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Lincoln Electric IDEALARC IM10018-A manual

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Table of contents for the manual

  • Page 1

    IDEALARC ®  DC-600 VRD "#% ' "%O&N !(   December, 2010 &.32AF2=2;1@<;,<B 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 pa[...]

  • Page 2

    "%!! =<D2?212>B6=:2;A 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

    66 &', 66 %J)% ARC R A Y S can bur n. 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[...]

  • Page 4

    666 &', 666 %J)% FOR ELECTRIC ALL Y pow er ed 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 rec[...]

  • Page 5

    %J)% PRÉC A UTIONS 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

    C C Thank Y ou for selecting a $(', 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! %2.1A56@"=2?.A<?@ .;B.90<:=92A29F before attempting to use this equipment. Save this manual and keep it[...]

  • Page 7

    C6 C6 ' ""!'!'& Page ;@A.99.A6<; [...]

  • Page 8

    C66 C66 ' ""!'!'& Page .6;A2;.;02  ?[...]

  • Page 9

    BAFF092 122/61/49 68  !&'  '"! %J)%  '! &# '"!&K%J)% )<9A@.A%.A21:=2?2@ 44 44[...]

  • Page 10

     !&'  '"! %J)%  &', #%('"!& %2.1 2;A6?2 ;@A.99.A6<; &20A6<; /23<?2 6;@A.996;4A52%J)% '%?[...]

  • Page 11

     !&'  '"! %J)%  '% !#('"!!'"!& Before installing the machine check that the input sup- ply voltage, phase, and frequency are the same as the voltage, phase, and fre[...]

  • Page 12

    (% %20<;;20A#.;29<.?1#<@6A6<;@3<?&6;492) <9A.42 .056;2@ 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.[...]

  • Page 13

     !&'  '"! %J)%  "('#('"!!'"!& See Table A.1 for recommended IDEALARC® DC-600 VRD cable sizes for combined lengths of electrode and work cables. '  [...]

  • Page 14

    '% !&'%#& 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 termi[...]

  • Page 15

     "#% '"! %J)%  SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. '%&"0.;8699 • Do not touch electrically live parts or electrodes with your skin or wet clo[...]

  • Page 16

     "#% '"!  %J)% !% &%#'"! 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[...]

  • Page 17

     "#% '"!  %J)% *!# ', 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% [...]

  • Page 18

    "!'%"& !&''!& 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. (%"!'%"# !,& 1 2 3 4 5 6 7 8 9 10 DC [...]

  • Page 19

     "#% '"!  %J)%  "('#('"!'%" This control provides continuous control of the machine’s 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 i[...]

  • Page 20

    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[...]

  • Page 21

     "#% '"!  The Lincoln VRD circuit meets the requirements of AS1674.2-2007, Safety in welding and allied processes - Electrical, for Category C environments. Category C environments include coffer dams, trenches, mines, in rain, etc. The Lincoln VRD circuit also meets recommendation of ANSI Z49.1- 2005, Safe[...]

  • Page 22

    "" % &'%! (!& "% ' ! *' ' %J  )% ! ' ) !!%& ) &( % % "% ?[...]

  • Page 23

     "#% '"!  %J)% % &'%! *' %J  )% ! '!&'%'"% When electrical strikeouts exceed 1 3/4” (44.4mm) a[...]

  • Page 24

     &&"%&  %J)% *%%& !'%'"%& The IDEALARC® DC-600 VRD can be used to power any of the following Lincoln Wire Feeders and Tractors: Semi-Automatic Wire Feeders: DH-10 LN-9 LN-7 LN-9 GMA L[...]

  • Page 25

     &&"%&  %J)% The MULTI-PROCESS SWITCH has two sets of out- put terminals. You connect the wire feeder unit cables to the set of terminals on the left side of the box and the stick or air/carbon arc cables to the set of termi- nals on the right side [...]

  • Page 26

     &&"%&  12. Connect stick or air/carbon arc electrode and work cable. See Figure C.2. • Insert the electrode and work cables through the strain relief loop on the right side (facing the front of the machine) of the IDEALARC® DC-600 VRD. • Connect the electrode cable to the "Positive&quo[...]

  • Page 27

    %"('! !#%" !'!! 1 . Disconnect input AC power supply lines to the machine before performing periodic maintenance, tightening, cleaning, or replacing parts. #2?3<?:A523<99<D6;41.69F 1. Check that no combustible materials are in the welding or cutting area [...]

  • Page 28

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technica[...]

