Lincoln Electric DC-600 Mode d'emploi
- Catégorie
- Système de soudage
- Taper
- Mode d'emploi
IDEALARC
®
DC600 VRD
Operator’s Manual
Save for future reference
Date Purchased
Code:
(ex: 10859)
Serial: (ex: U1060512345)
IM10018-A | Issue D ate 11-Aug
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
11598, 11613, 11707, 11725,
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
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.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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.
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.
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.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.
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 fields may interfere with some pacemakers, 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.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018
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 It ems 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
hardfacing (see instructions on container or SDS)
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
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also 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 vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to 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.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018
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 the welding sparks
from starting a fire. 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 though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
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.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil 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.
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.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed 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, 14501 George Carter Way
Chantilly, VA 20151.
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.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018
IDEALARC
®
DC-600 VRD
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 suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons 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 l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
iv
SAFETY
iv
vi
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ............................................................................................. A-1
Safety Precautions ..................................................................................................... A-2
Select Proper Location.................................................................................................A-2
Limit on Stacking ...................................................................................................A-2
Stacking.................................................................................................................A-2
Tilting .....................................................................................................................A-2
Electrical Input Connections ....................................................................................... A-3
Fuses and Wire Sizes............................................................................................A-3
Ground Connection .............................................................................................. A-3
Input Power Supply Connections...........................................................................A-3
Reconnect Procedure ................................................................................................ A-4
Output Connections ................................................................................................... A-5
Electrode, Work and #21 Lead ..............................................................................A-5
Auxiliary Power and Control Connections .............................................................A-6
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions ............................................................................................... B-1
General Description ............................................................................................. B-2
Recommended Processes and Equipment ...........................................................B-2
Design Features and Advantages ........................................................................B-2
Welding Capability ............................................................................................... B-3
Meaning of Graphical Symbols on Case Front......................................................B-3
Meaning of Graphical Symbols on Rating Plate ....................................................B-4
Meaning of Graphical Symbol for Ground Connection ..........................................B-4
Controls and Settings ....................................................................................B-4, B-5
Auxiliary Power in MS - Receptacle.......................................................................B-5
Overload, Overcurrent and Fault Protection..........................................................B-6
VRD Voltage Reduction Device Operation............................................................B-6
Operating Steps ................................................................................................... B-7
Remote Control of Machine Operation ..................................................................B-7
Welding Procedure Recommendations ............................................................... B-7
Semi-Automatic and Automatic Wire Feeding
with a IDEALARC
®
DC-600 VRD and Wire Feeders .............................................B-7
NA-3 Automatic Wire Feeder ..........................................................................B-8
NA-5 Automatic Wire Feeder ..........................................................................B-9
________________________________________________________________________
Accessories.....................................................................................................Section C
Wire Feeders and Tractors....................................................................................C-1
Field Installed Options...........................................................................................C-1
Remote Output Control (K775 or K857)..........................................................C-1
Remote Control Adapter Cable (K864) ...........................................................C-1
Undercarriages (K817P, K842).......................................................................C-1
Factory or Field Installed Options..........................................................................C-1
Multi-Process Switch (K804-1)........................................................................C-1
Connections for Semi-Automatic or Automatic Wire Feeder Control ....................C-3
________________________________________________________________________
vii
vii
TABLE OF CONTENTS
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F
Parts List....................................................................................................P-631 Series
60% Duty Cycle
122/61/49
68
A-1
INSTALLATION
IDEALARC
®
DC-600 VRD
A-1
TECHNICAL SPECIFICATIONS – IDEALARC
®
DC-600 VRD
Volts at Rated Amperes
44
44
44
Auxiliary Power
See the OPERATION section
for Auxiliary Power
information by model
Amps
600
680
750
Maximum Open Circuit Voltage
5V for 60 HZ models
5V for 50/60 HZ models
Duty Cycle
100% Duty Cycle
60% Duty Cycle
50% Duty Cycle
Output Range
70A/13V-780A/44V (CV)
90A/24V-780A/44V (CC)
INPUT - THREE PHASE ONLY
OUTPUT
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.
