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: 216.481.8100 FAX: 216.486.1751 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 •
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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.
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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.
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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
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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
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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
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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.
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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
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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
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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
B-4
OPERATION
B-4
MEANING OF GRAPHICAL SYMBOLS ON RATING PLATE (LOCATED ON CASE BACK)
Designates welder complies with National Electrical Manufacturers
NEMA EW 1 (100%)
Association requirements EW 1 Class I with 100% duty cycle at 600Amps output.
Three Phase Input Power
3 Phase transformer with rectified DC output
Line Connection
Gas Metal Arc Welding (GMAW)
MEANING OF GRAPHICAL SYMBOL FOR GROUND CON­NECTION
Signifies the equipment connection point for the protective earth ground
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the Case Front Assembly of the IDEALARC VRD. See Figure B.1 for the location of each control.
5
3
6
8
14
5
6
4
7
7
3
2
1
8
9
10
DC-600 VRD
9
®
DC-600
15
4
1
2
NRTL/C
Flux Cored Arc Welding (FCAW)
Shielded Metal Arc Welding (SMAW)
Submerged Arc Welding (SAW)
Designates welder complies with both Underwriters Laboratories (UL) standards and Canadian Standards Association (CSA) standards. (60 Hertz Models)
11
10
12
13
FIGURE B.1 - CONTROL PANEL KEYS
1. Input POWER ON/OFF Switch
This toggle switch turns the machine on or off. Putting the switch in the ON “ ” position ener­gizes the machineʼs input contactor applying input power to the machine. Switching the switch to the OFF “ ” position de-energizes the input con­tactor.
2. POWER Light
When the POWER switch is in the ON position the machineʼs white POWER light will illuminate. If the input contactor de-energizes the machine in an abnormal situation the pilot light will turn off. In this situation it may be necessary to reset the machine by switching the POWER switch to the OFF and then to the ON position. (See Overload, Overcurrent, and Fault Protection Section)
IDEALARC®DC-600 VRD
B-5
3. OUTPUT CONTROL
This control provides continuous control of the machineʼs output voltage and current from mini­mum to maximum (typical full pot range between 15 to 44 volts and 90 to 750 amps) as it is rotated clock-wise. Voltage or current control is deter­mined by setting of Mode Switch (CV or CC).
OPERATION
11. Terminal Strip Cover Panel
Rotate this panel to gain access to the circuits made available at the two terminal strips (T.S.1 and T.S.2). These terminal strips contains the same circuits as the 14 pin MS-receptacle. There is a box connector adjacent to this cover for rout­ing leads to the terminal strips.
B-5
4. OUTPUT TERMINALS ON/REMOTE Switch
When this switch is in the REMOTE “ ” posi­tion, the IDEALARC®DC-600 VRDʼs output termi­nals will be electrically “cold” until a remote device such as a wire feeder closes the #2 and #4 circuit in the MS-receptacle or terminal strip (T.S.2). When this switch is in the ON “ ” position the machineʼs output terminals will be electrically energized all the time.
5. LOCAL/REMOTE Switch
When this switch is set to the LOCAL “ “ posi­tion, control of the output voltage and current is via the OUTPUT CONTROL on the IDEALARC 600 VRDʼs control panel. When this switch is set to the REMOTE “ ” position, control is through a remote source such as a wire feeder via the #75, #76, and #77 leads in the MS-receptacle or terminal strip (T.S.1).
6. Mode Switch
This switch allows for selecting the welding process to be used:
CC STICK-for SMAW and AAC CV SUBMERGED ARC- for SAW CV INNERSHIELD- for FCAW and GMAW
7. 115VAC Duplex Receptacle (60 Hertz Models)
This receptacle provides up to 15 amps of 115 VAC auxiliary power.
8. 115VAC 15 Amp Circuit Breaker
This breaker protects the 115 VAC auxiliary cir­cuits located in the duplex receptacle, terminal strip (T.S.2) and MS-receptacle.
9. 42VAC 10 Amp Circuit Breaker
This breaker protects the 42VAC auxiliary circuits located in the terminal strip (T.S.2) and MS-recep­tacle.
10. 14 Pin MS-Receptacle
This connector provides easy connection for a wire feeder control cable. It provides connections for auxiliary power, output switching, remote out­put control, wire feeder voltmeter sense lead and ground. Refer to 14 Pin MS Type Receptacle in the Installation Section for information about the circuits made available at this receptacle.
®
DC-
12. Negative Output Terminal
This output terminal is for connecting a welding cable. To change welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section.
13. Positive Output Terminal
This output terminal is for connecting a welding cable. To change welding polarity and for proper welding cable size refer to Electrode and Work Cables in the Installation Section.
14. VRD Lights
When VRD is active, in CC mode, these lights illuminate based on the stud voltage while weld­ing. The green light will be on when the welding voltage is under 30 volts and the red light light will turn on when the voltage is 30 volts or greater.
15. Thermal Protection Light (Only on Codes 11707 and 11725)
An amber light on the machine control panel indi­cates when either of the two protective ther­mostats has opened. Output power will be dis­abled temporarily. Thermostat will automatically reset when the machine cools to an acceptable operating temperature.
AUXILIARY POWER IN MS-RECEP­TACLE
42 volt AC auxiliary power, as required for some wire feeders, is available through the wire feeder MS­receptacle. A 10 amp circuit breaker protects the 42 volt circuit from overloads.
On Codes 11598 and 11613, IDEALARC®DC-600 VRD machines supply 115 volt AC auxiliary power through the wire feeder receptacle. A 15 amp circuit breaker protects the 115 volt circuit from overloads.
IDEALARC®DC-600 VRD
B-6
OPERATION
OVERLOAD, OVERCURRENT, AND FAULT PROTECTION
This welder has thermostatic protection from exces­sive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the welder is subjected to an overload or loss of cooling, a thermostat will open. The input contactor will open and remain open until the machine cools; the white POWER light stays illuminated. No welding is possible during this cool down period. The machine will reset automatically when the thermostat cools.
The power source is also protected against overcur­rents in the SCR bridge assembly through an elec­tronic protection circuit. This circuit senses currents over 780 amps on the power source and opens the input contactor should the overcurrent remain for a predetermined time (the white POWER light also turns off).
The predetermined time varies with the amount of overcurrent; the greater the overcurrent, the shorter the time. The input contactor will remain open until the power source is manually started by resetting the POWER ON/OFF toggle switch.
For codes 11707 and above.
The power source is protected against overvoltage when not welding in CC mode. If the protection circuit senses voltage in excess of 49V at the studs when no welding is taking place, the POWER light will turn off. The input contactor will open up and remain open until the power source is manually restarted by toggling the ON/OFF switch.