  • Page 29

    '%&"0.;8699 .C2 .; 2920A?606.; 6;@A.99 .;1 @2? C602 A56@ 2>B6=:2;A 'B?; A52 6;=BA =<D2? " .A A52 3B@2 /<E /23<?2 D<?86;4 <; 2>B6=:2;A < ;<A A<B05 2920A?60.99F5<A=.?[...]

  • Page 30

     '%"(&""'!  %J)% If all recommended possible areas of possible cause have been checked and the problem persists, <;A.0AF<B?9<0.96;0<9; BA5<?6G216291&2?C602.0696AF #%" &[...]

  • Page 31

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technica[...]

  • Page 32

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technica[...]

  • Page 33

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technica[...]

  • Page 34

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technica[...]

  • Page 35

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technica[...]

  • Page 36

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technica[...]

  • Page 37

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for te[...]

  • Page 38

     '%"(&""'!  %J)% If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for te[...]

  • Page 39

    # "%'%"(&""'!( %! # "% 1 . All 10 LED’s must be ON when the POWER SOURCE is turned “ON” and the trigger circuit* is closed. 2. LED’s 7, 8, and 9 indicate AC power being supplied to the P.C. board from auxiliary wi[...]

  • Page 40

     '%"(&""'!  %J)% Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;[...]

  • Page 41

     % &  %J)% !"' 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, w[...]

  • Page 42

     % &  %J)% !"' 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, w[...]

  • Page 43

     % &  %J)% !"' 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, w[...]

  • Page 44

     % &  %J)% !"' 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, w[...]

  • Page 45

    %J)%  % &  S20409 1-28-94 CONNECTION OF LN-742 TO THE DC-600 VRD POWER SOURCE Only qualified persons should install, use or service this machine. ELECTRODE CABLE - + 14 PIN AMPHENOL POWER SOURCE LINCOLN TO WORK LN-742 WIRE FEEDER Power Source before connecting the [...]

  • Page 46

     % &  %J)% N.C. Tape up bolted connection if lead #21 is extended. N.D. Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source grounding terminal (marked and located near the power source input powe[...]

  • Page 47

     % &  %J)% N.C. Tape up bolted connection if lead #21 is extended. N.D. Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source grounding terminal (marked and located near the power source input powe[...]

  • Page 48

     % &  %J)% Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power NEGATIVE POSITIVE 32 31 2 4 GND 21 N.A. N.D. ELECTRODE CABLE TO WORK POWER SOURCE Only qualified persons should instal[...]

  • Page 49

     % &  %J)% NEGATIVE POSITIVE 32 31 2 4 GND 21 N.A. N.D. TO WORK POWER SOURCE Only qualified persons should install, use or service this machine. Do not operate with covers removed. Disconnect power source before servicing. Do not touch electrically live parts. 21 F[...]

  • Page 50

     % &  %J)% S22980 ELECTRODE CABLE - + 14 PIN AMPHENOL POWER SOURCE TO WORK AND 14-PIN CABLE PLUG, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW K=42 I=41 H=21 D=4 C=2 PIN B C D E F 75 76 77 4 2 LEAD 42V AC 42V AC TRIGGER CIRCUIT (SEE APPROPRIATE WIRING DIAGRAM)[...]

  • Page 51

     % &  %J)% LOCATION OF BASE MOUNTING HOLES .94 * * * * 20.00 M12244-6 DC-600 VRD 1-20-89A 27.87 9.20 27.50 3.25 39.95 22.25 29.93 THIS DIMENSION WILL VARY WITH POSITION OF HANDLE DIMENSION PRINT (WITH K817P UNDERCARRIAGE) 11.12 17.75 38.00 5.90 4.75 L O C A T[...]

  • Page 52

     % &  %J)% 6-18-93C 36.12 M15200-3 17.76 38.00 5.19 DIMENSION PRINT (WITH K842 UNDERCARRIAGE) 20.00 27.65 * 37.86 LOCATION OF BASE MOUNTING HOLES * * 29.93 .94 * * 3.25 23.28 22.25 11.12 27.50 7.11 54.91 49.89 DIMENSION PRINT (WITH K842 UNDERCARRIAGE) DC-600 [...]

  • Page 53

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INSTR UCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LA S INS TRUCCIONES DEL F ABRIC [...]

  • Page 54

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A AS INS TR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E AS P ARTES DE USO , E SIGA AS PRÁTIC AS DE SEGUR ANÇA DO EMPRE GADOR. • Kee p yo ur h ead out of fum es. • Use ven tila tio n or exh aus[...]

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    • Sales 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 Products •[...]