RECOMMENDED INPUT WIRE AND FUSE SIZES
Standard
Voltage
230/460/575/60
415/50/60
CODES
11613, 11707
11598, 11725
100% Duty Cycle
108/54/43
62
50% Duty Cycle
134/67/54
73
Input Current at Rated Output
RATED OUTPUT
INPUT
VOLTAGE /
FREQUENCY
230
460
575
415
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
1
175 Amp
90 Amp
70 Amp
100 Amp
TYPE 75°C
GROUND WIRE
IN CONDUIT
AWG(IEC-MM
2
) SIZES
6 (14)
8 (8.4)
8 (8.4)
8 (8.4)
TYPE 75°C
COPPER WIRE
IN CONDUIT
AWG(IEC-MM
2
) SIZES
30°C (86°F) Ambient
2 (34)
6 (14)
8 (8.4)
6 (14)
INPUT AMPERE
RATING ON
NAMEPLATE
108
54
43
61
HERTZ
60
60
60
50/60
PHYSICAL DIMENSIONS
HEIGHT
30.75 in
781 mm
WIDTH
22.25 in
567 mm
DEPTH
39.0 in
988 mm
WEIGHT
525 lbs.
238 kg.
A-2
INSTALLATION
IDEALARC
®
DC-600 VRD
A-2
SAFETY PRECAUTIONS
Read entire Installation Section before
installing the IDEALARC
®
DC-600 VRD.
ELECTRIC SHOCK CAN KILL.
• 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
®
DC-600 VRD
grounding terminal to a good electrical earth
ground.
• Set the IDEALARC
®
DC-600 VRD Power ON/OFF
PUSH BUTTON to the OFF position when con-
necting power cord to input power.
__________________
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 mini-
mum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
shut-downs.
LIMIT ON STACKING
STACKING
Three IDEALARC
®
DC-600 VRD machines can be
stacked.
DO NOT stack more than three machines in one
grouping.
DO NOT stack the IDEALARC
®
DC-600 VRD 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 bot-
tom 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.
FIGURE A.1 - Stacking IDEALARC
®
DC-600
VRD machines
TILTING
The IDEALARC
®
DC-600 VRD must be placed on a
stable, level surface so it will not topple over.
STACKING HOLE
STACKING PINS
WARNING
• Lift only with equipment of ade-
quate 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 VRD on top of
any other machine.
------------------------------------------------------------------------
WARNING
A-3
INSTALLATION
IDEALARC
®
DC-600 VRD
A-3
ELECTRICAL INPUT CONNECTIONS
Before installing the machine check that the input sup-
ply 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 open-
ing, Input Contactor (CR1), and reconnect panel
assembly for dual voltage machines.
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 ther-
mal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in “nui-
sance” 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 contac-
tor. Access to the Input Box Assembly is at the upper
rear of the machine. See your local and national elec-
trical codes for proper grounding methods.
INPUT POWER SUPPLY CONNECTIONS
A qualified electrician should connect the input power
supply leads.
1. Follow all national and local electrical codes.
2. Use a three-phase line.
3. Remove Input Access Door at upper rear of
machine.
4. Follow Input Supply Connection Diagram located
on the inside of the door.
5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
terminals in the Input Box Assembly by passing
them thru the three aligned .50” diameter holes in
the baffle and tighten them in the terminal connec-
tors. Be sure to close the baffle by inserting the
tab into the slot in the baffle. See Figure A.3.
FIGURE A.3 - Input Power Supply
Connections
INPUT SUPPLY
CABLE ENTRY
OPENING
INPUT
CONTACTOR (CR1)
RECONNECT
PANEL ASSEMBLY
INPUT POWER SUPPLY
CABLE WITH BUSHING
OR BOX CONNECTOR
INPUT
CONTACTOR (CR1)
RECONNECT
PANEL ASSEMBLY
FIGURE A.4-Reconnect Panel Board Positions for Single Voltage Machines
L3
L2
L1
LINES
INPUT
GND
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
W
V
U
CONTACTOR
CRI
FIGURE A.5-Reconnect Panel Board Positions for 230/460/575 VAC Machines
A-4
INSTALLATION
IDEALARC
®
DC-600 VRD
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 con-
nected for the proper voltage.