The power source circuitry is protected from faults on leads 75, 76, or 77. If any of these leads are connect­ed to either the positive or negative output leads, the IDEALARC pletely (input contactor opens and white POWER light turns off), or will operate at minimum output thus pre­venting any damage to the IDEALARC®DC-600 VRD. If IDEALARC®DC-600 VRD shuts down, it must be manually started by resetting the POWER ON/OFF toggle switch.
®
DC-600 VRD will either shut down com-
VRD (VOLTAGE REDUCTION DEVICE) OPERATION
B-6
Whenever the CC welding mode is selected and power is turned on, or power is on and the welding mode is changed from Constant Voltage (CV) to Constant Current (CC), the VRD circuitry performs a self test for approximately five seconds. For one sec­ond the input contactor and the cooling fan will turn on, then off. With welding inhibited, the studs will be examined. Both VRD lights will be on to indicate that the machine is in self test mode.
After passing the self test, only the green light remains on and the machine is ready to weld. If the test fails, both lights will remain on and welding remains inhibit­ed. This could be caused by the stick electrode hold­er being shorted to work, or if an across the arc wire feeder, such as the LN 25, is connected to the power source.
To use a system with sense leads in CC mode on a VRD model, disconnect the feederʼs work sense lead prior to the self test. After passing the self test, recon­nect the work sense lead.
• In CC mode, the VRD will reduce the output voltage
regardless of the position of the “TERMINALS ON/REMOTE” Switch.
• The voltmeter will display zero volts until the elec­trode contacts the work and establishes the welding arc.
LED STATUS RED ON ON OFF OFF
NOTE:
Under normal circumstances, the machine will never be able to exceed 49 volts while not welding. If, under abnormal circumstances, the output voltage were to exceed 49 volts while not welding, the VRD turns the output off. The green light would be on because the voltage would be zero and the pilot light will be off, but establishing an arc would not be pos­sible. The machineʼs “POWER ON/OFF” Switch must be cycled off, then back on, to restore normal operation.
GREEN ON OFF ON
OFF
Power source is in self test mode. Output voltage is greater than 30 V. Output voltage is less than 30 V. Power source is in CV mode.
LED STATUS
The VRD electronic circuitry is designed to reduce the OCV of the power source in the Constant Current (CC) Stick welding mode only. The operation of the machine with the VRD is slightly different than the operation of a standard machine. The following describes the machine operation with the VRD installed in the DC600.
IDEALARC®DC-600 VRD
B-7
The Lincoln VRD circuit meets the requirements of AS1674.2-2007, Safety in welding and allied processes - Electrical, for Category C environments. Category C environments include coffer dams, trenches, mines, in rain, etc.
The Lincoln VRD circuit also meets recommendation of ANSI Z49.1- 2005, Safety in Welding, Cutting and Allied Processes, for use in 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 ).
OPERATION
OPERATING STEPS
The following procedures are for using the IDE­ALARC®DC-600 VRD in the local control mode of operation. For remote control of the machine, see the Remote Control of Machine Operation section.
B-7
3. Set the Welding Mode switch to welding process being used:
• CC STICK (for SMAW and AAC)
4. Turn the POWER ON/OFF Toggle Switch to the “ON” position:
• The white pilot light glows and the fan starts for 1 second.
• The machine continues the 5 second pretest indi­cated by both red and green VRD lights glowing. When the red light turns off, the pilot light turns on and the fan restarts, the machine is ready.
5. Set OUTPUT CONTROL Potentiometer to desired current.
6. Set the OUTPUT TERMINALS switch to either “ON” ( output terminals active) or “REMOTE” (out­put terminals active when #2 and #4 is closed by remote device such as wire feeder).
7. Make the weld.
REMOTE CONTROL OF MACHINE OPERATION
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.
CV MODE
1. Connect the #21 work lead to either + or - on termi­nal strip (T.S.2).
2. Turn on the main AC power supply to the machine.
3. Set the Welding Mode switch to welding process being used:
• CV SUBMERGED ARC (for SAW)
• CV INNERSHIELD (for FCAW and GMAW)
4. Turn the POWER ON/OFF Toggle Switch to the “ON” position:
• The white pilot light glows and the fan starts.
5. Set OUTPUT CONTROL Potentiometer to desired voltage.
6. Set the OUTPUT TERMINALS switch to either “ON” ( output terminals energized) or “REMOTE” (output terminals energized when #2 and #4 closed by remote device such as wire feeder)
7. Make the weld.
The toggle switch on the control panel labeled “Remote - Panel” 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.
WELDING PROCEDURE RECOMMENDATIONS
Select Welding Mode Switch position based on type of welding to be done.
1. Innershield Welding (FCAW)/MIG (GMAW)
Welding: Use the CV INNERSHIELD mode.
2. Submerged Arc Welding (SAW): 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.
CC MODE
1. Connect the #21 work lead to either + or - on termi­nal strip (T.S.2).
2. Turn on the main AC power supply to the machine.
IDEALARC®DC-600 VRD
B-8
3. Air/Carbon Arc Cutting (AAC) / Stick Welding (SMAW) / High Current, Large Puddle Submerged Arc Welding (SAW): Use the CC STICK mode. When the IDEALARC®DC-600 VRD 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-8
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 VRD IN THE CV INNERSHIELD, CV SUBMERGED ARC OR CC STICK WELDING MODES.
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.
SEMI-AUTOMATIC AND AUTOMATIC WIRE FEEDING WITH THE IDEALARC®DC-600 VRD AND WIRE FEEDERS
When using the IDEALARC®DC-600 VRD with semi­automatic 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.
To use a feeder with sense leads in CC mode on the IDEALARC®DC-600 VRD, disconnect the feederʼs work sense lead prior to the VRD self test. Reconnect the work sense lead after passing the self test.
NA-3 AUTOMATIC WIRE FEEDER
1. Set the IDEALARC®DC-600 VRD LOCAL/REMOTE Switch to REMOTE. Set the OUTPUT TERMINALS 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 CC mode posi­tion and when welding in positive polarity only. Some earlier models are capable of cold starting only in the 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 IDEALARC®DC-600 VRD welding mode switch for the desired process: CV SUBMERGED ARC, CV INNERSHIELD mode or CC STICK mode.
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 16 volts to 56 volts in the CV INNERSHIELD or CV SUBMERGED ARC modes. The open circuit voltage is essentially zero in the CC STICK mode.
3. Run a test weld. Set proper current, voltage, and travel speed.
• 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.
• 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.
®
DC-600 VRD varies from approximately
3. Set the NA-3 mode Switch Position to either CV or CC to match the IDEALARC®DC-600 VRD 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 IDE­ALARC®DC-600 VRD.
IDEALARC®DC-600 VRD
• Cold starts. For cold starts, be sure the work piece is clean and the electrode makes positive contact with the work piece.
• Hot "On the Fly" starts. For hot starts, travel should begin before the wire contacts the work piece.
