Lincoln Electric IDEALARC DC-600 Operating Manual
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Lincoln Electric IDEALARC DC-600 Operating Manual

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See also: Service Manual , Operator's Manual
IMA 607A
December 2005
OPERATING MANUAL
IDEALARC DC-600
SAFETY DEPENDS ON YOU
Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be
increased by proper installation and thoughtful operation on your part. Read and observe the general safety
precautions on page 2 and follow specific installation and operating instructions included in this manual.
Most importantly, think before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
(AUSTRALIA) PTY. LTD.
A.B.N. 36 000 040 308
SYDNEY. AUSTRALIA
A Subsidiary of
THE LINCOLN ELECTRIC CO. U.S.A.
Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS

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Summary of Contents for Lincoln Electric IDEALARC DC-600

  • Page 1 IDEALARC DC-600 SAFETY DEPENDS ON YOU Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be increased by proper installation and thoughtful operation on your part. Read and observe the general safety precautions on page 2 and follow specific installation and operating instructions included in this manual.

  • Page 2: Arc Welding Safety Precautions

    PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION. ARC WELDING SAFETY PRECAUTIONS ARC RAYS can burn ELECTRIC SHOCK can kill 1.
  • Page 3 3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric. 4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Service Facilities. (The “Lincoln Service Directory”...

  • Page 4: Welding, Emf & Pacemakers

    That welder and his or her pacemaker may be quite practice to eliminate a common problem on welding - a different from you and your pacemaker. poor work connection. • Do not work next to the welding power source. Page 4 Idealarc DC-600 IMA 607A...

  • Page 5: Instructions For Electromagnetic Compatibility

    Maintenance of the Welding Equipment Products are: The welding equipment should be routinely maintained according • for use with other Lincoln Electric/LiquidArc equipment. to the manufacturer’s recommendations. All access and service • designed for industrial and professional use. doors and covers should be closed and properly fastened when Introduction the welding equipment is in operation.

  • Page 6: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - IDEALARC DC-600 INPUT - THREE PHASE ONLY Part No.. Standard Voltage Rated Input Current to AS1966 KA1342-1 415/3/50/60 KA1342-2 380/500/3/50/60 68/51 KA1342-3 220/380/440/3/50/ 117/68/58 KA1342-3 230/380/460/3/60 100/68/50 KA1342-4 200/3/5/60 KA1342-5 380/550/3/50 79/55 KA1342-5 380/575/3/60 79/47 RATED OUTPUT...

  • Page 7: Safety Precautions

    Figure A.1 Stacking Idealarc DC-600 machines STACKING HOLE STACKING PINS TILTING The Idealarc DC-600 must be placed on a stable, level surface so it will not topple over. IMA 607A Idealarc DC-600 Page 7...

  • Page 8: Input Power Supply Connections

    For 200 Voltage, see Figure A.4. (AT3164-11). For 380/550/575, see Figure A.5. (AT3164-12). For Voltages not listed, see the Input Connection Diagram pasted on the inside of the Case Back Input Access Door. Page 8 Idealarc DC-600 IMA 607A...
  • Page 9 INPUT CONTACTOR 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 WITH THE PROVIDED HEX NUTS. PILOT TRANSF IMA 607A Idealarc DC-600 Page 9...

  • Page 10: Output Connections

    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 Electrode and Work Cable (Copper) at 100% Duty Cycle Cable Length...

  • Page 11: Recommended Processes And Equipment

    OPERATING INSTRUCTIONS WARNING RECOMMENDED PROCESSES AND EQUIPMENT The Idealarc DC-600 is recommended for the following welding or Read and understand entire section before operating machine. cutting processes within its output capacity of 70 amps to 850 amps in the Constant Voltage mode and 90 amps to 850 amps in...

  • Page 12: Welding Capability

    (Based on 10 min) 100% 50/60 CONTROLS AND SETTINGS All operator controls and adjustments are located on the Case Front Assembly of the Idealarc DC-600. See Figure B.1 for the location of each control. Figure B.1 Control Panel Keys 8. AMP FUSE...

  • Page 13: Operating Steps

    OPERATING STEPS SEMI-AUTOMATIC AND AUTOMATIC WIRE FEEDING WITH A IDEALARC DC- The following procedures are for using the Idealarc DC-600 in the local control mode of operation. For remote control of the 600 AND WIRE FEEDERS machine, see the Remote Control of Machine Operation section.