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 con-
nection diagrams for the following codes are listed
below.
1. For 415 Single Voltage, see Figure A.4. (S17894)
2. For 230/460/575, see Figure A.5. (M15666)
CAUTION
A-5
INSTALLATION
IDEALARC
®
DC-600 VRD
A-5
OUTPUT CONNECTIONS
See Table A.1 for recommended IDEALARC
®
DC-600 VRD cable sizes for combined lengths of electrode and
work cables.
TABLE A.1
IDEALARC
®
DC-600 VRD Cable Sizes for Combined Lengths of Copper Electrode and Work
Cable at 100% Duty Cycle
Cable SizeParallel CablesCable Length
1/0 (53mm
2
)2
2
2
Lengths up to 150 ft. (46m)
2/0 (67mm
2
)150 ft.(46m) to 200 ft (61m)
3/0 (85mm
2
)200 ft.(61m) to 250 ft.(76m)
ELECTRODE, WORK AND #21 LEAD
CONNECTIONS
A. Connect Electrode and Work Leads to
Output Terminals.
1. Set the ON/OFF toggle switch to OFF.
2. Locate the retractable strain relief loops directly
below the output terminals in the lower right and
lower left corners of the Case Front Assembly.
See Figure A.6.
3. Pull out the retractable strain relief loops.
4. Insert the electrode lead through the loop directly
below the desired polarity (positive or negative).
Pull through enough cable to reach the output
terminals.
5. Connect electrode lead to the desired terminal
(positive/negative).
6. Tighten the output terminal nut with a wrench.
7. Connect the work lead to the other output
terminal following steps 4-6.
FIGURE A.6 - Output Terminals.
B. Connect #21 Work Sense Lead to Proper
Terminal
There are two work sense lead connection points (+21
and -21) on terminal strip (T.S.2) located behind the
hinged access panel on the right side of the case
front. See 14 Pin MS Type Receptacle section or
Terminal Strip Section for connection procedure.
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 termi-
nals 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 weld-
ing negative polarity.
TERMINAL STRIP 1 (T.S.1)
TERMINAL STRIP 2 (T.S.2)
Lead No. Function
75 Output Control
76 Output Control
77 Output Control
Lead No. Function
+21
Work Connection (Electrode Negative)
-21
Work Connection (Electrode Positive)
(2)
41 42 VAC
4 Trigger Circuit
2 Trigger Circuit
31 115 VAC
(1)
32 115 VAC
(1)
A-6
INSTALLATION
IDEALARC
®
DC-600 VRD
A-6
AUXILIARY POWER AND CONTROL CON-
NECTIONS
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 con-
nections for auxiliary equipment are located behind the
hinged access panel on the right side of the case front.
(see Auxiliary Power Table for details)
115VAC DUPLEX RECEPTACLE (60 HERTZ
MODELS ONLY)
The 115VAC duplex receptacle is protected by a 15
Amp circuit breaker located on the nameplate. The
receptacle is a NEMA 5-15R.
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 15A No Duplex
Receptacle 115V
Terminal strip 115V 15A 115V 15A
terminals 31 & 32
MS-Receptacle 115V 15A 115V 15A
pins A & J
MS-Receptacle 42V 10A 42V 10A
pins I & K
PIN LEAD NO. FUNCTION
A 32 115 VAC
(3)
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
(2)
I 41 42 VAC
J 31 115 VAC
(3)
K 42 42 VAC
L --- ---
M --- ---
N --- ---
F=76
G=75
H=21
I=41
J=31
K
=
42
A=32
B=GND
C=2
D=4
E=77
L N
M
F=76
G=75
H=21
I=41
K
=
42
B=GND
C=2
D=4
E=77
LN
M
(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 con-
figuration for positive welding. If welding negative polarity, con-
nect lead #21 to the “+21” connection point on the terminal strip
(T.S.2).
(3)
115VAC is not available at the 14 Pin connector on Codes 11707,
11725.
14 PIN MS TYPE RECEPTACLE
(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
Refer to the Figure A.7 for the available circuits in the
14 pin receptacle.
