IMA 607A

December 2005

OPERATING MANUAL

IDEALARC DC-600

SAFETY DEPENDS ON YOU

Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be
increased by proper installation and thoughtful operation on your part. Read and observe the general safety
precautions on page 2 and follow specific installation and operating instructions included in this manual.
Most importantly, think before you act and be careful.

THE LINCOLN ELECTRIC COMPANY

(AUSTRALIA) PTY. LTD. A.B.N. 36 000 040 308
SYDNEY. AUSTRALIA
A Subsidiary of
THE LINCOLN ELECTRIC CO. U.S.A.
Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.
THE WORLD’S LEADER IN WELDING AND CUTTING PRODUCTS
 PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND
BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER
EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION.

ARC WELDING SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill ARC RAYS can burn

1. a. T h e

electrode and work (or ground) circuits are electrically 3. a. Use a shield with the proper filter and cover plates to
“hot” when the welder is on. Do not touch these “hot” protect your eyes from sparks and the rays of the arc
parts with your bare skin or wet clothing. Wear dry, when welding or observing open arc welding.
hole-free gloves to insulate hands. Headshield and filter lens should conform to AS
b. In semi-automatic and automatic wire welding, the 1674.2-2003 AS1337-1992 and AS1338-1992
electrode, electrode reel, welding head and nozzle or standards.
semi-automatic welding gun are also electrically “hot”. b. Use suitable clothing made from durable flame
c. Insulate yourself from work and ground using dry resistant material to protect your skin and that of your
insulation. When welding in damp locations, on metal helpers from the arc rays.
framework such as floors, gratings or scaffolds, and c. Protect other nearby personnel with suitable non
when in positions such as sitting or lying, make certain flammable screening and/or warn them not to watch
the insulation is large enough to cover your full area of the arc or expose themselves to the arc rays or to hot

WELDING SPARKS can

physical contact with work and ground. spatter or metal.

cause fire or explosion

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.
e. Ground the work or metal to be welded to a good
electrical (earth) ground. 4. a. Remove fire hazards from the welding area. If this is
f. Maintain the electrode holder, work clamp, welding not possible, cover them to prevent the welding sparks
cable and welding machine in good, safe operating from starting a fire. Remember that welding sparks and
condition. Replace damaged insulation. hot materials from welding can easily go through small
g. Never dip the electrode holder in water for cooling. cracks and openings to adjacent areas. Have a fire
extinguisher readily available.
h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because b. Where compressed gases are to be used at the job
voltage between the two can be the total of the open site, special precautions should be used to prevent
circuit voltage of both welders. hazardous situations. Refer to AS1674 Parts 1 & 2
“Safety in Welding and Allied Processes”, WTIA
i. When working above floor level, protect yourself from
Technical Note 7 “Health and Safety in Welding” and
a fall should you get a shock.
the operating information for the equipment being

FUMES AND GASES

j. Also see items 4c and 6. used.

can be dangerous
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.
d. Do not heat, cut or weld tanks, drums or containers
2. a. Welding may produce fumes and gases hazardous to until the proper steps have been taken to insure that
health. Avoid breathing these fumes and gases. When such procedures will not cause flammable or toxic
welding, keep your head out of the fume. Use enough vapours from substances inside. These can cause an
ventilation and/or exhaust at the arc to keep fumes and explosion even though the vessel has been “cleaned”.
gases away from the breathing zone. When welding on For information purchase AS 1674-1990.
galvanised, lead or cadmium plated steel and other e. Vent hollow castings or containers before heating,
metals which produce toxic fumes, even greater care cutting or welding. They may explode.
must be taken.
f. Sparks and spatter are thrown from the welding arc.
b. Do not weld in locations near chlorinated hydrocarbon Wear oil free protective garments such as leather
vapours coming from degreasing, cleaning or spraying gloves, heavy shirt, cuffless trousers, high shoes and
operations. The heat and rays of the arc can react with a cap over your hair. Wear ear plugs when welding out
solvent vapours to form phosgene, a highly toxic gas, of position or in confined places. Always wear safety
and other irritating products. glasses with side shields when in a welding area.
c. Shielding gases used for arc welding can displace air g. Connect the work cable to the work as close to the
and cause injury or death. Always use enough welding area as possible. Work cables connected to
ventilation, especially in confined areas, to ensure the building framework or other locations away from
breathing air is safe. the welding area increase the possibility of the welding
d. Read and understand the manufacturer’ s instructions current passing through lifting chains, crane cables or
for this equipment and the consumables to be used, other alternate circuits. This can create fire hazards or
including the material safety data sheet (MSDS) and overheat lifting chains or cables until they fail.
follow your employer’s safety practices.
h. Also see Item 7c.
e. Also see Item 7b.
 CYLINDER may explode if FOR ENGINE
damaged powered equipment
5. a. Use only compressed gas cylinders containing the 7. a. Turn the engine off before troubleshooting
correct shielding gas for the process used and and maintenance work unless the
properly operating regulators, designed for the gas maintenance work requires it to be
and pressure used. All hoses, fittings, etc. should be running.
suitable for the application and maintained in good
condition. b. Operate engines in open, well ventilated
b. Always keep cylinders in an upright position and areas or vent the engine exhaust fumes
securely chained to an undercarriage or fixed support. outdoors.
c. Cylinders should be located :
• Away from areas where they may be struck or c. Do not add fuel near an open flame,
subjected to physical damage. welding arc or when the engine is running.
Stop the engine and allow it to cool before
• A safe distance from arc welding or cutting refuelling to prevent spilled fuel from
operations and any other source of heat, sparks or vaporizing on contact with hot engine
flame. parts and igniting. Do not spill fuel when
d. Never allow the electrode, electrode holder, or any filling tank. If fuel is spilled, wipe it up and
other electrically “hot” parts to touch a cylinder. do not start engine until fumes have been
eliminated.
e. Keep your head and face away from the cylinder valve
outlet when opening the cylinder valve.
d. Keep all equipment, safety guards, covers
f. Valve protection caps should always be in place and
and devices in position and in good repair.
hand-tight except when the cylinder is in use or Keep hands, hair, clothing and tools away
connected for use. from V-belts, gears, fans and all other
g. Read and follow the instructions on compressed gas moving parts when starting, operating or
cylinders and associated equipment, and AS 2030 repairing equipment.