B-9
ARC STRIKING WITH IDEALARC®DC-600 VRD AND THE NA-3 START BOARD
When electrical strikeouts exceed 1 3/4” (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.
OPERATION
B-9
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.
• 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.
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.
• Set the Start Board current control to 1 1/2 dial num­bers below that set on the NA-3 current control.
• 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.
• 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.
• Set the start time to as low a time as possible while still getting satisfactory starts.
7. Start and make the weld.
IDEALARC®DC-600 VRD POWER SOURCE SETTING WHEN CONNECTED TO NA-5 WIRE FEEDER
When using the IDEALARC®DC-600 VRD with the NA-5 wire feeder, set the controls on the IDEALARC DC-600 VRD as follows for the best performance:
1. Turn OFF main AC input power supply to the IDE­ALARC®DC-600 VRD.
2. Connect the electrode cables to terminal polarity to be used. NOTE: Cold starting is only availiable in positive polarity.
3. Connect the #21 work lead (on T.S.2) to the same polarity as the work cable connection.
4. Set the IDEALARC®DC-600 VRD LOCAL/REMOTE Switch to REMOTE.
®
• 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."
IDEALARC®DC-600 VRD
5. Set the IDEALARC®DC-600 VRD OUTPUT TER­MINALS switch to REMOTE.
®
6. Set the IDEALARC MODE SWITCH to the position that matches the welding process being used.
• For submerged arc welding, set WELDING MODE SWITCH to CV SUBMERGED ARC posi­tion.
• For all open arc welding processes set WELDING MODE SWITCH to CV INNERSHIELD position.
DC-600 VRD WELDING
C-1
ACCESSORIES
WIRE FEEDERS AND TRACTORS
C-1
Undercarriages (K817P, K842)
The IDEALARC®DC-600 VRD can be used to power any of the following Lincoln Wire Feeders and Tractors:
For easy moving of the machine, optional undercar­riages are available with polyolefin wheels (K817P) or a platform undercarriage (K842) with mountings for two gas cylinders at rear of welder.
Semi-Automatic Wire Feeders:
DH-10 LN-9 LN-7* LN-9 GMA* LN-7 GMA* LN-23P LN-742 LN-25
*
FACTORY OR FIELD INSTALLED OPTIONS
LN-8* LN-10
Multi-Process Switch (K804-1)
Automatic Wire Feeders*:
NA-3 NA-5R NA-5
The MULTI-PROCESS SWITCH gives you the ability to:
• Switch between "stick welding or air/carbon arc cut-
Tractors*:
LT-7 LT-56
ting" and using a semi-automatic or automatic wire feeder.
• Change the polarity of a semi-automatic or auto­matic wire feeder without changing any electrical
*
Codes 11707 and 11725 only provide 115VAC for these feeders at the ter­minal strip.
cable connections.
See Figure C.1
FIELD INSTALLED OPTIONS
FIGURE C.1 - MULTI-PROCESS SWITCH
Remote Output Control (K775 or K857 with K864 Adapter)
An optional “remote out control” is available. The K775 is the same remote control that is used on other Lincoln power sources. The K775 consist of a control box with 28 feet (8.5mm) of four conductor cable. This connects to terminals 75,76, and 77 on the terminal strip (T.S.1) and the case grounding screw so marked with the symbol “ ” on the machine. These termi­nals are located behind the hinged cover on the case front. This control will give the same control as the output control on the machine.
The K857 is similar to the K775, except the K857 has a 6-pin MS-style connector. The K857 requires a K864 adapter cable which connects to the 14-pin con­nector on the case front.
Remote Control Adapter Cable (K864)
STRAIGHT PLUG (14 PIN)
TO POWER SOURCE
A "V" cable 12" (.30 m) long to connect a K857 Remote Control (6-pin connector) with an LN-7 wire­feeder (14-pin connector) and the machine (14-pin connector). If a remote control is used alone the wire­feeder connection is then not used.
CABLE RECEPTACLE (6 SOCKET)
TO: K857 REMOTE CONTROL
CABLE RECEPTACLE (14 SOCKET) TO: LN-7 WIRE FEEDERS
WIRE FEEDER CABLES
+
-
STICK OR
AIR
CARBON
ARC
+
STICK OR
AIR/CARBON
ARC CABLES
IDEALARC®DC-600 VRD
C-2
ACCESSORIES
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. The output terminals are pro­tected against accidental contact by hinged covers.
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 MULTI-PROCESS SWITCH:
®
1. Confirm that the IDEALARC
DC-600 VRD
POWER ON/OFF switch is in the OFF position.
2. Disconnect main AC input power to the IDE­ALARC®DC-600 VRD.
21-21+ 41 4 2 31 32
NEGATIVE (–)
OUTPUT
STUD
ELECTRODE
CABLE
WIRE
FEEDER
WORK
CABLE
WORK
ELECTRODES
(IF NEEDED
JUMPER SEE INSTRUCTIONS)
75 76 77
+
+
TERMINAL
STRIP COVER
BOX CONNECTOR
CONTROL
LEADS
POSITIVE (+)
OUTPUT
STUD
ELECTRODE
CABLE
STICK AIR/CARBON ARC WELDING EQUIPMENT
WORK
CABLE
C-2
3. Open the terminal strip hinged cover located on the Case Front Assembly.
4. The MULTI-PROCESS SWITCH is mounted to the case front with four 1/4” self-tapping screws. The screw holes are 13.8” apart side to side and
4.5” apart top to bottom, Run one of the 1/4” screws part way in and out of the screw holes to open them up. Make sure that the two sleeved control leads do not get pinched when hanging the switch; route them out the side to the right of the switch. Support the switch in position and start the four screws, then tighten them.
5. Route the MULTI-PROCESS SWITCH control leads through the strain-relief box connectors and into the terminal strip. Connect wire feeder control cable as specified in specific connection diagram and make other terminal strip connections as specified on the connection diagram for the Lincoln wire feeder being used.
6. Connect the control leads from the MULTI­PROCESS SWITCH to terminals #2 and #4 on
®
the IDEALARC
DC-600 VRD's terminal strip.
FIGURE C.2 - MULTI-PROCESS SWITCH CABLE CONNECTIONS.
8. Connect the left cable from the MULTI-PROCESS SWITCH (facing the front of the machine) to the IDEALARC minal. See Figure C.2.
9. Connect the wire feeder electrode and work cables. See Figure C.2.
• Insert the wire feeder electrode and work cables through the strain relief loop on the left side of the IDEALARC®DC-600 VRD (facing the front of the machine).
• Connect the wire feeder electrode and work cables to the electrode and work terminals on the left side of the MULTI-PROCESS SWITCH.
10. Connect wire feeder control cable and make other terminal strip connections as specified on the connection diagram for the Lincoln wire feeder being used.
