________

1.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.

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

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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

2.b. EMF fi elds m ay interf ere wi th some pacemak ers, a nd
welders having a pacemaker should consult their physician
before welding.

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

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

2.d.1.

Route the electrode and work cables together - Secure

them 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

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

___________________________________________________

1.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.

IDEALARC®DC-600 VRD

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet 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
area of 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
welding gun are also electrically “hot”.

3.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.

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 and
welding machine in good, safe operating condition. Replace
damaged insulation.

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

3.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.

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

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.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 observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

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

4.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.

FUMES AND GASES
can be dangerous.

5.a. Welding ma y produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding 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 within applicable OSHA PEL and
ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

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

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. 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.

5.f. Also see item 1.b.

IDEALARC®DC-600 VRD

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings 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,
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.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such 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).

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

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding 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.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e on ly compr es sed ga s 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.

7.b. Alway s keep cylin ders i n an up right position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

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

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

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

7.g. Re ad and foll ow the inst ru ctions o n c ompressed 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.

FOR ELECTRICALLY
powered equipment.

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

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

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

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

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

Refer to http://www.lincolnelectric.com/safety for additional safety information.

IDEALARC®DC-600 VRD

iv

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.

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.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
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” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

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.

IDEALARC®DC-600 VRD

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.

Thank You

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

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

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

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

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

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

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

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

Your Product”. Please complete the form and submit your registration.

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

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

WARNING

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

CAUTION

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

vi

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ............................................................................................. A-1

Safety Precautions ..................................................................................................... A-2

Select Proper Location.................................................................................................A-2

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

Stacking.................................................................................................................A-2

Tilting .....................................................................................................................A-2

Electrical Input Connections ....................................................................................... A-3

Fuses and Wire Sizes............................................................................................A-3

Ground Connection .............................................................................................. A-3

Input Power Supply Connections...........................................................................A-3

Reconnect Procedure ................................................................................................ A-4

Output Connections ................................................................................................... A-5

Electrode, Work and #21 Lead ..............................................................................A-5

Auxiliary Power and Control Connections .............................................................A-6

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precautions ............................................................................................... B-1

General Description ............................................................................................. B-2

Recommended Processes and Equipment ...........................................................B-2

Design Features and Advantages ........................................................................B-2

Welding Capability ............................................................................................... B-3

Meaning of Graphical Symbols on Case Front......................................................B-3

Meaning of Graphical Symbols on Rating Plate ....................................................B-4

Meaning of Graphical Symbol for Ground Connection ..........................................B-4

Controls and Settings ....................................................................................B-4, B-5

Auxiliary Power in MS - Receptacle.......................................................................B-5

Overload, Overcurrent and Fault Protection..........................................................B-6

VRD Voltage Reduction Device Operation............................................................B-6

Operating Steps ................................................................................................... B-7

Remote Control of Machine Operation ..................................................................B-7

Welding Procedure Recommendations ............................................................... B-7

Semi-Automatic and Automatic Wire Feeding

with a IDEALARC

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

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

________________________________________________________________________

®

DC-600 VRD and Wire Feeders .............................................B-7

vi

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

Wire Feeders and Tractors....................................................................................C-1

Field Installed Options...........................................................................................C-1

Remote Output Control (K775 or K857)..........................................................C-1

Remote Control Adapter Cable (K864) ...........................................................C-1

Undercarriages (K817P, K842).......................................................................C-1

Factory or Field Installed Options..........................................................................C-1

Multi-Process Switch (K804-1)........................................................................C-1

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

________________________________________________________________________

vii

TABLE OF CONTENTS

Page

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

Safety Precautions ................................................................................................D-1

Routine and Periodic Maintenance........................................................................D-1

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

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

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

vii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – IDEALARC®DC-600 VRD

INPUT - THREE PHASE ONLY

CODES

Standard

Voltage

100% Duty Cycle

Input Current at Rated Output

60% Duty Cycle

A-1

50% Duty Cycle

11613, 11707
11598, 11725

100% Duty Cycle

70A/13V-780A/44V (CV)
90A/24V-780A/44V (CC)