42 VAC is available at receptacle pins I and K.
A 10 amp circuit breaker protects this circuit.
On codes 11598 and 11613, 115 VAC is available at
receptacle pins A and J. A 15 amp circuit breaker pro-
tects this circuit. (See Figure A.7 for pin allocation).
Note that the 42 VAC and 115 VAC circuits are electri-
cally isolated from each other.
FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE
Table for Codes 11598, 11613
Auxiliary 60 Hz 50/60 Hz
Power Models Models
Connections
At Duplex 15A No Duplex
Receptacle 115V
Terminal strip 115V 15A 115V 15A
terminals 31 & 32
MS-Receptacle 42V 10A 42V 10A
pins I & K
Table for Codes 11707, 11725
FIGURE A.7
Pin location for Codes 11598, 11613
Pin location for Codes 11707, 11725
B-1
OPERATION
IDEALARC
®
DC-600 VRD
B-1
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
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 cloth-
ing, gloves or work area is damp or
if working on, under or inside work-
piece.
Use the following equipment:
-Semiautomatic DC constant volt-
age (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.
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 GOUG-
ING SPARKS can cause fire or
explosion.
• Do not weld near flammable material.
• Do not weld, cut or gouge on contain-
ers which have held flammable materi-
al.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines
detailed in the beginning of this manual.
------------------------------------------------------------------------
WARNING
B-2
OPERATION
B-2
IDEALARC
®
DC-600 VRD
GENERAL DESCRIPTION
The IDEALARC
®
DC-600 VRD includes a proprietary design which is
available in certain arc welding power sources such as the DC 600
and 400. This internal circuitry applies a high frequency, low voltage
signal through the Electrode and Work terminals, while disabling the
output of the power source. The OCV ( open circuit voltage) during
this period is less than 2 Volts RMS at 70kHz. When an Electrode to
Work load of 100 ohms or less is applied, the output of the power
source is enabled, allowing normal welding operation. When the out-
put load is removed, within 0.3 seconds, the output is again disabled
reducing the OCV to less than 2 Volts RMS
The IDEALARC
®
DC-600 VRD is an SCR controlled three phase
welding and cutting power source. It uses a single range potentiome-
ter to control:
• Submerged Arc Semi-Automatic or Automatic Welding
• Open Arc Semi-Automatic or Automatic Welding
• Stick Welding
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to 3/8” Diameter)
The IDEALARC
®
DC-600 VRD has a three-position Welding Mode
Switch to enable the user to operate in one of three modes:
• Constant Current (CC) Stick also used for Air Carbon Arc Cutting
Process (AAC)
• Constant Voltage (CV) Submerged Arc
• Constant Voltage (CV) Innershield (also used for FCAW/GMAW)
Two VRD models are available:
• Domestic - 230/460/575V 60 Hertz model
• Export-415V 50/60 Hertz model
The optional Multi-Process Switch allows the user to switch between
semi-automatic or automatic welding and stick welding or air/carbon
arc cutting without disconnecting the wire feeder equipment control,
electrode, and work leads.
RECOMMENDED PROCESSES AND EQUIPMENT
The IDEALARC
®
DC-600 VRD is designed for GMAW (MIG), FCAW,
and submerged arc (SAW) within the capacity of the machine. It can
also be used for stick welding (SMAW) and for air carbon arc (AAC)
cutting with carbon rods up to 3/8" diameter.
The IDEALARC
®
DC-600 VRD is provided with a three position mode
switch that selects CV Innershield, CV Submerged Arc, or CC Stick.
The IDEALARC
®
DC-600 VRD can be easily connected to wire feed-
ing equipment, including:
• Semi-automatic wire feeders LN-7*, LN-7 GMA*, LN-742, LN-8*,
LN-9*, LN-9 GMA*, LN- 10, LN-15 LN-23P, LN-25, and DH-10.
• Automatic wire feeders NA-3*, NA-5*, and NA-5R*.
• Tractors LT-56* and LT-7*
*The 14-pin MS receptacle on codes 11707 and 11725 does not provide
115VAC for these feeders; 115VAC must be obtained from terminal
strip.
