Lincoln Electric Idealarc DC-600 Operator's Manual
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Lincoln Electric Idealarc DC-600 Operator's Manual

Lincoln Electric Idealarc DC-600 Operator's Manual

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Operator's Manual
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM642-E
| Issue D ate Oct-17
© Lincoln Global, Inc. All Rights Reserved.
DC-600
™
For use with machines having Code Numbers:
10588; 10589; 10590; 10591; 10592;
10593; 10594; 10595; 10596; 10639;
10640; 10641; 10700; 10701; 11071;
11072; 11129; 11130; 11131; 11132;
11133; 11140; 11335; 11336; 11337;
11338; 11339; 11537; 11538; 11539;
11540; 11541; 11568; 12778

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Summary of Contents for Lincoln Electric Idealarc DC-600

  • Page 1 Operator’s Manual Idealarc DC-600 ™ For use with machines having Code Numbers: 10588; 10589; 10590; 10591; 10592; 10593; 10594; 10595; 10596; 10639; 10640; 10641; 10700; 10701; 11071; 11072; 11129; 11130; 11131; 11132; 11133; 11140; 11335; 11336; 11337; 11338; 11339; 11537; 11538; 11539; 11540;...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).

  • Page 4: Electric Shock Can Kill

    S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    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 ....................
  • Page 7 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......................parts.lincolnelectric.com Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – IDEALARC® DC-600 INPUT - THREE PHASE ONLY Input Current at Rated Output Standard 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle Volatge 108/54 122/61 134/67 230/460/60 134/67/54 108/54/43 122/61/49 230/460/575/60 460/60 575/60 138/80/69 116/67/58 128/74/64 220/380/440/50/60 67/51 74/56...

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS STACKING Read entire Installation Section before installing Three IDEALARC® DC-600 machines can be the IDEALARC® DC-600. stacked. ELECTRIC SHOCK CAN KILL. DO NOT stack more than three machines in one grouping. WARNING DO NOT stack the IDEALARC® DC-600 on another type of machine.

  • Page 10: Electrical Input Connections

    INSTALLATION ELECTRICAL INPUT CONNECTIONS INPUT POWER SUPPLYCONNECTIONS A qualified electrician should connect the input power Before installing the machine check that the input sup- supply leads. ply voltage, phase, and frequency are the same as the voltage, phase, and frequency as specified on the 1.

  • Page 11: Reconnect Procedure

    INSTALLATION RECONNECT PROCEDURE 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. Multiple voltage machines are shipped connected to Follow The Input Connection Diagram located on the the highest input voltage listed on the machine’s rating inside of Case Back Input Access Door.
  • Page 12 INSTALLATION CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ) 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 LINES LEAST 600 VOLT INSULATION.
  • Page 13 INSTALLATION SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES. LINES 3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN. INPUT CONTACTOR FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines...

  • Page 14: Output Connections

    INSTALLATION OUTPUT CONNECTIONS See Table A.1 for recommended IDEALARC® DC-600 cable sizes for combined lengths of electrode and work cables. TABLE A.1 IDEALARC® DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable at 100% Duty Cycle Cable Length Parallel Cables Cable Size Lengths up to 150 ft.

  • Page 15: Auxiliary Power And Control Connections

    INSTALLATION AUXILIARY POWER AND LEAD NO. FUNCTION CONTROL CONNECTIONS 115 VAC Located at the left side of the front of the welder Chassis Connection behind a hinged cover is a 115VAC duplex receptacle Trigger Circuit for auxiliary power (60 Hertz Models only). On the right Trigger Circuit side of the case front is a 14 Pin MS type receptacle Output Control...

  • Page 16: Operation

    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.

  • Page 17: General Description

    OPERATION GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES The IDEALARC® DC-600 is an SCR controlled three phase welding and cutting power source. It uses a • Excellent arc characteristics for optimum constant single range potentiometer to control: voltage submerged arc and Innershield welding performance.

