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Lincoln Electric IDEALARC DC-600 VRD, Operator'S Manual

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Lincoln Electric IDEALARC DC-600 VRD Operator'S Manual Download Page 8

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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

Summary of Contents for IDEALARC DC-600 VRD

Page 1: ...Y PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful 1 2 3 4 5 6 7 8 9 10 DC 600 VRD 1 2 3 4 5 6 7 8 9 10 DC 600 VRD For use with machines having Code Numbers 1...

Page 2: ...S 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...

Page 3: ...n 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...

Page 4: ...d 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...

Page 5: ...i s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan t...

Page 6: ...mportant when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the...

Page 7: ...ical 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 Operat...

Page 8: ...y 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 Diagra...

Page 9: ...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 D...

Page 10: ...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 weigh...

Page 11: ...et 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...

Page 12: ...es 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 machine s rating plate Before installing the...

Page 13: ...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 lo...

Page 14: ...tions 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...

Page 15: ...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...

Page 16: ...ors or Solid State switches such as SCR s 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...

Page 17: ...D 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 Out...

Page 18: ...ding 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 SYM...

Page 19: ...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 abou...

Page 20: ...emain 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...

Page 21: ...T TERMINALS switch to either ON output terminals energized or REMOTE output terminals energized when 2 and 4 closed by remote device such as wire feeder 7 Make the weld CC MODE 1 Connect the 21 work l...

Page 22: ...piece Hot On the Fly starts For hot starts travel should begin before the wire contacts the work piece b 8 OPERATION b 8 IDEALARC DC 600 VRD 3 Air Carbon Arc Cutting AAC Stick Welding SMAW High Curre...

Page 23: ...shooting the desired arc voltage the Open Circuit Voltage Control is set properly If the voltmeter pointer overshoots the desired voltage and then returns back to the desired volt age the Open Circuit...

Page 24: ...with an LN 7 wire feeder 14 pin connector and the machine 14 pin connector If a remote control is used alone the wire feeder connection is then not used Undercarriages K817P K842 For easy moving of t...

Page 25: ...and make other terminal strip connections as specified on the connection diagram for the Lincoln wire feeder being used 6 Connect the control leads from the MULTI PROCESS SWITCH to terminals 2 and 4 o...

Page 26: ...verse the cables NOTE When it is not necessary to have separate ground cables for stick and semi automatic or automatic welding connect a jumper from the MULTI PROCESS SWITCH Work terminal to the MULT...

Page 27: ...r any condition that would affect the proper operation of the machine Perform Periodically Clean the inside of the machine with low pressure air stream Clean the following parts Main transformer and c...

Page 28: ...SIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause gener...

Page 29: ...and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a static charge If the P C Board can t be installed immediately put it back in the...

Page 30: ...for blown or missing fuses in input lines 2 Check the three phase input line voltage at the machine The input voltage must match the rating plate and reconnect panel 3 Power ON OFF switch may be defe...

Page 31: ...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 1 Poor electrode or work lead...

Page 32: ...e OUTPUT TERMINAL Switch to ON or install a jumper from 2 to 4 on machine terminal strip If machine weld output is restored the problem is in the wire feeder or control cable 2 If remote control is no...

Page 33: ...ntrol VRD passes self test and green light is on but machine will not Weld POSSIbLE CAUSE 1 LOCAL REMOTE Switch S3 in wrong position 2 LOCAL REMOTE Switch S3 is faulty or an open lead going to the LOC...

Page 34: ...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 position 2 If a remote control cable is con nected to terminal...

Page 35: ...ch is in ON position The DC600 will NOT shut off when the Power Switch is turned to OFF POSSIbLE CAUSE 1 Remove all welding cables and control cables from the DC 600 Jumper 2 to 4 at the terminal stri...

Page 36: ...coln Authorized Field Service Facility PRObLEMS SYMPTOMS The weld output terminals are always electrically hot POSSIbLE CAUSE 1 Remove any external leads hooked to 2 and 4 on the ter minal strip or an...

Page 37: ...ObLEMS SYMPTOMS Poor arc starting when the IDE ALARC DC 600 VRD is in the CV Sub Arc or CV Innershield Modes Machine has output but trips off immediately when wire feed unit trigger is activated POSSI...

Page 38: ...e been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility PRObLEMS SYMPTOMS Poor arc characteristics in all processes POSSIbLE CAUSE 1 Check for the correct...

Page 39: ...ss sec ondary winding of the control transformer T2 which supplies leads 255 and 256 Measure 16VDC from TEST POINTS A to C and 10VDC from TEST POINTS A to J on Control board 2 LED 2 indicates welder o...

Page 40: ...ECTING REMOTE OUTPUT CONTROL RHEOSTAT TO THE MACHINE Extreme caution must be observed when installing or extending the wiring of a remote control Improper connection of this unit can lead to loss of c...

Page 41: ...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...

Page 42: ...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...

Page 43: ...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...

Page 44: ...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...

Page 45: ...N B D I A G R A M S H O W S E L E C T R O D E P O S I T I V E T O C H A N G E P O L A R I T Y T U R N P O W E R O F F R E V E R S E E L E C T R O D E A N D W O R K C A B L E S A T P O W E R S O U R C...

Page 46: ...6 s o u r c e a n d p o s i t i o n t h e s w i t c h o n w i r e f e e d e r i f e q u i p p e d t o p r o p e r p o l a r i t y A l s o r e f e r t o n o t e N F N B N C 1 4 P I N R E C E P T A C L...

Page 47: ...r i p N o t e t h a t t h i s i s n o t t h e p r e f e r r e d c o n n e c t i o n b e c a u s e i t a d d s e r r o r s e p a r a t e f r o m t h e w e l d i n g w o r k l e a d c i r c u i t a n d...

Page 48: ...o p e r m i t t h e i n c h d o w n b u t t o n t o o p e r a t e T h i s j u m p e r h o w e v e r w i l l d i s a b l e t h e c o l d s t a r t i n g a u t o s t o p f e a t u r e o f t h e a u t o...

Page 49: ...l t a g e P C b o a r d T h i s j u m p e r h o w e v e r w i l l d i s a b l e t h e p e r m i t t i n g o n l y H o t S t a r t i n g t e c h n i q u e s t o b e u s e d C o l d S t a r t i n g A u...

Page 50: ...N O F D H 1 0 O R L N 1 0 T O T H E D C 6 0 0 V R D P O W E R S O U R C E W I T H 1 4 P I N A M P H E N O L R E F E R T O P O W E R S O U R C E O P E R A T I N G M A N U A L F O R L I N C O L N W I R...

Page 51: ...I M E N S I O N W I L L V A R Y W I T H P O S I T I O N O F H A N D L E D I M E N S I O N P R I N T W I T H K 8 1 7 P U N D E R C A R R I A G E 1 1 1 2 1 7 7 5 3 8 0 0 5 9 0 4 7 5 LOCATION OF BASE MO...

Page 52: ...O U N T I N G H O L E S 2 9 9 3 9 4 3 2 5 2 3 2 8 2 2 2 5 1 1 1 2 2 7 5 0 7 1 1 5 4 9 1 4 9 8 9 D I M E N S I O N P R I N T W I T H K 8 4 2 U N D E R C A R R I A G E D C 6 0 0 V R D 6 18 93C 36 12 M15...

Page 53: ...h electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 54: ...te Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentac...

Page 55: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

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