FOR ELECTRICALLY
Parts 1 & 2. e. In some cases it may be necessary to
remove safety guards to perform required

powered equipment
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.
6. a. Turn off input power using the disconnect switch at the f. Do not put your hands near the engine fan.
fuse box before working on the equipment. Do not attempt to override the governor or
b. Install equipment in accordance with the SAA Wiring idler by pushing on the throttle control rods
Rules, all local codes and the manufacturer’s while the engine is running.
recommendations. g. To prevent accidentally starting petrol
c. Ground the equipment in accordance with the SAA engines while turning the engine or
Wiring Rules and the manufacturer’s welding generator during maintenance
recommendations. work, disconnect the spark plug wires,
distributor cap or magneto wire as
appropriate.

h. To avoid scalding do not remove the

radiator pressure cap when the engine is
hot.

HAVE ALL INSTALLATIONS, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED BY QUALIFIED PEOPLE

For more detailed information it is strongly recommended that you purchase a copy of “Safety in Welding and Cutting - ANSI Standard Z
49.1” and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the Welding Technology Institute of
Australia, P.O. Box 6165, Silverwater NSW 2128. For copies of various Australian Standards contact your local S.A.A. office.

HOW TO ORDER REPLACEMENT PARTS

To ensure that you receive the correct replacement part the following procedure should be followed:
1. Quote Serial Number and Code Number.
2. Quote the Description, Item Number and Parts List Number of the desired part. When ordering parts for items carrying brand
names of other companies, such as fan motors, drive shafts, etc., be sure to include the other company’s name and part number
and other relevant information.
3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric.
4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Service Facilities. (The “Lincoln Service Directory”
listing these shops geographically is available on request.)
Note: “Hardware” in the Lincoln Parts Lists are not Lincoln stock items but can be obtained via the Authorised Service Facilities.
Component parts of assemblies such as stator coils or armature coils, etc., which require electrical testing or locating fixtures are not
considered replaceable items. This is to ensure that the customer receives parts which will keep the welder in the best operating condition.

BUY ONLY GENUINE REPAIR PARTS

 WELDING, EMF & PACEMAKERS
All welders should follow safe practices that minimise their Welders with pacemakers
exposure to electric and magnetic fields (EMF).

There is no question that the fields in arc welding can interfere

For welders wearing implanted pacemakers, safe welding
with a pacemakers function. Generally the interference does not
practices are particularly important and additional procedures
permanently damage the pacemaker. Once the wearer leaves the
should be followed by those who have decided to continue to
arc welding environment or stops welding, the pacemaker returns
weld. (Hopefully in keeping with a doctor’s advice).
to normal functioning. The welding arc has little or no effect on the
operation of some pacemakers, especially designs that are bi-
The following procedures will not eliminate exposure to EMF or polar or designed to filter out such interference.
the possibility of arc welding having an effect on a pacemaker,
however if followed, they will significantly reduce exposure to
For a welder or anyone working around electrical equipment the
electric and magnetic fields. Electric and magnetic fields are
selection of a pacemaker is very important. Get a doctor’s advice
created any time electric current flows through a conductor,
about which pacemaker is the least sensitive to interference from
however it is not clear whether such exposure affects ones health.
welding while still being medically suitable.

Some researchers have reported that exposure to EMF may

In addition to the normal safety precautions, the following
cause leukemia or other illnesses. These claims originally arose
additional procedures should be adopted by welders with
in relation to high voltage electric power lines and are very much
pacemakers.
in dispute in the medical and scientific arena, however the best
advice is to minimise your exposure to EMF to protect your health • Use gas welding when the application is suitable.
should doctors eventually decide there is a risk. • Use the lowest current setting appropriate for the
application. Do not exceed 400 amps. Low current
(75-200 amps) direct current (DC) welding should be used
There are four fundamental facts about EMF:
if arc welding is necessary. Do not TIG weld with high
• With direct current (DC), the field strength is relatively frequency.
constant and does not change.
• Do not use repeated, short welds. Wait about ten seconds
• With alternating current (AC), the field strength constantly between stopping one weld and starting the next. When
changes. having difficulty starting an electrode, do not re-strike the
• The greater the current flow, i.e. the higher the amps, the rod repeatedly.
stronger the field created by the current • If you feel light headed, dizzy or faint, immediately stop
• The closer the conductor or electrical device is to the body, welding. Lay the electrode holder down so that it does not
the greater the exposure to the field. contact the work and move away from any welding being
performed. Arrange your work in advance so that, if you
become dizzy and drop the electrode holder, the electrode
holder will not fall on your body or strike the work.
Minimising exposure • Do not work on a ladder or other elevated position or in a
cramped, confined place.
• Do not work alone. Work only in the presence of an
individual who understands these precautions and the
All welders should use the following procedures to minimise EMF possible effect welding may have on your pacemaker.
exposure.
• Do not work near spot welding equipment.
• If you have a pacemaker and wish to continue arc welding,
• Route electrode or gun and work cables together. Secure discuss this and any other questions you may have with
them with tape if possible. your physician and follow his or her advice. The doctor may
• Never coil the electrode lead around your body. wish to contact the pacemaker manufacturer for a
recommendation. As mentioned before, the design of the
• Do not place your body between the electrode and work
pacemaker significantly affects the degree to which it is
cables. If your electrode cable is on your right side the work
subject to interference from a welding circuit. Do not rely on
cable should also be on your right side.
the fact that you know another welder with a pacemaker
• Connect the work cable to the work piece as close as who has welded for years without experiencing a problem.
possible to the area being welded. (This is also a good That welder and his or her pacemaker may be quite
practice to eliminate a common problem on welding - a different from you and your pacemaker.
poor work connection.
• Do not work next to the welding power source.