  • Page 14: Semi-Automatic Wire Feeder

    IDEALARC DC-600 POWER SOURCE SETTING WHEN CONNECTED TO NA-5 WIRE FEEDER When using the Idealarc DC-600 with the NA-5 wire feeder, set the controls on the Idealarc DC-600 as follows for the best performance: Turn OFF main AC input power supply to the Idealarc DC- 600.

  • Page 15: Multi-Process Switch

    Follow these steps to install the MULTI-PROCESS SWITCH: Connect the control leads from the MULTI-PROCESS Confirm that the Idealarc DC-600 ON/OFF PUSH BUTTON SWITCH to terminals #2 and #4 on the Idealarc DC-600's is in the OFF position. terminal strip.

  • Page 16: Paralleling Kit For Dc-600

    Connect the right cable from the MULTI-PROCESS installed, the Idealarc DC-600 lift bail is no longer functional. Do SWITCH (facing the front of the machine) to the Idealarc not attempt to lift the machine with the undercarriage attached. DC-600 positive (+) output terminal. See Figure C.4.
  • Page 17 To change polarity: c. Keep the # 21 lead electrically separate from the work a. Set the Idealarc DC-600 ON/OFF PUSH BUTTON to cable circuit and connection. OFF. d. Tape the # 21 lead to work cable for ease of use.
  • Page 18 Note: The Idealarc DC-600 must be properly grounded. Figure C.7 LN-8 or LN-9 Wire Feeder Connectionto the Idealarc DC-600 PERFORM THIS STEP ONLY IF THE LN-7 IS EQUIPPED WITH A METER KIT. LN8 OR LN 9 WIRE FEEDER Extend wire feeder control cable lead #21 so it can be...

  • Page 19: Ground Test Procedure

    Inspect the electrode cables for any slits or punctures in the Note: The fan motor has sealed bearings which require no cable jacket, or any condition that would affect the proper maintenance. operation of the machine. IMA 607A Idealarc DC-600 Page 19...
  • Page 20 NOTES Page 20 Idealarc DC-600 IMA 607A...

  • Page 21: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorised 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 22: Pc Board Troubleshooting Procedures

    If the P.C. Board uses protective shorting jumpers, don’t remove them until installation is complete. If you return a P.C. Board to The Lincoln Electric Sometimes machine failures appear to be due to PC board Company for credit, it must be in the static-shielding failures.

  • Page 23: Output Problems

    (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Major Physical or Electrical Contact the Lincoln Electric Service Damage is Evident The machine is dead - the Input 1. Check for blown or missing fuses contactor does not operate. in input lines.
  • Page 24 If the problem disappears the fault is in the control cable or wire feeder. 2. If some open circuit voltage is present (over 3VDC) after performing Step #1, then the problem is within the DC-600. Page 24 Idealarc DC-600 IMA 607A...

  • Page 25: Welding Problems

    Lincoln Authorised Field Service the DC-600. Facility 2. Make sure the proper welding procedures are being used (wire feed speed, arc voltage and wire size). 3. Check the welding cables for loose or faulty connections. IMA 607A Idealarc DC-600 Page 25...
  • Page 26 Figure D.1 General Assembly Exploded View Page 26 Idealarc DC-600 IMA 607A...

  • Page 27: Parts List

    AP216-E AP216-F AP216-G AP216-H AP216-J AP239 AP84-J CODE NO. 1272 1273 1311 1312 1318 1319 1322 1323 1327 1329 1334 1435 1434 1485 1503 1548 1549 1622 1623 1633 # Indicates a change this printing IMA607A Idealarc DC-600 Page 27...

  • Page 28: Optional Equipment Listing

    Paralleling Kit ..............Order KA1010 Page 28 Idealarc DC-600 IMA 607A...