  • Page 18: Welding Capability

    OPERATION WELDING CAPABILITY The IDEALARC® DC-600 has the following Output and Duty Cycle based on operation for a 10 minute period: 600 Amps, 44 Volts at 100% 680 Amps, 44 Volts at 60% 750 Amps, 44 Volts at 50% MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT Input POWER ON/OFF Switch LOCAL/REMOTE Switch SYMBOL...

  • Page 19: Meaning Of Graphical Symbols On Rating Plate

    OPERATION MEANING OF GRAPHICAL MEANING OF GRAPHICAL SYMBOLS ON RATING PLATE SYMBOL FOR GROUND CON- (LOCATED ON CASE BACK) NECTION Designates welder complies with Signifies the equipment connection National Electrical Manufacturers point for the protective earth ground NEMA EW 1 (100%) Association requirements EW 1 Class I with 100% duty cycle at CONTROLS AND SETTINGS 600Amps output.

  • Page 20: Auxiliary Power In Ms-Receptacle

    OPERATION 3. OUTPUT CONTROL 11.Terminal Strip Cover Panel This control provides continuous control of the machine’s output voltage and current from mini- Rotate this panel to gain access to the circuits mum to maximum (typical full pot range between made available at the two terminal strips (T.S.1 15 to 44 volts and 90 to 750 amps) as it is rotated and T.S.2).

  • Page 21: Operating Steps

    OPERATION REMOTE CONTROL OF MACHINE The power source circuitry is protected from faults on OPERATION leads 75, 76, or 77. If any of these leads are connect- ed to either the positive or negative output leads, the IDEALARC® DC-600 will either shut down completely The toggle switch on the control panel labeled (input contactor opens and white POWER light stays “Remote - Panel”...

  • Page 22: Na-3 Automatic Wire Feeder

    OPERATION NA-3 AUTOMATIC WIRE FEEDER • To adjust the Open Circuit Voltage Control to get the best starting performance, make repeated starts observing the NA-3 voltmeter. 1. Set the IDEALARC® DC-600 LOCAL/REMOTE Switch to REMOTE. Set the OUTPUT TERMINALS When the voltmeter pointer swings smoothly up to switch to REMOTE.
  • Page 23 OPERATION IDEALARC® DC-600 POWER SOURCE NOTE: These Start Board current and voltage set- SETTING WHEN CONNECTED TO NA-5 tings result in a start up current that is lower than the NA-3 current setting and approximately equal WIRE FEEDER with the NA-3 voltage setting for the desired weld- ing procedure.

  • Page 24: Automatic Wire Feeder

    ACCESSORIES WIRE FEEDERS AND TRACTORS Undercarriages (K817P, K842) For easy moving of the machine, optional undercar- The IDEALARC® DC-600 can be used to power any riages are available with polyolefin wheels (K817P) or of the following Lincoln Wire Feeders and Tractors: a platform undercarriage (K842) with mountings for two gas cylinders at rear of welder.
  • Page 25 ACCESSORIES The MULTI-PROCESS SWITCH has two sets of out- put terminals. You connect the wire feeder unit cables to the set of terminals on the left side of the box and the stick or air/carbon arc cables to the set of termi- TERMINAL STRIP COVER nals on the right side (facing the front of the machine)

  • Page 26: Connections For Semi-Automatic Or Automatic Wire Feeder Control

    ACCESSORIES CONNECTIONS FOR SEMI-AUTO- 12. Connect stick or air/carbon arc electrode and work MATIC OR AUTOMATIC WIRE FEED- cable. See Figure C.2. ER CONTROL • Insert the electrode and work cables through the strain relief loop on the right side (facing the front 1.

  • Page 27: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. Only qualified personnel should perform this maintenance. Turn the input power OFF at the disconnect switch or fuse box before working on this equip- ment. Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE 1.

