Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii IDEALARC® DC-600 VRD ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable cloth...
Page 4 - iii; Refer to
iii SAFETY iii IDEALARC® DC-600 VRD FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendati...
Page 5 - PRÉCAUTIONS DE SÛRETÉ; iv
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...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TAbLE OF CONTENTS
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ............................................................................................. A-1Safety Precautions .......
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – IDEALARC® DC-600 VRD; See the OPERATION section; INPUT - THREE PHASE ONLY
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 444444 Auxiliary Power See the OPERATION section for Auxiliary Power information by model Amps 600680750 Maximum Open Circuit Voltage 5V for 60 HZ models 5V fo...
Page 10 - SAFETY PRECAUTIONS; LIMIT ON STACKING; STACKING HOLE
A-2 INSTALLATION IDEALARC® DC-600 VRD A-2 SAFETY PRECAUTIONS R e a d e n t i r e I n s t a l l a t i o n S e c t i o n b e f o r einstalling the IDEALARC® DC-600 VRD. ELECTRIC SHOCK CAN KILL. • Only qualified personnel should install this machine. • Turn the input power OFF at the d i s c o n n e c ...
Page 11 - ELECTRICAL INPUT CONNECTIONS; FUSE AND WIRE SIzES; DO NOT; GROUND CONNECTION
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 thevoltage, phase, and frequency as specified on thew e l d e r R a t i n g P l a t e l o c a t e d o n t h e C a s e B a c ...
Page 12 - SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE; RECONNECT PROCEDURE
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. CONN...
Page 13 - OUTPUT CONNECTIONS
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 andwork cables. TAbLE A.1 IDEALARC® DC-600 VRD Cable Sizes for Combined Lengths of Copper Electrode and Work Cable at 100% Duty Cycle Cable Si...
Page 14 - TERMINAL STRIPS; AUXILIARY POWER TAbLE; PIN; 4 PIN MS TYPE RECEPTACLE
TERMINAL STRIPS Terminal strips are available behind the cover on thecase front to connect wire feeder control cables thatdo not have a 14 Pin MS-type connector. These termi-nals supply the connections as shown in the followingTerminal Strip charts. NOTE: There are two worksense lead connection poin...
Page 15 - OPERATION; ELECTRIC SHOCK can kill.
b-1 OPERATION IDEALARC® DC-600 VRD b-1 SAFETY PRECAUTIONS Read this entire section of operating instructionsbefore operating the machine. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or e l e c t r o d e s w i t h y o u r s k i n o r w e tclothing. • Insulate yourself from the wor...
Page 16 - GENERAL DESCRIPTION
b-2 OPERATION b-2 IDEALARC® DC-600 VRD GENERAL DESCRIPTION The IDEALARC® DC-600 VRD includes a proprietary design which isavailable in certain arc welding power sources such as the DC 600and 400. This internal circuitry applies a high frequency, low voltagesignal through the Electrode and Work termi...
Page 17 - WELDING CAPAbILITY; SYMbOL
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...
Page 18 - CONTROLS AND SETTINGS; Line Connection
CONTROLS AND SETTINGS All operator controls and adjustments are located onthe Case Front Assembly of the IDEALARC® DC-600VRD. 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 49 8 6 3 10 15 14 1 2 3 4 5 6 7 8 9 10 DC-60...
Page 19 - On Codes
b-5 OPERATION b-5 IDEALARC® DC-600 VRD 3. OUTPUT CONTROL This control provides continuous control of themachine’s output voltage and current from mini-mum to maximum (typical full pot range between15 to 44 volts and 90 to 750 amps) as it is rotatedclock-wise. Voltage or current control is deter-mine...
Page 20 - “TERMINALS
W h e n e v e r th e C C w e l d i n g mo d e i s s e l e c t e d a n dpower is turned on, or power is on and the weldingm o d e i s c h a n g e d f r o m C o n s t a n t V o l t a g e ( C V ) t oConstant Current (CC), the VRD circuitry performs aself test for approximately five seconds. For one sec...
Page 21 - OPERATING STEPS; CV MODE; CV INNERSHIELD
b-7 OPERATION b-7 The Lincoln VRD circuit meets the requirements ofA S 1 6 7 4 . 2 - 2 0 0 7 , S a f e t y i n w e l d i n g a n d a l l i e dprocesses - Electrical, for Category C environments.C a t e g o r y C e n v i r o n m e n t s i n c l u d e c o f f e r d a m s ,trenches, mines, in rain, etc...