Page 4 Idealarc DC-600 IMA 607A

 INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY
WARNING
in the environment is compatible. This may require additional
protection measures;
h. The time of the day that welding or other activities are to be
This welding machine must be used by trained operators carried out.
only. Read this manual carefully before attempting to use The size of the surrounding area to be considered will depend on
the welding machine. the structure of the building and other activities that are taking
place. The surrounding area may extend beyond the boundaries
of the premises.
Conformance
Products displaying the C-Tick mark are in conformity with
Australian/New Zealand requirements for Electromagnetic
Methods of Reducing Emissions
Compatibility (EMC) according to standard AS/NZS “Industrial Mains Supply
scientific and medical (ISM) radio-frequency equipment - Welding equipment should be connected to the mains supply
Electromagnetic disturbance characteristics - Limits and methods according to the manufacturer’s recommendations.If interference
of measurement”. occurs, it may be necessary to take additional precautions such
Products displaying the CE mark are in conformity with European as filtering the mains supply. Consideration should be given to
Community Council Directive 89/336/EEC requirements for EMC shielding the supply cable of permanently installed welding
by implementing EN60974-10 “Arc Welding Equipment - Part 10: equipment in metallic conduit or equivalent. Shielding should be
Electromagnetic Compatibility (EMC) requirements”. electrically continuous throughout its length. The shielding should
• manufactured in conformity with Australian/New Zealand be connected to the welding power source so that good electrical
Standard (Emission):- AS/NZS 3652 ‘Electromagnetic contact is maintained between the conduit and the welding power
Compatibility - Arc Welding Equipment’ (Identical to and source enclosure.
reproduced from British Standard EN 50199) Maintenance of the Welding Equipment
Products are: The welding equipment should be routinely maintained according
• for use with other Lincoln Electric/LiquidArc equipment. to the manufacturer’s recommendations. All access and service
• designed for industrial and professional use. doors and covers should be closed and properly fastened when
Introduction the welding equipment is in operation. The welding equipment
All electrical equipment generates small amounts of should not be modified in any way except for those changes and
electromagnetic emission. Electrical emission may be transmitted adjustment covered in the manufacturer’s instructions. In
through power lines or radiated through space, similar to a radio particular, the spark gaps of arc initiation and stabilising devices
transmitter. When emissions are received by other equipment, should be adjusted and maintained according to the
electrical interference may result. Electrical emissions may effect manufacturer’s recommendations.
many kinds of electrical equipment: other nearby welding Welding Cables
equipment, radio and TV transmitters and receivers, numerical The welding cables should be kept as short as possible and
controlled machines, telephone systems, computers, etc. Be should be positioned close together, running at or close to the
aware that interference may result and extra precautions may be floor level.
required when a welding power source is used in a domestic
Equipotential Bonding
establishment.
Bonding of all metallic components in the welding installation and
Installation and Use adjacent to it should be considered. However, metallic
The purchaser/user is responsible for installing and using the components bonded to the work piece will increase the risk that
welding equipment according to the manufacturer’s instructions. If the operator could receive a shock by touching these metallic
electromagnetic disturbances are detected then it shall be the components and the electrode at the same time. The operator
responsibility of the purchaser/user of the welding equipment to should be insulated from all such bonded metallic components.
resolve the situation with the technical assistance of the
Earthing of the workpiece
manufacturer. In some cases this remedial action may be as
Where the workpiece is not bonded to earth for electrical safety,
simple as earthing (grounding) the welding circuit (see note
nor connected to earth because of its size and position, eg. ship’s
below). In other cases it could involve constructing an
hull or building steelwork, a connection bonding the workpiece to
electromagnetic screen enclosing the power source and the work
earth may reduce emissions in some, but not all instances. Care
complete with associated input filters. In all cases
should be taken to prevent the earthing of work pieces increasing
electromagnetic disturbances must be reduced to the point where
the risk of injury to users, or damage to other electrical
they are no longer troublesome.
equipment. Where necessary, the connection of the workpiece to
NOTE: The welding circuit may or may not be earthed for safety
earth should be made by direct connection to the workpiece, but
reasons according to national codes. Changing the earthing
in some countries where direct connection is not permitted, the
arrangements should only be authorised by a person who is
bonding should be achieved by suitable capacitance, selected
competent to assess whether the changes increase the risk of
according to national regulations.
injury, eg. by allowing parallel welding current return paths which
may damage the earth circuits of other equipment. Screening and Shielding
Selective screening and shielding of other cables and equipment
Assessment of Area in the surrounding area may alleviate problems of interference.
Screening of the entire welding installation may be considered for
Before installing welding equipment the purchaser/user shall
special applications.*
make an assessment of potential problems in the surrounding
Portions of the preceding text are extracted from:
area.
• Australian/New Zealand standard AS/NZS 3652. permission to
The following shall be taken into account:
reproduce has been granted by Standards Australia and
a. Other supply cables, control cables, signalling and telephone
Standards New Zealand. For further explanation, reads should
cables above, below and adjacent to the welding equipment;
be referred to the standard itself.
b. Radio and television transmitters and receivers;
• British Standards Institution standard BS EN 50199: 1995.
c. Computer and other control equipment;
Reproduced with permission of BSI under license number
d. Safety critical safety equipment, eg. guarding of industrial
2000SK0631. Complete standards can be obtained from BSI
equipment;
Customer Services, 389 Chiswick High Road, London W4 4AL,
e. The health of people around, eg. the use of pacemakers and
United Kingdom. (Tel +44 (0) 20 8996 9001).
hearing aids;
Copyright of the above text is property of Standards Australia,
f. Equipment used for calibration or measurement;
Standards New Zealand and British Standards Institution.
g. The immunity of other equipment in the environment. The
Permission to reproduce the text must be obtained.
purchaser/user shall ensure that other equipment being used
May ‘07
 INSTALLATION

TECHNICAL SPECIFICATIONS - IDEALARC DC-600

INPUT - THREE PHASE ONLY

Part No.. Standard Voltage Rated Input Current to AS1966
KA1342-1 415/3/50/60 62
KA1342-2 380/500/3/50/60 68/51
KA1342-3 220/380/440/3/50/ 117/68/58
KA1342-3 230/380/460/3/60 100/68/50
KA1342-4 200/3/5/60 129
KA1342-5 380/550/3/50 79/55
KA1342-5 380/575/3/60 79/47

RATED OUTPUT
Duty Cycle Amps Volts at Rated Amps
100% 600 44
60% 680 44
50% 750 44

OUTPUT
Mode Current Maxmimum Open Auxilliary Power
Range Circuit Voltage
Constant Current 90 to 850 Amps 72 VDC 42/115 VAC, 8 Amps
Constant Voltage 70 to 850 Amps 55 VDC