INPUT

VOLTAGE /

FREQUENCY

230
460
575
415

230/460/575/60

415/50/60

Duty Cycle

60% Duty Cycle
50% Duty Cycle

Output Range

RECOMMENDED INPUT WIRE AND FUSE SIZES

HERTZ

50/60

60
60
60

108/54/43

62

RATED OUTPUT

Amps

600
680
750

OUTPUT

Maximum Open Circuit Voltage

5V for 60 HZ models

5V for 50/60 HZ models

INPUT AMPERE

RATING ON

NAMEPLATE

108

54
43
61

TYPE 75°C

COPPER WIRE

IN CONDUIT

AWG(IEC-MM2) SIZES

30°C (86°F) Ambient

2 (34)
6 (14)

8 (8.4)

6 (14)

122/61/49

68

Volts at Rated Amperes

See the OPERATION section

information by model

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG(IEC-MM2) SIZES

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

134/67/54

73

44
44
44

Auxiliary Power

for Auxiliary Power

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

175 Amp

90 Amp
70 Amp

100 Amp

1

PHYSICAL DIMENSIONS

HEIGHT

30.75 in

781 mm

1

Also 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.

WIDTH

22.25 in
567 mm

DEPTH

39.0 in

988 mm

WEIGHT

525 lbs.

238 kg.

IDEALARC®DC-600 VRD

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

Read entire Installation Section before
installing the IDEALARC

®

DC-600 VRD.

ELECTRIC SHOCK CAN KILL.

WARNING

• 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
grounding terminal to a good electrical earth
ground.

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

DC-600 VRD

__________________

SELECT PROPER LOCATION

Place the welder where clean cooling air can freely
circulate in through the front louvers and out through
the rear louvers. Dirt, dust or any foreign material that
can be drawn into the welder should be kept at a mini­mum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
shut-downs.

STACKING

Three IDEALARC®DC-600 VRD machines can be
stacked.

DO NOT stack more than three machines in one
grouping.

DO NOT stack the IDEALARC
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.

®

DC-600 VRD on

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

STACKING HOLE

LIMIT ON STACKING

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when
lifting.

• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

• Do not stack more than three high.

• Do not stack the IDEALARC
any other machine.

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

®

DC-600 VRD on top of

IDEALARC®DC-600 VRD

STACKING PINS

TILTING

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

A-3

INSTALLATION

A-3

ELECTRICAL INPUT CONNECTIONS

Before installing the machine check that the input sup­ply voltage, phase, and frequency are the same as the
voltage, phase, and frequency as specified on the
welder Rating Plate located on the Case Back
Assembly. Input power supply entry is through the
hole in the Case Back Assembly. See Figure A.2 for
the location of the machineʼs input cable entry open­ing, Input Contactor (CR1), and reconnect panel
assembly for dual voltage machines.

INPUT SUPPLY

CABLE ENTRY

OPENING

CONTACTOR (CR1)

INPUT

RECONNECT

PANEL ASSEMBLY

INPUT POWER SUPPLY CONNECTIONS

A qualified electrician should connect the input power
supply leads.

1. Follow all national and local electrical codes.

2. Use a three-phase line.

3. Remove Input Access Door at upper rear of
machine.

4. Follow Input Supply Connection Diagram located
on the inside of the door.

5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
terminals in the Input Box Assembly by passing
them thru the three aligned .50” diameter holes in
the baffle and tighten them in the terminal connec­tors. Be sure to close the baffle by inserting the
tab into the slot in the baffle. See Figure A.3.

FIGURE A.2 - Rear Panel

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or 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.

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

CONTACTOR (CR1)

INPUT POWER SUPPLY
CABLE WITH BUSHING

OR BOX CONNECTOR

RECONNECT

PANEL ASSEMBLY

FIGURE A.3 - Input Power Supply
Connections

IDEALARC®DC-600 VRD

A-4

INSTALLATION

A-4

RECONNECT PROCEDURE

Multiple voltage machines are shipped connected to
the highest input voltage listed on the machineʼs rating
plate. Before installing the machine, check that the
Reconnect Panel in the Input Box Assembly is con­nected for the proper voltage.