  • Page 29: Miscellaneous Items

    200/3/50 AL2331 380/550/575/3/50 AL2331 380/500/3/50 AL2331 Ground Decal T13259 Identification Sticker (CR1) T14798-1 Caution Decal S16307 Warning Decal AS4244 Instruction Decal T14446 Ground Decal T13259 Caution Decal (Case Front) T13086-20 Reed Switch (3CR) S12334-32 IMA 607A Idealarc DC-600 Page 29...
  • Page 30 AP-216-C Operative: May 2003 Supersedes: Case Front Panel Assembly (Control Box Assembly shown) Page 30 Idealarc DC-600 IMA 607A...
  • Page 31 This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates. IMA 607A Idealarc DC-600 Page 31...
  • Page 32 AP-216-D Operative: May 2003 Supersedes: Control Box Assembly (Case Front Panel Assembly shown) Page 32 Idealarc DC-600 IMA 607A...
  • Page 33 14 pin Amphenol Plug Base (code 1548 & above) S12021-40 Box Connector T9639-1 Plug Button T13597-1 Number Plate AS4236 Door and Welded Assembly S17750 Self Tapping Screw S8025-71 Decal T13260-3 Terminal Strip S8542-7 Self Tapping Screw S8025-15 IMA 607A Idealarc DC-600 Page 33...
  • Page 34 AP-216-E Operative: May 2003 Supersedes: Case Rear Panel Assembly Page 34 Idealarc DC-600 IMA 607A...
  • Page 35 380/500 Volt AM2681-2 575 Volt (60HZ) 380/500/575 PT0064 Self Tapping Screw S8025-71 Bushing T12380-2 Rear Panel AL2375 Self Tapping Screw S8025-71 - Whit Hex Nut AM3055-90 * Codes below 1503 require Contactor Kit G3146 IMA 607A Idealarc DC-600 Page 35...
  • Page 36 AP-216-F Operative: May 2003 Supersedes: Transformer Assembly Page 36 Idealarc DC-600 IMA 607A...
  • Page 37 9355C 380/500/3/50 9359C 380/500/575/3/50 9384CX Top Secondary Transformer Coil M13904-1 Bottom Secondary Transformer Coil M13904-2 Threaded Rod AS4324-6 Washer S9262-120 3/8-16 Hex Nut AM3055-115 Transformer Lamination Assembly L3841-29 Thermostat (Secondary) T13359-7 Thermostat (Primary) M17192-2 IMA 607A Idealarc DC-600 Page 37...
  • Page 38 AP-216-G Operative: May 2003 Supersedes: SCR Bridge Assembly (Lift Base Assembly shown) Page 38 Idealarc DC-600 IMA 607A...
  • Page 39 Aluminum Heat Sink M12314-3 Bridge Tie Bar S16181-6 Bridge Tie Bar S16181-5A SCR* M12283-10 Plug & Lead Assembly (Not Shown) S18250-213 Cathode Heat Sink AM2435-1 Mounting Clamp Spring S14724A Mounting Clamp, S14724B Shunt Assembly M19044 IMA 607A Idealarc DC-600 Page 39...
  • Page 40 AP-216-H Operative: May 2003 Supersedes: Lift Bale, Choke Assembly (SCR bridge Assembly shown) Page 40 Idealarc DC-600 IMA 607A...
  • Page 41 #8-32 x .50 Round Head Screw Reed Switch Plate S11797-15 Lock Washer #8-32 Hex Nut Identification Sticker T14798-3 Shunt Assembly includes: M19044 -16 x 1.00 Hex Head Cap Screw -16 Hex Nut Shunt (500 amp) S6602-20 IMA 607A Idealarc DC-600 Page 41...
  • Page 42 AP-216-J Operative: Supersedes: Base, Fan, Sides & Roof Assembly Page 42 Idealarc DC-600 IMA 607A...
  • Page 43 Cover Seal S12934 Fan Motor M9983-4 Fan Baffle L6247 Self Tapping Screw S8025-65 M6819-9 7&8 Fan Bracket Brace (Left & Right) M16525 Side Panel AL2098-2 Self Tapping Screw S8025-65 Self Tapping Screw S8025-79 Base L5928-3 IMA 607A Idealarc DC-600 Page 43...
  • Page 44 DIAGRAMS Page 44 Idealarc DC-600 IMA 607A...
  • Page 45 NOTES IMA 607A Idealarc DC-600 Page 45...
  • Page 46 NOTES Page 46 Idealarc DC-600 IMA 607A...
  • Page 47 NOTES IMA 607A Idealarc DC-600 Page 47...

  • Page 48: Limited Warranty

    Briggs & Stratton for 5 years. CUSTOMER ASSISTANCE POLICY service dealer). The business of The Lincoln Electric Company is manufacturing and selling high quality Kubota Engines and Accessories *Subject to conditions welding equipment, consumables, and cutting equipment. Our challenge is to meet the (Warranty service can only be carried out an imposed by Kubota.

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