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input Voltage / Fuse Input Ampere
Frequency (Super Lag) Rating on
or breaker Size Nameplate
220 50/60 175 125
230 50/60 175 113
415 50/60 100 63
460 50/60 90 57
575 50/60 80 45

PHYSICAL DIMENSION (approx)

Height Width Depth Weight

780mm 570mm 990mm 240kg

Page 6 Idealarc DC-600 IMA 607A

SAFETY PRECAUTIONS ELECTRICAL INPUT CONNECTIONS

ELECTRIC SHOCK can kill

Before installing the machine, check that the input supply voltage,
phase, and frequency are the same as the machine’s voltage,
phase, and frequency as specified on the machine’s rating plate
on the Case Rear Panel Assembly. Input power supply entry is
through the hole in the Case Rear Panel Assembly. See Figure
• Only qualified personnel should install this A.2 for the location of the machine’s input cable entry opening,
machine. Input Contactor (CR1), and reconnect panel assembly for multi-
• Turn the input power OFF at the disconnect voltage machines.
switch or fuse box before working on the
equipment. Figure A.2
• Do not touch electrically hot parts. Rear Panel
• Always connect the Idealarc DC-600 grounding
INPUT SUPPLY
terminal to a good electrical earth ground.
CABLE ENTRY
• Set the Idealarc DC-600 Power ON/OFF PUSH INPUT
OPENING
CONTACTOR (CR1)
BUTTON to the OFF position when connecting
power cord to input power. RECONNECT
PANEL ASSEMBLY
(if fitted)

SELECT PROPER LOCATION

Place the Idealarc DC-600 where clean air can freely circulate in
through the front intake and out through the rear louvers. Dirt,
dust, or any foreign material that can be drawn into the machine
should be kept at a minimum. Not following these precautions can
result in the nuisance shutdown of the machine because of
excessive operating temperatures.

FUSE AND WIRE SIZES

STACKING Protect the input circuit with the super lag fuses or delay type
Three IDEALARC DC-600 machines can be stacked. circuit breakers. They are also called inverse time or thermal/
DO NOT stack more than three machines in one grouping. magnetic circuit breakers.
DO NOT stack the Idealarc DC-600 on another type of machine. DO NOT use fuses or circuit breakers with too low amp rating.
This can result in “nuisance” tripping caused by inrush current
Following these guidelines when stacking:
even when machine is not being used for welding at high output
1. Select a firm, level surface capable of supporting the total currents. Use input and grounding wire sizes that meet local
weight of up to three machines 720kg. electrical codes or see the Technical Specifications page in this
manual.
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 bottom machine. GROUND CONNECTION
4. Repeat process for third machine. Ground the frame of the machine. A ground terminal marked with
the symbol ( ) is located inside the Case Rear Panel Assembly
Note: The machines must be stacked with the Case Front of each of the machine near the input contactor. Access to the Input Box
machine flush with each other. See Figure A.1. Assembly is at the upper rear of the machine. See your local and
national electrical codes for proper grounding methods.
Figure A.1
Stacking Idealarc DC-600 machines

STACKING HOLE

STACKING PINS

TILTING
The Idealarc DC-600 must be placed on a stable, level surface so
it will not topple over.

IMA 607A Idealarc DC-600 Page 7

INPUT POWER SUPPLY CONNECTIONS Figure A.3
A qualified electrician should connect the input power supply Input Power Supply Connections
leads.
1. Follow all national and local electrical codes.
2. Follow Input Supply Connection Diagram located on the
inside of the machine.
3. Use a three-phase line.
4. Remove Input Access Door at upper rear of machine.
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 INPUT
the baffle and tighten them in the terminal connectors. Be sure CONTACTOR (CR1)
to close the baffle by inserting the tab into the slot in the
INPUT POWER SUPPLY
baffle. See Figure A.3. CABLE WITH BUSHING RECONNECT
OR BOX CONNECTOR PANEL ASSEMBLY
(if fitted)

RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different voltage,

remove input power and change the position of the reconnect
Multiple voltage machines are shipped connected to the highest
board on the Reconnect Panel. Follow The Input Connection
input voltage listed on the machine’s rating plate. Before installing
Diagram located on the inside of Case Rear Input Access Door.
the machine, check that the Reconnect Panel in the Input Box
These connection diagrams for the following codes are listed
Assembly is connected for the proper voltage.

CAUTION
below.
1. For 415 Voltage, see Figure A.4. (AT3164-1).
2. For Dual Voltage 380/500, see Figure A.5. (AT3164-9).

Failure to follow these instructions can cause immediate 3. For 220/380/440, see Figure A.6. (AM3237)
failure of components within the machine. 4. For 200 Voltage, see Figure A.4. (AT3164-11).
5. For 380/550/575, see Figure A.5. (AT3164-12).
6. For Voltages not listed, see the Input Connection Diagram
pasted on the inside of the Case Back Input Access Door.

Page 8 Idealarc DC-600 IMA 607A

 Figure A.4
Reconnect Panel Board Positions for Single Voltage Machines

SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI
2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
LINES
INPUT L2
V 3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
CONTACTOR

L1 U

GND

Figure A.5
Reconnect Panel Board Positions for 380/500 VAC Machines

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI 13
2. DISCONNECT AND INSULATE THE H2, H3 & H4 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES L2 V 14 LEAST 600 VOLT INSULATION.
INPUT L1
CONTACTOR
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H5 TRANSFORMER LEADS TO THE INPUT SIDE OF
U 15 THE CRI CONTACTOR AS SHOWN.

GND H1 H4 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H5 H2 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
PILOT
H3 TRANSF REMAINING HEX NUTS IN PLACE.

CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI 1 2. DISCONNECT AND INSULATE THE H2, H4 & H 5LEAD TERMINAL WITH TAPE TO PROVIDE
AT
LINES L2 V 2 LEAST 600 VOLT INSULATION.
CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
INPUT L1 U 3 THE CRI CONTACTOR AS SHOWN.
H4 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND H1 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
H3 H2
PILOT
H5 TRANSF

Figure A.6
Reconnect Panel Board Positions for 220/380/440 VAC Machines

CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
LINK W CRI 2. DISCONNECT AND INSULATE THE H2,H3 & H5 LEAD TERMINALS SEPARA
T ELY WITH TAPE TO PROVIDE AT
L3 LEAST 600 VOLT INSULATION.
LINES L2 V 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE
CONTACTOR
INPUT L1 INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.
U
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND H1 H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE
H4 H2 POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUM
CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
PILOT
H5 TRANSF

CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.