DESIGN FEATURES AND ADVANTAGES
• No large output mechanical contactors or Solid State switches such
as SCRʼs, etc; are added to the Electrode to Work output circuit.
• “Tamper Resistant” design. Circuitry is built into power source, not
an exterior package which could easily be tampered with.
• No reduction of power source output rating. This feature does not
affect the rating of the power source.
• Self diagnostics upon machine power up. Indicator lights are test-
ed.
• Green lamp on when weld voltage is less than 30 volts. If weld volt-
age exceeds 30 volts, Green lamp turns off and Red lamp turns on.
• Output is disabled if OCV > 50 volts is sensed.
• Excellent arc characteristics for optimum constant voltage sub-
merged 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 con-
tinuous 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 ener-
gized.
• 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 mod-
els, 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 acci-
dentally 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 over-
loads.
• 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 perfor-
mance 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 dam-
age.
• 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.
B-3
OPERATION
B-3
IDEALARC
®
DC-600 VRD
WELDING CAPABILITY
The IDEALARC
®
DC-600 VRD has the following Output and Duty Cycle based on operation for a 10 minute period:
600 Amps, 44 Volts at 100%
680 Amps, 44 Volts at 60%
750 Amps, 44 Volts at 50%
MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT
Input POWER ON/OFF Switch
SYMBOL
MEANING
ON
OFF
INPUT POWER
Input power on when light is illuminated
(except for abnormal conditions).
Indicates main Transformer is operating.
Pilot Light
OUTPUT CONTROL
OUTPUT VOLTAGE
AND CURRENT
Clockwise Increase of Output
Voltage and Current
TERMINALS ON/REMOTE Switch
OUTPUT TERMINALS
ENERGIZED
Remote Control of Output Terminals
(Energized or Non-Energized)
LOCAL/REMOTE Switch
SYMBOL
MEANING
Control Of Output Voltage and
Current is Via IDEALARC
®
DC-600
VRD's Control Dial
Remote Control of Output Voltage
and Current
MODE Switch
CC STICK: Shielded Metal Arc
Welding (SMAW), this switch
position is also used for Air
Carbon Arc Cutting (AAC)
CV SUBMERGED ARC:
Constant Voltage Submerged
Arc Welding (SAW)
CV INNERSHIELD: Flux Cored
Arc Welding (FCAW), this switch
position is also used for Gas
Metal Arc Welding (GMAW).
Output Terminal Connections
Positive Output Terminal
Negative Output Terminal
WARNING Identification
Warning Identification
Circuit Breaker
Circuit Breaker (two breakers: 15A for
115V circuit and 10A for 42V circuit)
Thermal Protection Light
On when power source exceeds nor-
mal operating temperature.
CONTROLS AND SETTINGS
All operator controls and adjustments are located on
the Case Front Assembly of the IDEALARC
®
DC-600
VRD. See Figure B.1 for the location of each control.
FIGURE B.1 - CONTROL PANEL KEYS
1
2
3
4
5
6
7
8
9
10
DC-600 VRD
13
12
7
5
11
2
1
4
9
8
6
3
10
15
14
B-4
OPERATION
IDEALARC
®
DC-600 VRD
B-4
3 Phase transformer with rectified
DC output
Line Connection
Three Phase Input Power
Designates welder complies with
National Electrical Manufacturers
Association requirements EW 1
Class I with 100% duty cycle at
600Amps output.
Gas Metal Arc Welding (GMAW)
Flux Cored Arc Welding (FCAW)
MEANING OF GRAPHICAL
SYMBOLS ON RATING PLATE
(LOCATED ON CASE BACK)
NEMA EW 1 (100%)
Shielded Metal Arc Welding (SMAW)
Submerged Arc Welding (SAW)
MEANING OF GRAPHICAL
SYMBOL FOR GROUND CON-
NECTION
Signifies the equipment connection
point for the protective earth ground
1. Input POWER ON/OFF Switch
This toggle switch turns the machine on or off.
Putting the switch in the ON “ ” position ener-
gizes the machineʼs input contactor applying input
power to the machine. Switching the switch to the
OFF “ ” position de-energizes the input con-
tactor.
