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.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
1.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 f iel ds m ay i nte rfe re w ith som e pa cem akers, and
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
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may 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
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. U s e o n l y c o m p r e ssed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright 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. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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.
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 nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
IDEALARC® DC-600
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F
Parts List.....................................................................................................P-349 Series
vii
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – IDEALARC® DC-600
INPUT - THREE PHASE ONLY
Standard
Volatge
100% Duty Cycle
Input Current at Rated Output
60% Duty Cycle
A-1
50% Duty Cycle
230/460/575/60
220/380/440/50/60
Duty Cycle
100% Duty Cycle
60% Duty Cycle
50% Duty Cycle
Output Range
70A/13V-780A/44V (CV)
90A/24V-780A/44V (CC)
INPUT
VOLTAGE /
FREQUENCY
230
460
575
200
220
380
400
415
440
500
230/460/60
460/60
575/60
380/500/50/60
440/50/60
200/400/50/60
415/50/60
108/54
108/54/43
54
43
116/67/58
67/51
58
128/64
62
122/61
122/61/49
61
49
128/74/64
74/56
64
140/70
68
RATED OUTPUT
Amps
600
680
750
OUTPUT
Maximum Open Circuit Voltage
72V for 60 HZ models
69V for 50/60 HZ models
RECOMMENDED INPUT WIRE AND FUSE SIZES
HERTZ
60
60
60
50/60
50/60
50/60
50/60
50/60
50/60
50/60
INPUT AMPERE
RATING ON
NAMEPLATE
108
54
43
128
116
67
64
61
58
51
TYPE 75°C
COPPER WIRE
IN CONDUIT
AWG(IEC-MM2) SIZES
30°C (86°F) Ambient
2 (34)
6 (14)
8 (8.4)
1 (43)
2 (34)
6 (14)
6 (14)
6 (14)
6 (14)
8 (8.4)
134/67
134/67/54
67
54
138/80/69
80/61
69
152/76
73
Volts at Rated Amperes
44
44
44
AuxiliaryPower
See the OPERATION section
for Auxiliary Power
information by model
TYPE 75°C
GROUND WIRE
IN CONDUIT
AWG(IEC-MM2) SIZES
6 (14)
8 (8.4)
8 (8.4)
6 (14)
6 (14)
8 (8.4)
8 (8.4)
8 (8.4)
8 (8.4)
8 (8.4)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
175 Amp
90 Amp
70 Amp
175 Amp
175 Amp
100 Amp
100 Amp
100 Amp
90 Amp
80 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
IDEALARC® DC-600
DEPTH
39.0 in
988 mm
WEIGHT
522 lbs.
237 kg.
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
Read entire Installation Section before installing
the IDEALARC® DC-600.
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
IDEALARC® DC-600 grounding terminal to a
good electrical earth ground.
• Set the IDEALARC® DC-600 Power ON/OFF
PUSH BUTTON to the OFF position when connecting power cord to input power.
__________________
STACKING
Three IDEALARC® DC-600 machines can be
stacked.
DO NOT stack more than three machines in one
grouping.
DO NOT stack the IDEALARC® DC-600 on another
type of machine.
Follow these guidelines when stacking:
1. Select a firm, level surface capable of supporting the total weight of up to three
machines (1570 pounds/712 kilograms).
2. Set the bottom machine in place.
3. Stack the second machine on top of it by
aligning the two holes in the base rails of the
second machine with the two pins on top front
of the bottom machine.
4. Repeat process for third machine.
NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
Figure A.1.
SELECT PROPER LOCATION
Place the 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.
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® DC-600 on top of any
other machine.
The IDEALARC® DC-600 must be placed on a stable,
level surface so it will not topple over.
IDEALARC® DC-600
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 SUPPLYCONNECTIONS
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
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
------------------------------
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 Dual Voltage except 380/500-460/575, see
Figure A.4. (M15009)
2. For 220/380/460, see Figure A.5. (M15010)
3. For 380/500-460/575, see Figure A.6. (M15011)
4. For 460 and 440 Single Voltage, see Figure A.7.
(S17894)
5. For 230/460/575, see Figure A.8. (M15666)
6. For Voltages not listed, see the Input Connection
Diagram pasted on the inside of the Case
Back Input Access Door.
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
LINES
INPUT
L3
L2
L1
GND
H3
W
V
CONTACTOR
U
H1
TRANSF.
CRI
PILOT
H2
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
2.