LINK W CRI
L3 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
2. DISCONNECT AND INSULATE THE H2, H4 & H5 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
LINES L2 V LEAST 600 VOLT INSULATION.
CONTACTOR
INPUT L1 U 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
GND H1 H4 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H3 H2 5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,
PILOT LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
H5 TRANSF

CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
LINK W CRI 2. DISCONNECT AND INSULATE THE H3, H4 & H5 LEAD TERMINALS SEPARATE LY WITH TAPE TO PROVIDE AT
L3 LEAST 600 VOLT INSULATION.
LINES L2 V 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE
CONTACTOR
INPUT L1 U INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND H1 H4 5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
H2 H3 INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
PILOT
H5 TRANSF

Figure A.7
Reconnect Panel Board Positions for 380/550 and 380/575 Voltage Machines

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI 13
2. DISCONNECT AND INSULATE THE H2, LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES L2 V 14 LEAST 600 VOLT INSULATION.
INPUT L1
CONTACTOR
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
U 15 THE CRI CONTACTOR AS SHOWN.

GND H1 H2 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
PILOT
TRANSF REMAINING HEX NUTS IN PLACE.

CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI 1 2. DISCONNECT AND INSULATE THE H3, LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES L2 V 2 LEAST 600 VOLT INSULATION.
CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
INPUT L1 U 3 THE CRI CONTACTOR AS SHOWN.
H3 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND H1 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
H2
PILOT
TRANSF

IMA 607A Idealarc DC-600 Page 9

OUTPUT CONNECTIONS
See Table A.1 for recommended IDEALARC DC-600 cable sizes for combined lengths of electrode and work cables.

Table A.1
Idealarc DC-600 Cable Sizes for Combined Lengths of Electrode and Work Cable (Copper) at 100% Duty Cycle
Cable Length Parallel Cables Cable Size
Lengths up to 45m 2 50mm2
45m to 60m 2 70mm2
60m to 85m 2 95mm2

Connect Electrode and Work Leads to Output Terminals. Connection For Semi-Automatic or Automatic Wire Feeder
Control
1. Set the ON/OFF PUSH BUTTON to OFF.
Note: See the ACCESSORIES Section of this manual for specific
2. Locate the retractable strain relief loops directly below the
instructions on connecting the following semi-automatic and
output terminals in the lower right and lower left corners of
automatic wire feeders:
the Case Front Assembly. See Figure A.9.
3.
4.
Pull out the retractable strain relief loops.
Insert the electrode lead through the loop directly below the
desired polarity (positive or negative). Pull through enough
• LN-7
• LN-8
• LN-9
} Semi-Automatic Wire Feeders

cable to reach the output terminals.

• NA-3
• NA-5 } Automatic Wire Feeders
5. Connect electrode lead to the desired terminal
(positive/negative).
• LT-7
• LT-56 } Tractors
6. Tighten the output terminal nut with a spanner.
7. Connect the work lead to the other output terminal following
Connection for Stick Welding and Air/Carbon Arc Cutting
steps 4-6.
Operation

WARNING
Figure A.9
Output Terminals

The output terminals are energised at all times when the

Idealarc DC-600 is connected for stick welding and
S air/carbon arc cutting.

1. Set ON/OFF PUSH BUTTON to OFF.

2. Locate and open the hinged access door on the Front Case
Assembly.
3. If necessary, disconnect all wire feeder control cable
connections from the DC-600 terminal strip / amphenol.
4. Remove the leads from the unit by pulling them through and
out of the strain relief loops.
5. Connect a jumper wire from terminal #2 to terminal #4 on
the terminal strip.
6. Set the Welding Mode Switch to the VV position for both
stick welding and air/carbon arc cutting.
Note: To use the Idealarc DC-600 for both stick welding /
air/carbon arc cutting, AND semi-automatic / automatic welding,
the optional Multi-Process Switch (K804-1) must be used. See the
ACCESSORIES Section of this manual for instructions on
installing and using the Multi-Process Switch. When the Multi-
Process Switch is not used, all control, work, and electrode leads
from semi-automatic or automatic wire feeders must be
disconnected from the Idalarc DC-600 before connecting the
machine for stick welding or air/carbon arc cutting.

Page 10 Idealarc DC-600 IMA 607A

 OPERATING INSTRUCTIONS
WARNING
RECOMMENDED PROCESSES AND
EQUIPMENT
Read and understand entire section before operating The Idealarc DC-600 is recommended for the following welding or
machine. cutting processes within its output capacity of 70 amps to 850
amps in the Constant Voltage mode and 90 amps to 850 amps in
the Constant Current mode:
ELECTRIC SHOCK can kill
• Submerged Arc Semi-Automatic or Automatic Welding
• Do not touch electrically live parts or
• Open Arc Semi-Automatic or Automatic Welding
electrode with skin or wet clothing.
• Stick Welding (Standard on All Machines)
• Insulate yourself from work and ground.
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to 3/8”
• Always wear dry insulating gloves.
Diameter)

OPERATIONAL FEATURES AND

FUMES AND GASES can be dangerous. CONTROLS
• Keep your head out of fumes. The Idealarc DC-600 comes with the following standard controls:
• Use ventilation or exhaust to remove fumes • ON/OFF PUSH BUTTON
from breathing zone. • OUTPUT CONTROL POTENTIOMETER
• OUTPUT CONTROL SWITCH (Remote or Panel)
WELDING, CUTTING and GOUGING • WELDING MODE SWITCH
SPARKS can cause fire or explosion
• CONTROL CIRCUIT POLARITY SWITCH
• Keep flammable material away.
• POWER SOURCE PILOT LIGHT
• Do not weld, cut or gouge on containers that
have held combustibles. • DC AMMETER
• DC VOLTMETER