  • Page 28: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 29 ELECTRIC SHOCK can kill. Have an electrician install and ser- vice this equipment. Turn the input • If you return a P.C. Board to The Lincoln Electric power OFF at the fuse box before Company for credit, it must be in the static-shield- working on equipment.
  • Page 30 RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Major Physical or Electrical Contact the Lincoln Electric Service Damage is Evident Dept. 1-(888)-953-3877. 1. Check for blown or missing The Machine is dead- The Input fuses in input lines. contactor does not operate.
  • Page 31 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Input contactor (CR1) chatters. 1. The input line voltage may be low. Check all three phases. 2. Make sure input line voltage matches machine rating and the reconnect panel is connect- ed correctly for the line voltage.
  • Page 32 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine input contactor operates 1. Place OUTPUT TERMINAL machine weld Switch to “ON”, or install a output.Fan runs and pilot light jumper from #2 to #4 on glows.
  • Page 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine has maximum weld out- 1. LOCAL/REMOTE Switch (S3) put and no control. in wrong position. 2. LOCAL/REMOTE Switch (S3) is faulty, or an open lead going to the LOCAL/REMOTE Switch (S3).
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine has minimum output and 1. If a remote control unit is NOT no control. connected to the terminal strip #75, #76, and #77 terminals, or is not connected to the 14 pin MS receptacle the LOCAL/REMOTE SWITCH must be in the "Local"...
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Machine shuts off (input contactor 1. Remove all welding cables and drops out) when the welder output control cables from the DC 600. terminals are made electrically Jumper #2 to #4 at the terminal "hot".
  • Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS The weld output terminals are 1. Remove any external leads always electrically "hot". hooked to #2 and #4 on the ter- minal strip or any connections to the 14 pin MS connector.
  • Page 37 TROUBLESHOOTING E-10 E-10 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PROBLEMS Poor arc starting when the IDE- 1. Make sure the proper welding ALARC® DC-600 is in the CV procedures are being used. Sub-Arc or CV Innershield Modes.
  • Page 38 TROUBLESHOOTING E-11 E-11 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PROBLEMS Poor arc characteristics in all 1. Check for the correct input volt- processes. ages on the three- phase input lines at the IDEALARC®...

  • Page 39: Troubleshooting Guide

    TROUBLESHOOTING E-12 E-12 Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE Voltage across leads 255 and 256 should be approximately 115VAC. Check voltage across sec- FIRING P.C. BOARD ondary winding of the control transformer (T2) which supplies leads 255 and 256.
  • Page 40 TROUBLESHOOTING E-13 E-13 Observe all Safety Guidelines detailed throughout this manual CHECKING POWER ON/OFF SWITCH (S1) CONNECTING REMOTE OUTPUT CONTROL RHEOSTAT TO THE MACHINE 1. Turn off the machine input power (" "position). Extreme caution must be observed when installing or SW1 has 115 volts across it when the input power extending the wiring of a remote control.
  • Page 41 DIAGRAMS IDEALARC® DC-600...
  • Page 42 DIAGRAMS IDEALARC® DC-600...
  • Page 43 DIAGRAMS IDEALARC® DC-600...
  • Page 44 DIAGRAMS IDEALARC® DC-600...
  • Page 45 DIAGRAMS IDEALARC® DC-600...
  • Page 46 DIAGRAMS IDEALARC® DC-600...
  • Page 47 DIAGRAMS IDEALARC® DC-600...
  • Page 48 DIAGRAMS IDEALARC® DC-600...
  • Page 49 DIAGRAMS IDEALARC® DC-600...
  • Page 50 DIAGRAMS F-10 F-10 IDEALARC® DC-600...
  • Page 51 DIAGRAMS F-11 F-11 IDEALARC® DC-600...
  • Page 52 DIAGRAMS F-12 F-12 IDEALARC® DC-600...
  • Page 53 NOTES IDEALARC® DC-600...
  • Page 54 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 55 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 56 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.

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