Lincoln Electric IM642 User Manual

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IDEALARC ® DC-600
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
10588 to 10701,11071, 11072,11129, 11130, 11131, 11132, 11133 and 11140 11335, 11336, 11337, 11338, 11339 11537,11538, 11539, 11540, 115 41,11 5 68
DC-600
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
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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.
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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
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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. 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
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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 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
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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-7
Electrode, Work and #21 Lead ..............................................................................A-7
Auxiliary Power and Control Connections .............................................................A-8
________________________________________________________________________
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-6
Overload, Overcurrent and Fault Protection..........................................................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® DC-600 and Wire Feeders.....................................................B-8
NA-3 Automatic Wire Feeder ..........................................................................B-8
NA-5 Automatic Wire Feeder ........................................................................B-10
LN-8 Semi-Automatic Wire Feeder ...............................................................B-10
LN-7 & LN-9 Semi-Automatic Wire Feeders .................................................B-10
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vi
Accessories.....................................................................................................Section C
Wire Feeders and Tractors....................................................................................C-1
Field Installed Options...........................................................................................C-1
Remote Output Control (K775 or K857)..........................................................C-1
Remote Control Adapter Cable (K864) ...........................................................C-1
Undercarriages (K817P, K842).......................................................................C-1
Paralleling Kit (K1611-1) .................................................................................C-1
TIG Module (K930-2) ......................................................................................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-2
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-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
Auxiliary Power
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.
------------------------------------------------------------------------
STACKING HOLE
STACKING PINS
FIGURE A.1 - Stacking IDEALARC® DC-600 machines
TILTING
The IDEALARC® DC-600 must be placed on a stable, level surface so it will not topple over.
IDEALARC® DC-600
A-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
Auxiliary 60 Hz 50/60 Hz
Power Models Models
Connections
At Duplex 115V 15A No Duplex
Receptacle
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)
A-8
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 Connection 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.
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
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).
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
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.
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
IDEALARC® DC-600
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