DESIGN FEATURES AND ADVANTAGES

ARC RAYS can burn
The following list of design features will help you understand the
• Wear eye, ear and body protection. machine’s total capabilities and how you can take advantage of
them to get maximum use of your machine.
• Excellent arc characteristics for optimum constant voltage
submerged arc and Innershield welding performance.
• A control circuit designed to provide good starting for a
Observe additional Safety Guidelines detailed in the large variety of processes and procedures.
beginning of this manual.
• Output Control Potentiometer that provides easy single
range continuous control.
• Output Control Switch that provides simple switching from
GENERAL DESCRIPTION local to remote control.
The Idealarc DC-600 is an SCR controlled three phase welding • Red neon pilot light to confirm that the Input Contactor is
and cutting power source. It uses a single range potentiometer to energised.
control: • Auxiliary power source to provide 42/115-volt AC power
• Submerged Arc Semi-Automatic or Automatic Welding 330/1000 to wire feeding equipment.
• Open Arc Semi-Automatic or Automatic Welding • Multi-functional amphenl plug to terminal strip for easy
connection of wire feeding control cables and switching
• Stick Welding (Standard on All Machines) between CV Innershield and CV Submerged Arc welding
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to 3/8” when using the Dual Process or Dual Procedure Kits.
Diameter) • Recessed output terminals to avoid any person or object
The Idealarc DC-600 has a three-position Welding Mode Switch from accidentally coming into contact with the output
to enable the user to operate in one of three modes: terminals and labeled positive and negative for easy
identification.
• Constant Voltage (CV) Submerged Arc
• Thermostatically protected power source.
• Constant Voltage (CV) Innershield
• Electronic protection circuit to protect power source against
• Constant Current (CC) Stick
overloads.
The Idealarc DC-600 can be easily connected to wire feeding
• Input line voltage compensation to provide an essentially
equipment, including:
constant output.
• Semi-automatic wire feeders LN-7, LN-8, and LN-9
• SCR electronically controlled welder output provides extra
• Automatic wire feeders NA-3 and NA-5 long life, especially for highly repetitive welding
applications.
• Tractors LT-56 and LT-7
• Three circuit solid state control system provides maximum
The optional Multi-Process Switch allows the user to switch
performance and circuit protection.
between semi-automatic or automatic welding and stick welding
or air/carbon arc cutting without disconnecting the wire feeder • Low profile case provides maximum use of space.
equipment control, electrode, and work leads.
• Convenient access to all controls.

IMA 607A Idealarc DC-600 Page 11

• Output lead strain relief loops to prevent terminal and cable • Outdoor operation because enclosure is designed with air
damage. intake louvers that keep dripping water from entering the
unit. Transformer, SCR bridge, and choke have special
• Easily removed case side, even when stacked.
corrosion resistant varnish for added protection.

WELDING CAPABILITY
The IDEALARC DC-600 has the following duty cycle ratings:
If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal operating temperature.

Duty Cycle Amps Volts Hertz

50% 750 44 50/60
(Based on 10 min)
60% 680 44 50/60
(Based on 10 min)
100% 600 44 50/60

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the Case Front Assembly of the Idealarc DC-600. See Figure B.1 for the location of
each control.

Figure B.1
Control Panel Keys

8. AMP FUSE
6. AMMETER 7. VOLTMETER 3. WELDING MODE
SWITCH 4. OUTPUT CONTROL
SWITCH

1. ON/OFF
5 6

4 7
PUSH
BUTTON
3 8
& PILOT LIGHT
2 9

1 10

5. CONTROL CIRCUIT 2. OUTPUT CONTROL

POLARITY SWITCH POTENTIOMETER

1. ON/OFF PUSH BUTTON: This push button turns the 5. CONTROL CIRCUIT POLARITY SWITCH: This toggle
machine ON or OFF. (Illuminated in ON position). switch is used to set power source voltage sensing polarity
to match the polarity to which the electrode is connected to
2. OUTPUT CONTROL POTENTIOMETER: This control
the machine. This provides the correct polarity at the
provides tapered, continuous control of the machine output.
amphenol/terminal strip for correct operation of the
The control can be rotated from minimum to maximum
automatic wire feeding equipment powered by the auxiliary
while machine is under load to adjust the machine output.
power from the power source.
3. WELDING MODE SWITCH: This toggle switch is used to
6. AMMETER:
select the proper welder performance characteristics for the
process being used. There are three modes: CV (Constant 7. VOLTMETER:
Voltage) Submerged Arc, CV (Constant Voltage)
Innershield, and CC (Constant Current) Stick.
4. OUTPUT CONTROL SWITCH: This toggle switch is used
to switch between "Panel" for local control of machine
output and "Remote" for remote control of machine output.

Page 12 Idealarc DC-600 IMA 607A

OPERATING STEPS SEMI-AUTOMATIC AND AUTOMATIC
The following procedures are for using the Idealarc DC-600 in the WIRE FEEDING WITH A IDEALARC DC-
local control mode of operation. For remote control of the 600 AND WIRE FEEDERS
machine, see the Remote Control of Machine Operation section.
When using the Idealarc DC-600 with semi-automatic or
Before operating the machine, make sure you have all materials
automatic wire feeding equipment and for stick welding or
needed to complete the job. Be sure you are familiar with and
air/carbon arc cutting, it is recommended that the optional MULTI-
have taken all possible safety precautions before starting work. It
PROCESS SWITCH be used. This switch permits you to easily
is important that you follow these operating steps each time you
change the polarity of the connected wire feeding equipment or
use the machine.
switch to stick welding or air/carbon arc cutting.
1. Turn on the main AC power supply to the machine.
2. Set the CONTROL CIRCUIT POLARITY SWITCH to the
appropriate position. NA-3 AUTOMATIC WIRE FEEDER
- Set toggle to "Electrode Negative" position if the 1. Set the DC-600 Output Control Switch to Remote. Note:
electrode is connected to the negative (-) output Later model NA-3 automatic wire feeders are capable of
terminal. cold starts when the NA-3 Mode switch is in the CV or CC
mode position. Some earlier models are capable of cold
- Set toggle to "Electrode Positive" position if the starting only in the CC mode position. Cold starting enables
electrode is connected to the positive (+) output you to inch the wire down to the work, automatically stop,
terminal. and automatically energize the flux hopper valve.
3. Set the WELDING MODE SWITCH to welding process 2. Set the DC-600 welding mode switch for the desired
being used. process: CV Submerged Arc, CV Innershield mode or CC
- CV Submerged Arc mode.
- CV Innershield 3. Set the NA-3 mode Switch Position to either CV or CC to
match the DC-600 mode selected in step 2.
- CC Stick
4. Refer to the NA-3 operators manual for instructions on how
4. Push the ON/OFF PUSH BUTTON to the ON position to use the NA-3 in conjunction with the DC-600.
- The red neon light glows. 5. Follow the following guidelines for good arc striking detailed
- The fan starts. below for each welding mode.
5. Set Output Control Potentiometer to desired voltage or GOOD ARC STRIKING GUIDELINES FOR THE NA-3 WITH THE
current. IDEALARC DC-600 IN THE CV INNERSHIELD, CV
SUBMERGED ARC OR CC STICK WELDING MODES.
6. Make the weld (Note: Terminal #2 and #4 must be
connected together to energize the machine output). Following are some basic arc striking techniques that apply to all
wire feed processes. Using these procedures should provide
trouble-free starting. These procedures apply to single, solid wires
and Innershield wires.
REMOTE CONTROL OF MACHINE
1. Cut the electrode to a sharp point.
OPERATION
2. Set the NA-3 Open Circuit Voltage Control to the same dial
The toggle switch on the control panel labelled “Remote - Panel” setting as the Arc Voltage Control. If this is a new welding
gives the operator the option of controlling the machine output procedure, a good starting point is to set the Open Circuit
from a remote location. If in the Remote position a wire feeder with Voltage Control to # 6.
remote control capabilities or a remote control device such as a
K857 must be connected to terminals 75, 76, and 77. Refer to Note: The open circuit voltage of the IDEALARC DC-600 varies
Accessories Section for wire feeder remote information. from approximately 16 volts to 56 volts in the CV Innershield or CV
Submerged Arc modes. The open circuit voltage is constant in the
CC Stick mode.