CAUTION

Failure to follow these instructions can cause
immediate failure of components within the
machine.

When powering welder from a generator be sure
to turn off welder first, before generator is shut
down, in order to prevent damage to the welder

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

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

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

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

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

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

IDEALARC®DC-600 VRD

A-5

INSTALLATION

A-5

OUTPUT CONNECTIONS

See Table A.1 for recommended IDEALARC®DC-600 VRD cable sizes for combined lengths of electrode and
work cables.

TABLE A.1

IDEALARC®DC-600 VRD Cable Sizes for Combined Lengths of Copper Electrode and Work

Cable at 100% Duty Cycle

Cable SizeParallel CablesCable Length

2

Lengths up to 150 ft. (46m)

ELECTRODE, WORK AND #21 LEAD
CONNECTIONS

1/0 (53mm

2

2

2/0 (67mm

3/0 (85mm

)2

2

)150 ft.(46m) to 200 ft (61m)

2

)200 ft.(61m) to 250 ft.(76m)

A. Connect Electrode and Work Leads to

Output Terminals.

1. Set the ON/OFF toggle switch 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.6.

3. Pull out the retractable strain relief loops.

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

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

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 Proper

Terminal

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

IDEALARC®DC-600 VRD

A-6

K=42

K=42

INSTALLATION

AUXILIARY POWER AND CONTROL CON­NECTIONS

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

AUXILIARY POWER TABLE

Voltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various Models

Table for Codes 11598, 11613

Auxiliary 60 Hz 50/60 Hz
Power Models Models
Connections

At Duplex 15A No Duplex
Receptacle 115V

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

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

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

115VAC DUPLEX RECEPTACLE (60 HERTZ
MODELS ONLY)

Table for Codes 11707, 11725

Auxiliary 60 Hz 50/60 Hz
Power Models Models
Connections

At Duplex 15A No Duplex
Receptacle 115V

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

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

A-6

PIN LEAD NO. FUNCTION

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

H 21 Work Sense
I 41 42 VAC

J 31 115 VAC
K 42 42 VAC
L --- --­M --- --­N --- ---

TERMINAL STRIPS

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

(3)

Connection

(3)

(2)

The 115VAC duplex receptacle is protected by a 15
Amp circuit breaker located on the nameplate. The
receptacle is a NEMA 5-15R.

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 the
14 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 at
receptacle pins A and J. A 15 amp circuit breaker pro­tects this circuit. (See Figure A.7 for pin allocation).
Note that the 42 VAC and 115 VAC circuits are electri­cally isolated from each other.

FIGURE A.7

FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE

Pin location for Codes 11598, 11613

A=32

B=GND

L N

C=2

D=4

E=77

J=31

I=41

G=75

F=76

M

Pin location for Codes 11707, 11725

B=GND

LN

C=2

H=21

D=4

E=77

M

I=41

G=75

F=76

IDEALARC®DC-600 VRD

H=21

TERMINAL STRIP 1 (T.S.1)

Lead No. Function

75 Output Control
76 Output Control
77 Output Control

TERMINAL STRIP 2 (T.S.2)

Lead No. Function

+21

-21
41 42 VAC

4 Trigger Circuit

2 Trigger Circuit
31 115 VAC
32 115 VAC

(1)

115VAC circuit is on all models.

(2)

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

(3)

115VAC is not available at the 14 Pin connector on Codes 11707,

11725.

Work Connection (Electrode Negative)

Work Connection (Electrode Positive)

(1)

(1)

(2)

B-1

OPERATION

SAFETY PRECAUTIONS

Read this entire section of operating instructions
before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

• Do not use AC welder if your cloth­ing, gloves or work area is damp or
if working on, under or inside work­piece.

Use the following equipment:

-Semiautomatic DC constant volt­age (wire) welder.

-DC manual (stick) welder.

-AC welder with reduced voltage control.

• Do not operate with panels removed.

• Disconnect input power before servicing.

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

READ THIS WARNING, PROTECT
YOURSELF & OTHERS.