®
DC-600 VRD negative (-) output ter-
7. Connect the right cable from the MULTI­PROCESS SWITCH (facing the front of the machine) to the IDEALARC®DC-600 VRD posi­tive (+) output terminal. See Figure C.2.
IDEALARC®DC-600 VRD
11. Set the IDEALARC
MINALS switch to REMOTE.
®
DC-600 VRD OUTPUT TER-
C-3
ACCESSORIES
C-3
12. Connect stick or air/carbon arc electrode and work cable. See Figure C.2.
• Insert the electrode and work cables through the strain relief loop on the right side (facing the front of the machine) of the IDEALARC
• Connect the electrode cable to the "Positive" ter­minal on the right side of the MULTI-PROCESS SWITCH.
• Connect the work cable to the "Negative" terminal on the right side of the MULTI-PROCESS SWITCH.
NOTE: The instructions above are for connecting the stick polarity positive. To change the polarity, turn the IDEALARC 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.2.
®
DC-600 VRD OFF, and
®
DC-600 VRD.
CONNECTIONS FOR SEMI-AUTO­MATIC OR AUTOMATIC WIRE FEED­ER CONTROL
1. Set the IDEALARC®DC-600 VRD ON/OFF switch to OFF.
2. Set the IDEALARC LOCAL/REMOTE switch to REMOTE.
3. Set the IDEALARC®DC-600 VRD OUTPUT TER­MINALS switch to REMOTE.
4. Set the IDEALARC®DC-600 VRD MODE switch to the welding process being used.
5. Refer to the proper connection diagram in the DIA­GRAMS section for more information.
®
DC-600 VRD
To operate the MULTI-PROCESS SWITCH, refer to the operating instructions on the switch nameplate.
IDEALARC®DC-600 VRD
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
Only qualified personnel should perform this maintenance.
Turn the input power OFF at the disconnect switch or fuse box before working on this equip­ment.
Do not touch electrically hot parts.
ROUTINE AND PERIODIC MAINTENANCE
1. Disconnect input AC power supply lines to the machine before performing periodic maintenance, tightening, cleaning, or replacing parts.
D-1
Perform the following daily:
1. Check that no combustible materials are in the welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that could block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits or punctures in the cable jacket, or any condition that would affect the proper operation of the machine.
Perform Periodically:
Clean the inside of the machine with low pressure air stream. Clean the following parts.
Main transformer and choke.
Electrode and work cable connections.
SCR rectifier bridge and heat sink fins.
Control board.
Firing board.
Fan Assembly. NOTE: The fan motor has sealed bearings which require no maintenance.
------------------------------------------------------------------------
IDEALARC®DC-600 VRD
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-2
TROUBLESHOOTING
P.C. BOARD TROUBLESHOOTING PROCEDURES
E-2
WARNING
ELECTRIC SHOCK can kill. Have an electrician install and ser-
vice this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
CAUTION: Sometimes machine failures appear to be
due to P.C. board failures. These problems can some­times be traced to poor electrical connections. To avoid problems when troubleshooting and replacing P.C. boards, please use the following procedure:
1. Determine to the best of your technical ability that the P.C. board is the most likely component caus­ing the failure symptom.
2. Check for loose connections at the P.C. board to assure that the P.C. board is properly connected.
3. If the problem persists, replace the suspect P.C. board using standard practices to avoid static elec­trical damage and electrical shock. Read the warn­ing inside the static resistant bag and perform the following procedures:
P.C. Board can be damaged by static electricity.
• Remove your bodyʼs static charge before opening the static­shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connect-
ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations
Reusable Container Do Not Destroy
ed to a grounded part of the equipment frame.
• If you donʼt have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to pre­vent static build-up. Be sure not to touch any electrically live parts at the same time.
• If the P.C. Board uses protective shorting jumpers, donʼt remove them until installation is complete.
• If you return a P.C. Board to The Lincoln Electric Company for credit, it must be in the static-shield­ing bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure symp­tom has been corrected by the replacement P.C. board.
NOTE: It is desirable to have a spare (known good)
P.C. board available for P.C. board troubleshooting.
NOTE: Allow the machine to heat up so that all electri-
cal components can reach their operating tem­perature.
5. Remove the replacement P.C. board and substitute it with the original PC board to recreate the original problem.
• If the original problem does not reappear by substi­tuting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.
• If the original problem is recreated by the substitu­tion of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
• Tools which come in contact with the P.C. Board must be either conductive, anti-static or static-dis­sipative.
• Remove the P.C. Board from the static-shielding bag and place it directly into the equipment. Donʼt set the P.C. Board on or near paper, plastic or cloth which could have a static charge. If the P.C. Board canʼt be installed immediately, put it back in the static-shielding bag.
IDEALARC®DC-600 VRD

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
$&# !' '-!$(#!'
Maj or Physic al or Elect rical Damage is Evident
The Machine is dead- The Input contactor does not operate.
$#''  )'
#)($)($&# !'
Contact the Lincoln Electric Service Dept. ( 216) 383- 2531 or 1-888­935-3877
1. Check for blown or m issing fuses in input lines.
2. Check the three- phase input line voltage at the machine. The input voltage must match the rating plate and reconnect panel.
3. Power ON/OFF switch may be defective.
4. Rectifier bridge may be defec­tive.
5. VRD P.C. board may be defec­tive.
&#!!" #)&'#(#"
If all recommended possible areas of possible cause have been checked and the problem persists,
=<B/1BG=C@:=1/: 7<1=:< CB6=@7H3273:2'3@D713/17:7BG
)(#"
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
=1/: 7<1=:<CB6=@7H3273:2'3@D713/17:7BG for technical troubleshooting assistance before you proceed.
 &L*&
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-4
PROBLEMS (SYMPTOMS)
Input contactor (CR1) chatters.
Variable or sluggish welding arc.
POSSIBLE CAUSE
OUTPUT PROBLEMS
1. The input line voltage may be low. Check all three phases.
2. Make sure input line voltage matches machine rating and the reconnect panel is connect­ed correctly for the line voltage.
1. Poor electrode or work lead con­nection.
2. Welding cables too small.
3. Welding current or voltage too low.
RECOMMENDED COURSE OF ACTION
Output Control Pot. not functioning in “LOCAL” control.
No output control in “REMOTE” control.
115VAC duplex receptacle not working. (60HZ machines only)
1. LOCAL/REMOTE Switch (S3) faulty or in wrong position.
2. Faulty OUTPUT CONTROL Pot.
1. LOCAL/REMOTE Switch (S3) faulty or in wrong position.
2. Faulty Remote Control Unit.
1. 115VAC Circuit Breaker tripped.
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-5
PROBLEMS (SYMPTOMS)
Machine input contactor operates but machine has no weld output.Fan runs and pilot light glows.