2. POWER Light
When the POWER switch is in the ON position the
machineʼs white POWER light will illuminate. If the
input contactor de-energizes the machine in an
abnormal situation the pilot light will turn off. In this
situation it may be necessary to reset the machine
by switching the POWER switch to the OFF and
then to the ON position. (See Overload,
Overcurrent, and Fault Protection Section)
B-5
OPERATION
B-5
IDEALARC
®
DC-600 VRD
3. OUTPUT CONTROL
This control provides continuous control of the
machineʼs output voltage and current from mini-
mum to maximum (typical full pot range between
15 to 44 volts and 90 to 750 amps) as it is rotated
clock-wise. Voltage or current control is deter-
mined by setting of Mode Switch (CV or CC).
4. OUTPUT TERMINALS ON/REMOTE Switch
When this switch is in the REMOTE “ ” posi-
tion, the IDEALARC
®
DC-600 VRDʼs output termi-
nals will be electrically “cold” until a remote device
such as a wire feeder closes the #2 and #4 circuit
in the MS-receptacle or terminal strip (T.S.2).
When this switch is in the ON “ ” position the
machineʼs output terminals will be electrically
energized all the time.
5. LOCAL/REMOTE Switch
When this switch is set to the LOCAL “ “ posi-
tion, control of the output voltage and current is via
the OUTPUT CONTROL on the IDEALARC
®
DC-
600 VRDʼs control panel. When this switch is set
to the REMOTE “ ” position, control is
through a remote source such as a wire feeder via
the #75, #76, and #77 leads in the MS-receptacle
or terminal strip (T.S.1).
6. Mode Switch
This switch allows for selecting the welding
process to be used:
CC STICK-for SMAW and AAC
CV SUBMERGED ARC- for SAW
CV INNERSHIELD- for FCAW and GMAW
7. 115VAC Duplex Receptacle (60 Hertz Models)
This receptacle provides up to 15 amps of 115
VAC auxiliary power.
8. 115VAC 15 Amp Circuit Breaker
This breaker protects the 115 VAC auxiliary cir-
cuits located in the duplex receptacle, terminal
strip (T.S.2) and MS-receptacle.
9. 42VAC 10 Amp Circuit Breaker
This breaker protects the 42VAC auxiliary circuits
located in the terminal strip (T.S.2) and MS-recep-
tacle.
10. 14 Pin MS-Receptacle
This connector provides easy connection for a
wire feeder control cable. It provides connections
for auxiliary power, output switching, remote out-
put control, wire feeder voltmeter sense lead and
ground. Refer to 14 Pin MS Type Receptacle in
the Installation Section for information about the
circuits made available at this receptacle.
11. Terminal Strip Cover Panel
Rotate this panel to gain access to the circuits
made available at the two terminal strips (T.S.1
and T.S.2). These terminal strips contains the
same circuits as the 14 pin MS-receptacle. There
is a box connector adjacent to this cover for rout-
ing leads to the terminal strips.
12. Negative Output Terminal
This output terminal is for connecting a welding
cable. To change welding polarity and for proper
welding cable size refer to Electrode and Work
Cables in the Installation Section.
13. Positive Output Terminal
This output terminal is for connecting a welding
cable. To change welding polarity and for proper
welding cable size refer to Electrode and Work
Cables in the Installation Section.
14. VRD Lights
When VRD is active, in CC mode, these lights
illuminate based on the stud voltage while weld-
ing. The green light will be on when the welding
voltage is under 30 volts and the red light light will
turn on when the voltage is 30 volts or greater.
15. Thermal Protection Light (Only on Codes
11707 and 11725)
An amber light on the machine control panel indi-
cates when either of the two protective ther-
mostats has opened. Output power will be dis-
abled temporarily. Thermostat will automatically
reset when the machine cools to an acceptable
operating temperature.
AUXILIARY POWER IN MS-RECEP-
TACLE
42 volt AC auxiliary power, as required for some wire
feeders, is available through the wire feeder MS-
receptacle. A 10 amp circuit breaker protects the 42
volt circuit from overloads.
On Codes 11598 and 11613, IDEALARC
®
DC-600
VRD machines supply 115 volt AC auxiliary power
through the wire feeder receptacle. A 15 amp circuit
breaker protects the 115 volt circuit from overloads.