B-1

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust at the arc, or both, to
keep fumes and gases from your breathing zone
and general area.

WELDING, CUTTING and GOUG­ING SPARKS can cause fire or
explosion.

• Do not weld near flammable material.

• Do not weld, cut or gouge on contain­ers which have held flammable materi­al.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional Safety Guidelines

detailed in the beginning of this manual.

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

IDEALARC®DC-600 VRD

B-2

GENERAL DESCRIPTION

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

®

The IDEALARC
welding and cutting power source. It uses a single range potentiome­ter 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 Mode
Switch 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 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.

DC-600 VRD is an SCR controlled three phase

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 can
also 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 mode
switch that selects CV Innershield, CV Submerged Arc, or CC Stick.

®

The IDEALARC
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 provide

115VAC for these feeders; 115VAC must be obtained from terminal
strip.

DC-600 VRD can be easily connected to wire feed-

OPERATION

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

• “Tamper Resistant” design. Circuitry is built into power source, not
an exterior package which could easily be tampered with.

• No reduction of power source output rating. This feature does not
affect the rating of the power source.

• Self diagnostics upon machine power up. Indicator lights are test­ed.

• Green lamp on when weld voltage is less than 30 volts. If weld volt­age 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 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.

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

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

• DC Ammeter and Voltmeter

• 42VAC 10 Amp auxiliary power available for the wire feeder, circuit
breaker protected.

• Single MS-type (14 pin) connector for wire feeder.

• 115VAC 15 Amp auxiliary power available for the wire feeder, circuit
breaker protected.

• 115VAC 15 Amp duplex plug receptacle available on 60 Hertz mod­els, circuit breaker protected.

• Multi-functional terminal strip for easy connection of wire feeding
control cables.

• Recessed, output terminals to avoid any person or object from acci­dentally coming into contact with the output terminals and labeled "
+ " and " - " 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.

• Solid state 2 and 4 circuit for extra long life.

• Two circuit solid state control system provides maximum perfor­mance and circuit protection.

• Low profile case provides maximum use of space.

• Convenient access to all controls.

• Output lead strain relief loops to prevent terminal and cable dam­age.

• Easily removed case side, even when stacked.

• Outdoor operation because enclosure is designed with air intake
louvers that keep dripping water from entering the unit. Transformer,
SCR Bridge and choke have special corrosion resistant paint for
added protection.

DESIGN FEATURES AND ADVANTAGES

B-2

IDEALARC®DC-600 VRD

B-3

OPERATION

B-3

WELDING CAPABILITY

The 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 FRONT

Input POWER ON/OFF Switch

SYMBOL

MEANING

INPUT POWER

Pilot Light

Input power on when light is illuminated

(except for abnormal conditions).

Indicates main Transformer is operating.

OUTPUT CONTROL

ON

OFF

LOCAL/REMOTE Switch

SYMBOL

Control Of Output Voltage and

Current is Via IDEALARC®DC-600

VRD's Control Dial

Remote Control of Output Voltage

MODE Switch

CC STICK: Shielded Metal Arc

Welding (SMAW), this switch

position is also used for Air

Carbon Arc Cutting (AAC)

CV SUBMERGED ARC:

Constant Voltage Submerged

Arc Welding (SAW)

CV INNERSHIELD: Flux Cored

Arc Welding (FCAW), this switch

position is also used for Gas
Metal Arc Welding (GMAW).

MEANING

and Current

OUTPUT VOLTAGE

AND CURRENT

Clockwise Increase of Output

Voltage and Current

TERMINALS ON/REMOTE Switch

OUTPUT TERMINALS

ENERGIZED

Remote Control of Output Terminals

(Energized or Non-Energized)

Output Terminal Connections

Positive Output Terminal

Negative Output Terminal

WARNING Identification

Warning Identification

Circuit Breaker

Circuit Breaker (two breakers: 15A for

115V circuit and 10A for 42V circuit)

Thermal Protection Light

On when power source exceeds nor-

mal operating temperature.

IDEALARC®DC-600 VRD