POSSIBLE CAUSE
OUTPUT PROBLEMS
1. Place OUTPUT TERMINAL Switch to “ON”, or install a jumper from #2 to #4 on machine terminal strip. If machine weld output is restored the problem is in the wire feeder or control cable.
2. If remote control is not being used make certain the LOCAL/REMOTE SWITCH (SW3) is in the "Local" position.
3. Check 42V Circuit Breaker in the front panel. Reset if neces­sary.
4. Check for loose or faulty weld cable connections.
5. Trigger circuit not working.
6. If machine functions properly in
CV modes but not in CC mode, check for loose connections at VRD P.C. board.
RECOMMENDED COURSE OF ACTION
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
1. Check for faulty mode switch.
Red and Green lights do not come on for approximately 5 seconds when switching to or powering up in CC mode.
Both red and green lights stay on in CC mode well past the 5 second pretest time.
2. Check for loose connections at VRD P.C. board.
3. Possible bad VRD P.C. Board.
1. Check to make sure output is not shorted (electrode touching work).
2. If using an across the arc Wire Feeder, remove the clamp from the output stud until after the 5 second pretest is complete.
3. Uncoil output cables.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-6
PROBLEMS (SYMPTOMS)
Machine has maximum weld out­put and no control.
VRD passes self test and green light is on, but machine will not Weld.
POSSIBLE CAUSE
OUTPUT PROBLEMS
1. LOCAL/REMOTE Switch (S3) in wrong position.
2. LOCAL/REMOTE Switch (S3) is faulty, or an open lead going to the LOCAL/REMOTE Switch (S3).
1. Too much cable inductance.
• Uncoil output cables, shorten cable length, or wrap work and electrode cables together.
2. Too much cable.
• Maximum cable length (work and electrode) is approximately 300 feet.
3. Buildup on stick electrode. Clean or replace electrode.
4. Possible shorted bridge rectifier, if pilot light is off.
RECOMMENDED COURSE OF ACTION
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
5. Fault detected after self test. Cycle power to reset machine.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-7
PROBLEMS (SYMPTOMS)
Machine has minimum output and no control.
The machine does not have maxi­mum weld output.
POSSIBLE CAUSE
OUTPUT PROBLEMS
1. If a remote control unit is NOT connected to the terminal strip #75, #76, and #77 terminals, or is not connected to the 14 pin MS receptacle the LOCAL/REMOTE SWITCH must be in the "Local" position.
2. If a remote control cable is con­nected to terminals #75, #76 and #77 or is connected to the 14 pin MS receptacle the leads may be "shorted" to the positive weld out­put.
3. Make certain the Three Phase input voltage is correct and matches the machine rating and the reconnect panel.
1. Check all Three-Phase input lines at the DC600. Make sure input voltages match machine rating and reconnect panel.
RECOMMENDED COURSE OF ACTION
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
2. Put LOCAL/REMOTE SWITCH
(SW3) in "LOCAL" position. If problem is solved then check remote control unit or wire feeder.
3. Check for loose welding cable connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-8
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-8
PROBLEMS (SYMPTOMS)
Machine shuts off (input contactor drops out) when the welder output terminals are made electrically "hot". (#2 to #4 closure at terminal strip.) or OUTPUT TERMINALS switch is in ON position.
The DC600 will NOT shut off when the Power Switch is turned to OFF.
POSSIBLE CAUSE
OUTPUT PROBLEMS
1. Remove all welding cables and control cables from the DC 600. Jumper #2 to #4 at the terminal strip or set OUTPUT TERMI­NALS switch to ON position. If the machine does NOT shut off and normal open circuit voltage is present at the welder output terminals the problem is exter­nal to the DC600. Either the remote leads #75, #76 or #77 are grounded to the negative output cable or there is a short on the welding output terminals.
2. If the machine still shuts off when all control and welding cables are removed then the problem is internal to the DC-
600.
1. Contact your local Lincoln Authorized Field Service Facility.
RECOMMENDED COURSE OF ACTION
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-9
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-9
PROBLEMS (SYMPTOMS)
The weld output terminals are always electrically "hot".
POSSIBLE CAUSE
OUTPUT PROBLEMS
1. Remove any external leads hooked to #2 and #4 on the ter­minal strip or any connections to the 14 pin MS connector. Set OUTPUT TERMINALS switch to the OFF position. If the problem disappears the fault is in the control cable or wire feeder.
2. If some open circuit voltage is present (over 3VDC.) after per­forming Step #1. then the prob­lem is within the IDEALARC DC-600 VRD.
RECOMMENDED COURSE OF ACTION
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
®
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-10
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-10
PROBLEMS (SYMPTOMS)
Poor arc starting when the IDE­ALARC®DC-600 VRD is in the CV Sub-Arc or CV Innershield Modes.
Machine has output but trips off immediately when wire feed unit trigger is activated
POSSIBLE CAUSE
WELDING PROBLEMS
1. Make sure the proper welding procedures are being used. (wire feed speed , arc voltage and wire size)
2. Check weld cables for loose or faulty connections.
1. Remove output cables from IDEALARC®DC-600 VRD. If problem is resolved check for external short between welding cables. Also check control cable (#75, #76, & #77) for grounds or shorts.
RECOMMENDED COURSE OF ACTION
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-11
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-11
PROBLEMS (SYMPTOMS)
Poor arc characteristics in all processes.
POSSIBLE CAUSE
WELDING PROBLEMS
1. Check for the correct input volt­ages on the three- phase input lines at the IDEALARC®DC-600 VRD.
2. Make sure the proper welding procedures are being used. (wire feed speed, arc voltage and wire size).
3. Check the welding cables for loose or faulty connections.
RECOMMENDED COURSE OF ACTION
If all recommended possible areas of possible cause have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-12
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING
P.C. BOARD TROUBLESHOOTING GUIDE FIRING P.C. BOARD
1. All 10 LEDʼs must be ON when the POWER SOURCE is turned “ON” and the trigger circuit* is closed.
2. LEDʼs 7, 8, and 9 indicate AC power being supplied to the P.C. board from auxiliary windings on the main transformer (T1). If a LED is not “ON”, turn the machine off and unplug P5 from the firing board. Turn the machine back on and check the following voltages:
LED that was off
7 8 9
3. If all voltages are present, turn power off, and plug P5 back into J5. Turn power back on. If LEDʼs are still “OUT”, replace Firing P.C.B.
4. If voltages were not present then check the wiring back to the auxiliary windings for a possible open.
5. LED 10 senses when trigger circuit* is closed. Close trigger circuit, LED10 should be on be “ON”. Open trigger circuit, LED 10 should be “OFF”. If LED does not come “ON”, check to make sure leads 2,4, or 41 are not broken.