Page 22 - CC STICK; NA-3 AUTOMATIC WIRE FEEDER
GOOD ARC STRIKING GUIDELINES FOR THE NA-3W I T H T H E I D E A L A R C ® D C - 6 0 0 V R D I N T H E C VINNERSHIELD, CV SUbMERGED ARC OR CC STICKWELDING MODES. Following are some basic arc striking techniques thatapply to all wire feed processes. Using these proceduresshould provide trouble-free sta...
Page 23 - same polarity as the work cable connection.
b-9 OPERATION b-9 IDEALARC® DC-600 VRD ARC STRIKING WITH IDEALARC® DC-600 VRD ANDTHE NA-3 START bOARD When electrical strikeouts exceed 1 3/4” (44.4mm) anNA-3 Start Board may be required to improve arc strik-ing. When the NA-3 Start Board is used to improve arc strik-ing, use the following procedure...
Page 24 - ACCESSORIES; WIRE FEEDERS AND TRACTORS; Automatic Wire Feeders:; FIELD INSTALLED OPTIONS; • Change the polarity of a semi-automatic or auto-; WIRE
C-1 ACCESSORIES C-1 IDEALARC® DC-600 VRD WIRE FEEDERS AND TRACTORS The IDEALARC® DC-600 VRD can be used to powera n y o f t h e f o l l o w i n g L i n c o l n W i r e F e e d e r s a n dTractors: Semi-Automatic Wire Feeders: DH-10 LN-9 LN-7 LN-9 GMA LN-7 GMA LN-23P LN-742 LN-25 LN-8 LN-10 Automatic...
Page 27 - MAINTENANCE; Do not touch electrically hot parts.
ROUTINE AND PERIODIC MAINTENANCE 1. Disconnect input AC power supply lines to the machine before performing periodic maintenance,tightening, cleaning, or replacing parts. Perform the following daily: 1. Check that no combustible materials are in the welding or cutting area or around the machine. 2. ...
Page 28 - TROUbLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; CAUTION; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUbLESHOOTING GUIDE
E-1 TROUbLESHOOTING E-1 IDEALARC® DC-600 VRD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troublesh...
Page 30 - C h e c k f o r b l o w n o r m i s s i n g; OUTPUT PRObLEMS; Observe all Safety Guidelines detailed throughout this manual
E-3 TROUbLESHOOTING E-3 IDEALARC® DC-600 VRD If all recommended possible areasof possible cause have beenchecked and the problem persists, Contact your local LincolnAuthorized Field Service Facility. PRObLEMS(SYMPTOMS) M a j o r P h y s i c a l o r E l e c t r i c a lDamage is Evident The Machine is...
Page 34 - If a remote control unit is NOT; Check for loose welding cable
E-7 TROUbLESHOOTING E-7 IDEALARC® DC-600 VRD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION If all recomme...
Page 35 - Remove all welding cables and
E-8 TROUbLESHOOTING E-8 IDEALARC® DC-600 VRD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION If all recomme...
Page 36 - R e m o v e a n y e x t e r n a l l e a d s
E-9 TROUbLESHOOTING E-9 IDEALARC® DC-600 VRD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION If all recomme...
Page 37 - Make sure the proper welding; WELDING PRObLEMS
E-10 TROUbLESHOOTING E-10 IDEALARC® DC-600 VRD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION If all recom...
Page 38 - Check for the correct input volt-
E-11 TROUbLESHOOTING E-11 IDEALARC® DC-600 VRD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION If all recom...
Page 41 - DIAGRAMS
F-1 DIAGRAMS F-1 IDEALARC® DC-600 VRD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service De...
Page 51 - IM
F-11 DIAGRAMS F-11 IDEALARC® DC-600 VRD LO CA TIO N O F B AS E M OU NT IN G H OL ES .94 * * * * 20 .00 M 12 24 4-6 D C -6 00 V R D 1-2 0-8 9A 27 .87 9.2 0 27 .50 3.2 5 39 .95 22 .25 29 .93 TH IS D IM EN SIO N W ILL V AR Y W ITH P OS ITIO N O F H AN DL E D IM E N S IO N P R IN T (W IT H K 81 7P U N D...