Whenever the CC welding mode is selected and
power is turned on, or power is on and the welding
mode is changed from Constant Voltage (CV) to
Constant Current (CC), the VRD circuitry performs a
self test for approximately five seconds. For one sec-
ond the input contactor and the cooling fan will turn
on, then off. With welding inhibited, the studs will be
examined. Both VRD lights will be on to indicate that
the machine is in self test mode.
After passing the self test, only the green light remains
on and the machine is ready to weld. If the test fails,
both lights will remain on and welding remains inhibit-
ed. This could be caused by the stick electrode hold-
er being shorted to work, or if an across the arc wire
feeder, such as the LN 25, is connected to the power
source.
To use a system with sense leads in CC mode on a
VRD model, disconnect the feederʼs work sense lead
prior to the self test. After passing the self test, recon-
nect the work sense lead.
• In CC mode, the VRD will reduce the output voltage
regardless of the position of the “TERMINALS
ON/REMOTE” Switch.
• The voltmeter will display zero volts until the elec-
trode contacts the work and establishes the welding
arc.
NOTE:
Under normal circumstances, the machine will never
be able to exceed 49 volts while not welding. If,
under abnormal circumstances, the output voltage
were to exceed 49 volts while not welding, the VRD
turns the output off. The green light would be on
because the voltage would be zero and the pilot light
will be off, but establishing an arc would not be pos-
sible. The machineʼs “POWER ON/OFF” Switch
must be cycled off, then back on, to restore normal
operation.
B-6
OPERATION
B-6
OVERLOAD, OVERCURRENT, AND
FAULT PROTECTION
This welder has thermostatic protection from exces-
sive duty cycles, overloads, loss of cooling, and high
ambient temperatures. When the welder is subjected
to an overload or loss of cooling, a thermostat will
open. The input contactor will open and remain open
until the machine cools; the white POWER light stays
illuminated. No welding is possible during this cool
down period. The machine will reset automatically
when the thermostat cools.
The power source is also protected against overcur-
rents in the SCR bridge assembly through an elec-
tronic protection circuit. This circuit senses currents
over 780 amps on the power source and opens the
input contactor should the overcurrent remain for a
predetermined time (the white POWER light also turns
off).
The predetermined time varies with the amount of
overcurrent; the greater the overcurrent, the shorter
the time. The input contactor will remain open until
the power source is manually started by resetting the
POWER ON/OFF toggle switch.
For codes 11707 and above.
The power source is protected against overvoltage
when not welding in CC mode. If the protection circuit
senses voltage in excess of 49V at the studs when no
welding is taking place, the POWER light will turn off.
The input contactor will open up and remain open until
the power source is manually restarted by toggling the
ON/OFF switch.
The power source circuitry is protected from faults on
leads 75, 76, or 77. If any of these leads are connect-
ed to either the positive or negative output leads, the
IDEALARC
®
DC-600 VRD will either shut down com-
pletely (input contactor opens and white POWER light
turns off), or will operate at minimum output thus pre-
venting any damage to the IDEALARC
®
DC-600 VRD.
If IDEALARC
®
DC-600 VRD shuts down, it must be
manually started by resetting the POWER ON/OFF
toggle switch.
VRD (VOLTAGE REDUCTION
DEVICE) OPERATION
The VRD electronic circuitry is designed to reduce the
OCV of the power source in the Constant Current
(CC) Stick welding mode only. The operation of the
machine with the VRD is slightly different than the
operation of a standard machine. The following
describes the machine operation with the VRD
installed in the DC600.
IDEALARC
®
DC-600 VRD
RED
ON
ON
OFF
OFF
GREEN
ON
OFF
ON
OFF
Power source is in self test mode.
Output voltage is greater than 30 V.
Output voltage is less than 30 V.
Power source is in CV mode.
LED STATUS
LED STATUS
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Lincoln Electric DC-600 Mode d'emploi
- Catégorie
- Système de soudage
- Taper
- Mode d'emploi
dans d''autres langues
Documents connexes
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Lincoln Electric IM463-A Manuel utilisateur
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