Check AC voltage between pins specified, it should be approximately 32VAC . P5 pins 15 & 16 (wires 203,204) P5 pins 7 & 8 (wires 205,206) P5 pins 5 & 6 (wires 207,208)
E-12
Voltage across leads 255 and 256 should be approximately 115VAC. Check voltage across sec­ondary winding of the control transformer (T2) which supplies leads 255 and 256. Measure +16VDC from TEST POINTS “A” to “C” and -10VDC from TEST POINTS “A” to “J” on Control board.
2. LED 2 indicates welder output voltage is being sup­plied to the control circuit. LED 2 will be “ON” brightly in CC STICK mode with trigger circuit* closed and no load. (LED 2 diminishes in bright­ness as output voltage is reduced). If LED 2 is not “ON”, look for open connection in lead 222 circuit.
3. LED 3 indicates power is being applied to FAULT PROTECTION RELAY (CR2). LED 3 will be “ON” when machine POWER is “ON”. LED 3 goes “OUT” when CR2 drops out which turns off the INPUT CONTACTOR (CR1). When LED 3 goes out, LED 4 comes “ON”. See step 3.
4. LED 4 indicates an overload or fault condition; LED should not be on. If this LED comes “ON”, the INPUT CONTACTOR (CR1) will turn off and the red POWER light stays illuminated. This was do to either a short across output, or a current draw in excess of 780A, or leads 75, 76, or 77 grounded to negative output lead. Remove short or reduce out­put current or eliminate ground. Welder must be reset by turning POWER ON/OFF switch to “OFF” and then back to “ON”. If no short or loads above 780A exists or no ground, replace Control P.C.B.
6. LEDʼs 1 through 6 indicate gate signals are being sent to the main SCRʼs 1 through 6 respectively. If LED 5 (located on Control Board) is “ON”, along with LEDʼs 7, 8, and 9 (on Firing P.C.B), and LEDʼs 1 through 6 are “OFF”, check to make sure lead 231 between Control board and Firing board is not broken
7. If any one of LEDʼs 1 through 6 are “OFF” and LEDʼs 7, 8, and 9 are “ON”, replace the Firing P.C.B.
P.C. BOARD TROUBLESHOOTING GUIDE CONTROL P.C. BOARD
1. LED 1 indicates AC input voltage necessary to gen­erate the DC supply voltages is present. These volt­ages power the Control board circuitry. If LED 1 is not “ON” when machine POWER is “ON”, check leads 255, 256, X1, and X2 for broken connection.
5. LED 5 indicates DC control voltage (which supplies Firing board) is present. LED 5 will be “ON” in CV INNERSHIELD mode with trigger circuit* closed, CONTROL POT at minimum, and no load. (LED 5 diminishes in brightness as output voltage is increased). Replace P.C. board if LED 5 did not go “ON”.
6. LED 6 indicates trigger circuit* condition. LED 6 “ON” indicates trigger circuit is closed. LED 6 “OFF” indicates trigger circuit is open. If LED 6 does not come “ON”, when trigger circuit closed, look for open connections in the 2 & 4 circuit and in leads 290 and 291.
TRIGGER CIRCUIT is closed by any of the following:
• Wire feederʼs trigger is closed.
• A jumper is placed across 2 & 4 on terminal strip T.S.2. or across pins C & D in 14 pin connector.
• OUTPUT TERMINAL switch is in the “ON” position.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
E-13
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-13
CHECKING POWER ON/OFF SWITCH (S1)
1. Turn off the machine input power (" o "position).
SW1 has 115 volts across it when the input power is connected.
2. Isolate the switch to be tested by removing all co­nnecting leads.
3. Check to make sure the switch is making open and closed connections with a V.O.M. meter. Put ohm meter on X1 scale. The meter should read zero
resistance with switch " I " and infinite with switch
" o "
4. Put the ohmmeter on X1K scale and measure the resistance between the terminal and the case of the machine (touch a self-tapping screw). Reading should be infinite.
5. If either step (3) or step (4) fails, replace the switch.
CHECKING OUTPUT CONTROL RHEO­STAT ON MACHINE (R1)
1. Turn machine off (" o " position).
2. Remove the screws from the hinged control panel and open the panel.
3. Turn the LOCAL/REMOTE CONTROL switch to "REMOTE".
4. With an ohmmeter on X1K, connect it to lead 236 and 237 on R1.
5. Exercise caution to avoid damaging rheostat tabs.
6. Rotate the OUTPUT voltage control rheostat. The resistance reading should be from around zero to 10K ohms. Check the resistance reading between the two outer tabs on the rheostat (leads 236 and
75). The reading must be 10K "10% ohms. No reading will indicate an open rheostat and a low reading will indicate a shorted or partially shorted rheostat; in either case, replace.
CONNECTING REMOTE OUTPUT CONTROL RHEOSTAT TO THE MACHINE
Extreme caution must be observed when installing or extending the wiring of a remote control. Improper connection of this unit can lead to loss of control and/or poor welding. Only the green lead can and should be grounded to the machine case. When extending the standard remote control, make sure the leads are the same and the splice is waterproof. Be very careful not to ground the cable when in use and don't let the lugs touch against the case.
CHECKING REMOTE OUTPUT CONTROL RHEOSTAT
Disconnect the remote output control and connect an ohmmeter across 75 and 76 and rotate the rheostat in the remote control. The resistance reading should go from zero to 10K ohms. Repeat with ohmmeter across 77 and 76 with same results. Connect ohmmeter across 75 and 77. The reading should be 10K "10% ohms. A lower reading will indicate a shorted or par­tially shorted rheostat. A very high reading will indicate an open rheostat. In either of the last two cases, replace rheostat. Check cable for any physical dam­age.
P.C. BOARD TROUBLESHOOTING GUIDE VRD P.C. BOARD
1. LEDʼs 4 and 5 indicate power being supplied to the P.C. board from the 42 volt winding on the main transformer (T1), but only when the machine is in CC mode. If LED 4 and 5 are not “ON” while in CC mode, turn the machine off, check the wiring back to the 42V transformer winding and check the mode switch. If the LEDʼs are on when the machine is in CV mode then a wiring error exists. (For Codes
11598, 11613 only)
2. With the power on, change mode switch from CV to CC. LED 2 must be ON for the initial 5 seconds, and then LED 3 should turn “ON”. LED 3 indicates that the machine is ready to weld. LED 3 also indi­cates when 48V has been exceeded by turning “OFF” until the power is cycled.
3. When LED 3 is “ON”, LED 1 should then turn “ON” when the electrode touches the work.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC®DC-600 VRD
F-1
DIAGRAMS
F-1
IDEALARC®DC-600 VRD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
DIAGRAMS
F-2
IDEALARC®DC-600 VRD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-3
DIAGRAMS
F-3
IDEALARC®DC-600 VRD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-4
DIAGRAMS
F-4
IDEALARC®DC-600 VRD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-5
DIAGRAMS
K= 42
F-5
1-28-94
S20409
C= 2
D= 4
E= 77
Turn off (0) the power switch on the Welding
service this machine.