LEAST 600 VOLT INSULATION.
CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
3.
THE CRI CONTACTOR AS SHOWN.
CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
4.
MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
5.
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
REMAINING HEX NUTS IN PLACE.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
LINES
INPUT
L3
L2
L1
GND
H2
W
V
CTOR
U
H1
CRI
PILOT
TRANSF.
H3
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
2.
LEAST 600 VOLT INSULATION.
CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
3.
THE CRI CONTACTOR AS SHOWN.
CONNECT TERMINAL MARKED TO G ROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
4.
MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
5.
FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines
IDEALARC® DC-600
A-5
LINKS
LINKS
LINKS
LINES
INPUT
LINES
INPUT
LINES
INPUT
L3
L2
L1
GND
L3
L2
L1
GND
L3
L2
L1
GND
H4
H3
H2
INSTALLATION
CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)
W
V
CONTACTOR
U
H1
TRANSF.
W
V
CONTACTOR
U
H1
TRANSF.
W
V
CONTACTOR
U
H1
TRANSF.
PILOT
PILOT
PILOT
CRI
H3
H2
CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.
CRI
H4
H2
CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.
CRI
H4
H3
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE
POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUM
CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,
LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
A-5
FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines
CONNECTION FOR 380/460 VOLTAGES
H2
LINES
INPUT
GND
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN
ALL HEX NUTS
L3
L2
L1
H1
H3
W
V
CONTACTOR
U
CRI
TAPE
LINK
CONNECTION FOR 500/575 VOLTAGES
H3
LINES
INPUT
GND
L3
L2
L1
H1
H2
1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.
2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS
CRI
W
V
CONTACTOR
U
TAPE
LINK
FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines
IDEALARC® DC-600
A-6
LINES
INPUT
INSTALLATION
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE
CRI
L3
L2
L1
W
V
CONTACTOR
U
GND
FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines
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.
A-6
FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines
IDEALARC® DC-600
A-7
INSTALLATION
A-7
OUTPUT CONNECTIONS
See Table A.1 for recommended IDEALARC® DC-600 cable sizes for combined lengths of electrode and work
cables.
TABLE A.1
IDEALARC® DC-600 Cable Sizes for Combined Lengths of 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.9.
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.9 - 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
A-8
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
Auxiliary60 Hz50/60 Hz
PowerModelsModels
Connections
At Duplex115V 15ANo Duplex
Receptacle
Terminal strip115V 15A115V 15A
terminals 31 & 32
MS-Receptacle115V 15A115V 15A
pins A & J
MS-Receptacle42V 10A42V 10A
pins I & K
115VAC DUPLEX RECEPTACLE (60 HERTZ
MODELS ONLY)
A-8
PINLEAD NO.FUNCTION
A32115 VAC
BGNDChassis Connection
C2Trigger Circuit
D4Trigger Circuit
E77Output Control
F76Output Control
G75Output Control
H21Work Sense Connection
I4142 VAC
J31115 VAC
K4242 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.
1.
2
The 115VAC duplex receptacle is protected by a 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.10 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.
115 VAC is available at receptacle pins A and J (All
Models). A 15 amp circuit breaker protects this circuit.
Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other.
FIGURE A.10 FRONT VIEW OF 14-PIN
CONNECTOR RECEPTACLE
K=42
A=32
B=GND
LN
C=2
D=4
E=77
J=31
I=41
H=21
G=75
F=76
M
IDEALARC® DC-600
TERMINAL STRIP 1 (T.S.1)
Lead No.Function
75Output Control
76Output Control
77Output 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).
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 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
B-2
OPERATION
B-2
GENERAL DESCRIPTION
The IDEALARC® DC-600 is an SCR controlled three
phase welding and cutting power source. It uses a
single range potentiometer to control:
•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 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 AAC)
•Constant Voltage (CV) Submerged Arc
• Constant Voltage (CV) Innershield (also used for
FCAW/GMAW)
Three models are available:
•Domestic - all 60 Hertz models except
230/460/575V.
•Canadian-230/460/575V 60 Hertz models
•Export-50/60 Hertz models
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.
RECOMMENDED PROCESSES AND
EQUIPMENT
The IDEALARC® DC-600 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 is provided with a three
position mode switch that selects CV Innershield, CV
Submerged Arc, or CC Stick.
The IDEALARC® DC-600 can be easily connected to
wire feeding equipment, including:
DESIGN FEATURES AND
ADVANTAGES
•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.