WELDING PROCEDURE 3. Run a test weld. Set proper current, voltage, and travel
speed.
RECOMMEDATIONS a. For the best starting performance, the NA-3 Open
Select Welding Mode Switch position based on type of welding to Circuit Voltage Control and Voltage Control setting
be done. should be the same. Set the Inch Speed Control for the
slowest inch speed possible.
1. Innershield Welding/Other Open Arc Processes: Use the
CV Innershield mode. b. To adjust the Open Circuit Voltage Control to get the
best starting performance, make repeated starts
2. Submerged Arc Welding: Use the CV Submerged Arc
observing the NA-3 voltmeter.
mode. If performing high speed welding, switch between
the CV Submerged Arc and the CV Innershield mode and When the voltmeter pointer swings smoothly up to the desired arc
use the mode that produces the best welding results. voltage, without undershooting or overshooting the desired arc
voltage, the Open Circuit Voltage Control is set properly.
3. Air/Carbon Arc Cutting / Stick Welding / High Current, Large
Puddle Submerged Arc Welding: Use the CC Stick mode. If the voltmeter pointer overshoots the desired voltage and then
When the Idealarc DC-600 is used for Air/Carbon Arc returns back to the desired voltage, the Open Circuit Voltage
cutting, the OUTPUT CONTROL POTENTIOMETER Control is set too high. This can result in a bad start where the
should be set to "9" initially. Based on the size of the carbon wire tends to "Blast off."
being used or the process, turn the potentiometer to a lower If the voltmeter pointer hesitates before coming up to the desired
setting as required by the process.You can use carbon rods voltage, the Open Circuit Voltage Control is set too low. This can
up to 3/8" in diameter at currents as high as 750 amps with cause the electrode to stub.
excellent arc control. The welder protection circuit protects
the machine from extremely high short cir-cuiting pulses. 4. Start and make the weld.
a. Cold starts. For cold starts, be sure the work piece is
clean and the electrode makes positive contact with the
work piece.
b. Hot "On the Fly" starts. For hot starts, travel should
begin before the wire contacts the work piece.

IMA 607A Idealarc DC-600 Page 13

ARC STRIKING WITH IDEALARC DC-600 AND THE NA-3 5. Set the Idealarc DC-600 WELDING MODE SWITCH to the
START BOARD position that matches the welding process being used.
When electrical strikeouts exceed 44.4mm (1 3/4”) an NA-3 Start a. For submerged arc welding, set WELDING MODE
Board may be required to improve arc striking. SWITCH TO CV SUBMERGED ARC position.
When the NA-3 Start Board is used to improve arc striking, use b. For all open arc welding processes set WELDING
the following procedures: MODE SWITCH TO CV INNERSHIELD position.
1. Set start time at 0.
2. Set NA-3 start current and start voltage at mid-range.
3. Set the NA-3 output current and voltage to the proper
LN-8 SEMI-AUTOMATIC WIRE FEEDER
settings for the welding procedure to be used. To use the LN-8 Semi-Automatic Wire Feeder with Idealarc DC-
600.
4. Turn the Start Board Timer to maximum.
1. Set the Idealarc DC-600 WELDING MODE SWITCH to
5. Set Start Board current and voltage control. either CV Innershield mode or CV Submerged Arc mode
a. Set the Start Board current control to 1 1/2 dial numbers depending on the welding process being used.
below that set on the NA-3 current control. 2. Set the Idealarc DC-600 OUTPUT CONTROL SWITCH to
b. Set the Start Board voltage control equal with the NA-3 the REMOTE position.
voltage control setting. 3. Set the LN-8 Welding Mode Switch to the CV position. The
Note: These Start Board current and voltage settings result LN-8 Welding Mode Switch is located on the variable
in a start up current that is lower than the NA-3 current voltage (CC) board.
setting and approximately equal with the NA-3 voltage 4. Refer to the LN-8 Operator’s Manual for instructions on how
setting for the desired welding procedure. to use the LN-8.
6. Establish the correct arc striking procedure with the NA-3
Start Board timer set at maximum.
a. For the best starting performance, the NA-3 Open LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
Circuit Voltage Control and Voltage Control setting
should be the same. Set the Inch Speed Control for the FEEDERS OR OTHER CONSTANT WIRE
slowest inch speed possible. FEEDERS
b. To adjust the Open Circuit Voltage Control to get the To use the LN-7, LN-9, or other constant wire feed speed semi-
best starting performance, make repeated starts automatic wire feeders with Idealarc DC-600.
observing the NA-3 voltmeter. 1. Set the Idealarc DC-600 WELDING MODE SWITCH to
When the voltmeter pointer swings smoothly up to the either CV Innershield mode or CV Submerged Arc mode
desired arc voltage, without undershooting or overshooting depending on the welding process being used.
the desired arc voltage, the Open Circuit Voltage Control is Note: These semi-automatic wire feeders cannot be used
set properly. in the CC Stick mode.
If the voltmeter pointer overshoots the desired voltage and 2. Set the Idealarc DC-600 OUTPUT CONTROL SWITCH.
then returns back to the desired voltage, the Open Circuit
Voltage Control is set too high. This can result in a bad start a. LN-7: Use either an optional K857 Remote Control Box
where the wire tends to "Blast off." Assembly or set the Idealarc DC-600 OUTPUT
CONTROL SWITCH in the Local position.
If the voltmeter pointer hesitates before coming up to the
desired voltage, the Open Circuit Voltage Control is set too b. LN-9: Refer to the LN-9 Operator’s Manual for
low. This can cause the electrode to stub. instructions of how to use the LN-9.