Only qualified persons should install, use or
Power Source before connecting the wire feeder.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT
LN-742
WIRE
FEEDER
N.D.
AND DUTY CYCLE OF APPLICATION.
N.B. DI AGRAM SHOWS ELECTRODE POSI TIVE. TO
CHANGE POLARI TY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLES AT
IT Y SWITCH ON POWER
TMETER POLAR
POWER SOURCE AND SET W IRE FEEDER
VOL
SOURCE TO PROPER POLARI TY.
N.C. PI NS NOT LISTED ARE NOT CONNECTED
ON CABLE.
ASSEMBLY
LN-742
INPUT CABLE
F= 76
I=41
TO "REMOTE" POSIT ION.
N.D. IF USING K589-1, REMOTE CONTROL KI T,
SET POWER SOURCE CONTROL SWI TCH
K= 42
I=41
H= 21
G= 75
H= 21
G= 75
D= 4
C= 2
AND 14-PI N CABLE PLUG, FRONT VIEW
14-SOCKET BOX RECEPTACLE, REAR VI EW
F= 76
E= 77
AND 14-PI N CABLE PLUG, REAR VI EW
14-SOCKET BOX RECEPTACLE, FRONT VI EW
14 P IN
AMPHENOL
ELECTRODE CABLE
TO WORK
CONNECTION OF LN-742 TO THE DC-600 VRD POWER SOURCE
LINCOLN
POWER SOURCE
-
+
FUNCTIONS ARE LI STED FOR REFERENCE
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQ UI PMENT.
IDEALARC®DC-600 VRD
ION
E WI RI NG D IAGRAM)
FUNCT
LEAD
(SEE APPROPRIAT
PI N
TRIGGER CI RCUIT
2
C
OUTPUT CONTROL
TRIGGER CI RCUIT
4
77
E
D
WORK
OUTPUT CONTROL
OUTPUT CONTROL
21
76
75
F
H
G
42V AC
41
I
42V AC
42
K
F-6
S22976
Only qualified persons should install, use or
service this machine.
Do not touch electrically live parts.
Disconnect power source before
servicing.
Do not operate with covers removed.
DIAGRAMS
the terminal strip,
work pol arity. This
F-6
10-30-98F
e lectrode polarity is
MS-TYPE
OR
LEAD CONNECTORS
LN-7 TO INPUT
CABLE PLUG
21
FOR CONTROL CABLE
WI TH TERMINAL STRI P
CABLE
LN-7 CONTROL
FOR CONTROL CABLE
PLUG CONNECTOR
WI TH 14 P IN
CONTROL CABLE
14-PIN
RECEPTACLE
POWER SOURCE
N.A. Welding cables must be of proper capacity for the current and
duty cycl e of immediate and future appl ications. See LN-7
Operating Manual for proper sizes.
77
75 76
32
4231
41
21
-
21
+
N.B. If LN-7 is equipped with a meter kit, ex tend LN-7 control cabl e
N.E.
lead #21 from control cabl e with terminal strip connectors or from
marked near the power source terminal strip. The power
source grounding terminal (marked and located near the power
14-pin receptacl e using #14 AWG or larger insulated wire physically
voltage sensing work lead may be ordered for this purpose.
suitable for the installation. An S16586-[LENGTH] remote
32
Connect it directly to the work piece independent of the welding
31
work cabl e connection. For convenience, this ex tended #21 lead
2
should be taped to the welding work lead. (If the length of
4
can be expected to be reliabl e, then control cabl e lead #21 does
welding work cable is short, less than 25 feet, and connections
not need to be e xtended and can be directly connected to
terminal #21 on the terminal strip. Note that this is not the
GND
preferred connection because it adds error to the LN-7 voltmeter
21
reading.)
N.C. Tape up bolted connection if lead #21 is ex tended.
source input power connections) must be properly connected to
N.D. Connect the control cable ground lead to the frame terminal
N.D.
ELECTRODE CABLE
TO W IRE FEED UNI T
this terminal strip.
el ectrical ground per the power source operating manual .
N.E. If an optional remote vol tage control is used, connect it to
TO WORK
POSIT IVE
N.G.
N.A.
N.B. & N.C.
N.F.
NEGATIVE
CONNECTION OF LN-7 TO THE DC-600 VRD POWER SOURCE
If lead #21 is to be connected to
N.F.
connection must be changed whenever the
connect to the #21 terminal that matches
REMOTE VOLTAGE SENSING LEAD
changed.
Above diagram shows el ectrode connected positive. To change polarity,
appropriate output studs. Refer to power source operating manual
N.G. Illustration does not necessarily represent actual position of
source and position the switch on wire feeder (if equipped )
turn power off, reverse the el ectrode and work leads at the power
for more information.
see power source operating manual .
For proper setting of switches on power source,
to proper pol arity. A lso refer to note N.F.
IDEALARC®DC-600 VRD
F-7
Only qualified persons should install, use or
service this machine.
Do not touch electrically live parts.
Disconnect power source before
servicing.
Do not operate with covers removed.
DIAGRAMS
F-7
10-30-98F
S22977
OR
FOR CONTROL CABLE
WITH 14 PIN MS-TYPE
PLUG CONNECTOR
FOR CONTROL CABLE
WITH TERMINAL STRIP
separate from the welding work lead circuit and connection. For
welding work lead. (If the length of work lead circuit is
Connect it directly to the work piece keeping it electrically
remote voltage sensing work lead may be ordered for this purpose.
physically suitable for the installation. An S16586-[LENGTH]
N.B. Extend lead #21 from control cable with terminal strip connectors or
from 14-pin receptacle using #14 AWG or larger insulated wire
duty cycle of immediate and future applications.
N.A. Welding cables must be of proper capacity for the current and
LEAD CONNECTORS
short, and connections can be expected to be reliable, then
convenience, this extended #21 lead should be taped to the
to the wire feeder voltmeter reading.)
control cable lead #21 does not need to be extended and can be
directly connected to terminal #21 on the terminal strip. Note
that this is not the preferred connection because it adds error
marked near the power source terminal strip. The power
source grounding terminal (marked and located near the power
source input power connections) must be properly connected to
N.C. Tape up bolted connection if lead #21 is extended.
N.D. Connect the control cable ground lead to the frame terminal
electrical ground per the power source operating manual.
terminal strip, connect lead #76 to #76 on terminal strip, connect
N.E. If using an older LN-8 control cable: connect lead #75 to #75 on
N.F. The LN-9 voltage control jumpers must be connected as follows
changed whenever the electrode polarity is changed.
N.G. If lead #21 is to be connected to the terminal strip, connect to
N.H. Illustration does not necessarily represent actual position of appropriate
output studs. Refer to power source instruction manual for more info.
the #21 terminal that matches work polarity. This connection must be
Blue jumper on voltage board (later units only),
or on start board (earlier units), to pin "B".
White jumper on voltage board to pin "S" .
(refer to LN-9 Operating Manual):
lead #77 to #77 on the terminal strip.
N.E.
CONTROL CABLE
RECEPTACLE
14-PIN
CABLE
INPUT CABLE PLUG
TO LN-8 OR LN-9
N.F.
CONTROL
21
C
N.E.
77
75 76
32
2
32
A
B
4
31
GND
N.D.
21
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
REMOTE VOLTAGE SENSING LEAD
POSITIVE
CONNECTION OF LN-8 OR LN-9 TO THE DC-600 VRD POWER SOURCE
N.A.
source and position the switch on wire feeder (if equipped )
For proper setting of switches on power source,
see power source operating manual.
to proper polarity. Also refer to note N.F.
Above diagram shows electrode connected positive. To change polarity,
turn power off, reverse the electrode and work leads at the power
POWER SOURCE
4231
41 21
-
21
+
N.H.
N.B. & N.C.
N.G.
NEGATIVE
IDEALARC®DC-600 VRD
F-8
DIAGRAMS
F-8
IDEALARC®DC-600 VRD
F-9
DIAGRAMS
F-9
IDEALARC®DC-600 VRD
F-10
DIAGRAMS
F-10
10-30-98F
S22980
L
C=2
B=GND
A
D=4
E=77
Only qualified persons should install, use or
service this machine.
Do not touch electrically live parts.
Disconnect power source before
servicing.
Do not operate with covers removed.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT
AND DUTY CYCLE OF APPLICATION.
WIRE
FEEDER
K=42
J
MORE INFORMATION.
REFER TO POWER SOURCE OPERATING MANUAL FOR
ACTUAL POSITION OF APPROPRIATE OUTPUT STUDS.
N.D. IF LEAD #21 IS TO BE CONNECTED TO THE
N.C. PINS NOT LISTED ARE NOT CONNECTED
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO
CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLES AT
ON CABLE.
POWER SOURCE.
TERMINAL THAT MATCHES WORK POLARITY.
TERMINAL STRIP, CONNECT TO THE #21
WIRE FEEDER
9 PIN
AMPHENOL
N.E. ILLUSTRATION DOES NOT NECESSARILY REPRESENT
THIS CONNECTION MUST BE CHANGED WHENEVER
THE ELECTRODE POLARITY IS CHANGED.
J
K=42
A
INPUT CABLE
ASSEMBLY
I=41
I=41
C=2
B=GND
H=21
H=21
M
F=76
G=75
N
14-SOCKET BOX RECEPTACLE, REAR VIEW
AND 14-PIN CABLE PLUG, FRONT VIEW
N
G=75
F=76
M
E=77
D=4
L
14-SOCKET BOX RECEPTACLE, FRONT VIEW
AND 14-PIN CABLE PLUG, REAR VIEW
14 PIN
AMPHENOL
N.E.
ELECTRODE CABLE
TO WORK
42V AC
FUNCTION
CONNECTION OF DH-10 OR LN-10 TO THE DC-600 VRD POWER SOURCE WITH 14 PIN AMPHENOL
LINCOLN
POWER SOURCE
+
-
FOR PROPER SETTINGS OF SWITCHES ON POWER SOURCE,
SEE POWER SOURCE OPERATING MANUAL.
FUNCTIONS ARE LISTED FOR REFERENCE
(SEE APPROPRIATE WIRING DIAGRAM)
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQUIPMENT.
CHASSIS CONNECTION
GND
LEAD
B
PIN
OUTPUT CONTROL
TRIGGER CIRCUIT
TRIGGER CIRCUIT
2
4
77
C
E
D
WORK
OUTPUT CONTROL
OUTPUT CONTROL
42V AC
75
21
76
F
G
42
41
I
K
H
IDEALARC®DC-600 VRD
F-11
DIAGRAMS
F-11
22.25
11.12
3.25
27.50
39.95
9.20
*
20.00
1-20-89A
27.87
M12244-6
THIS DIMENSION WILL VARY
WITH POSITION OF HANDLE
5.90
.94
*
DIMENSION PRINT (WITH K817P UNDERCARRIAGE)
38.00
DC-600 VRD
17.75
*
29.93
LOCATION OF BASE MOUNTING HOLES
*
IDEALARC®DC-600 VRD
4.75
F-12
DIAGRAMS
F-12
23.28
22.25
5.19
11.12
3.25
27.50
37.86
7.11
*
20.00
27.65
6-18-93C
M15200-3
.94
*
*
29.93
*
38.00
54.91
DIMENSION PRINT (WITH K842 UNDERCARRIAGE)
DIMENSION PRINT (WITH K842 UNDERCARRIAGE)
17.76
36.12
DC-600 VRD
LOCATION OF BASE MOUNTING HOLES
*
49.89
IDEALARC®DC-600 VRD
G Keep your head out of fumes. G Use ventilation or exhaust to
remove fumes from breathing zone.
G Turn power off before servicing.
G Do not operate with panel open or
guards off.
WARNING
G Los humos fuera de la zona de res-
piración.
G Mantenga la cabeza fuera de los
humos. Utilice ventilación o aspiración para gases.
G Gardez la tête à l’écart des fumées. G Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones de travail.
G Vermeiden Sie das Einatmen von
Schweibrauch!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
G Mantenha seu rosto da fumaça. G Use ventilação e exhaustão para
remover fumo da zona respiratória.
G Desconectar el cable de ali-
mentación de poder de la máquina antes de iniciar cualquier servicio.
G Débranchez le courant avant l’entre-
tien.
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)
G Não opere com as tampas removidas. G Desligue a corrente antes de fazer
serviço.
G Não toque as partes elétricas nuas.
G No operar con panel abierto o
guardas quitadas.
G N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de protection enlevés.
G Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in Betrieb setzen!
G Mantenha-se afastado das partes
moventes.
G Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
WARNING
Spanish
AVISO DE
PRECAUCION
G Do not touch electrically live parts or
electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
G No toque las partes o los electrodos
bajo carga con la piel o ropa moja­da.
G Aislese del trabajo y de la tierra.
G Keep flammable materials away.
G Mantenga el material combustible
fuera del área de trabajo.
G Wear eye, ear and body protection.
G Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
G Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
G Não toque partes elétricas e elec-
trodos com a pele ou roupa molha­da.
G Isole-se da peça e terra.
G Gardez à l’écart de tout matériel
inflammable.
G Entfernen Sie brennbarres Material!
G Mantenha inflamáveis bem guarda-
dos.
G Protégez vos yeux, vos oreilles et
votre corps.
G Tragen Sie Augen-, Ohren- und Kör-
perschutz!
G Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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