c. Set NA-3 Start Board current and voltage as close to the

welding procedure current and voltage as possible.
Note: The Start Board current and voltage should be as
close as possible to the welding procedure current and
voltage, while still getting satisfactory starts.
d. Set the start time to as low a time as possible while still
getting satisfactory starts.
7. Start and make the weld.

IDEALARC DC-600 POWER SOURCE

SETTING WHEN CONNECTED TO NA-5
WIRE FEEDER
When using the Idealarc DC-600 with the NA-5 wire feeder, set
the controls on the Idealarc DC-600 as follows for the best
performance:
1. Turn OFF main AC input power supply to the Idealarc DC-
600.
2. Connect the electrode cables to terminal polarity to be
used.
3. Set the CONTROL CIRCUIT POLARITY SWITCH to the
same polarity as the electrode cable connection.
4. Set the OUTPUT CONTROL SWITCH to REMOTE.

Page 14 Idealarc DC-600 IMA 607A

 ACCESSORIES
OPTIONS/ACCESSORIES Figure C.2
Side Panel Removal
• Multi-Process Switch (K804-1)
REMOVE SCREWS
• Remote Control Box Assembly (K857) TO MOUNT
MULTI-PROCESS
• Undercarriages (KA1236 & KA1237) SWITCH
• Paralleling Kit (KA1010)
Semi-Automatic and Automatic Wire Feeders
• LN-7
• LN-8
• LN-9 } Semi-Automatic Wire Feeders
POSITIVE

• NA-3 STICK OR
• NA-5 } Automatic Wire Feeders NEGATIVE AIR
CARBON
ARC

MULTI-PROCESS SWITCH – +
The MULTI-PROCESS SWITCH gives you the ability to:
• Switch between "stick welding or air/carbon arc cutting" and
using a semi-automatic or automatic wire feeder.
5. Attach the MULTI-PROCESS SWITCH bracket across the
• Change the polarity of a semi-automatic or automatic wire front of the machine with the flange down. Use the long,
feeder without changing any electrical cable connections. self-tapping screws and lock washers provided. The bracket
The MULTI-PROCESS SWITCH has two sets of out-put should be on the outside of the side panel. See Figure C.3.
terminals. You connect the wire feeder unit cables to the set of Note: If the machine does not have any holes in the front of
terminals on the left side of the box and the stick or air/carbon arc the machine, use the switch template and drill two .153"
cables to the set of terminals on the right side (facing the front of diameter holes.
the machine) as shown in Figure C.1.
6. Position the MULTI-PROCESS SWITCH at the front of the
machine. See Figure C.3.
Figure C.1
Multi-Process Switch
Figure C.3
Attaching the Multi-Process Switch Bracket
MULTI-
PROCESS SELF TAPPING
SWITCH SCREWS
BRACKET CONTROL (DRILL .153"
LEADS HOLE IF
POSITIVE
NEEDED)
STICK OR
NEGATIVE AIR
CARBON
ARC

– +

WIRE STICK OR
FEEDER AIR/CARBON
CABLES ARC CABLES MULTI-
PROCESS
SWITCH WIRE FEED
CONTROL
CABLE
When the MULTI-PROCESS SWITCH is in the "Stick or
Air/Carbon Arc" position, only those terminals are energised. The 7. Route the MULTI-PROCESS SWITCH control leads
wire feeder nozzle or gun and electrode are not electrically "hot" through the strain-relief box connectors and into the
when in this mode. terminal strip. The wire feeder control cable is routed
Follow these steps to install the MULTI-PROCESS SWITCH: through the strain-relief box connector also. See Figure C.3.

1. Confirm that the Idealarc DC-600 ON/OFF PUSH BUTTON 8. Connect the control leads from the MULTI-PROCESS
is in the OFF position. SWITCH to terminals #2 and #4 on the Idealarc DC-600's
terminal strip.
2. Disconnect main AC input power to the Idealarc DC-600.
9. Position the MULTI-PROCESS SWITCH flush with the front
3. Open the terminal strip access door located on the Case of the machine about 2" lower than the bracket. Slide the
Front Assembly. switch straight up to the bracket.
4. Remove the two front, middle screws that secure the two 10. Check that the bottom of the switch is hooked behind the
side panels of the machine. See Figure C.2. top of the bottom louvre.

IMA 607A Idealarc DC-600 Page 15

11. Connect the right cable from the MULTI-PROCESS installed, the Idealarc DC-600 lift bail is no longer functional. Do
SWITCH (facing the front of the machine) to the Idealarc not attempt to lift the machine with the undercarriage attached.
DC-600 positive (+) output terminal. See Figure C.4. The undercarriage is designed for moving the machine by hand
only. Mechanised towing can lead to injury and/or damage to the
Idealarc DC-600.
Figure C.4
Multi-Process Switch Cable Connections

TERMINAL
METERS
STRIP Voltmeter and ammeter are factory installed.

41 21 4 2 31 32 75 76 77 80 81 PARALLELING KIT FOR DC-600

CONTROL
LEADS
Kit AT4000 - field installation only, permits paralleling of two DC-
600’s for welding currents of up to 1200 amps, 100% duty cycle.
NEGATIVE (—)
OUTPUT — +
POSITIVE (+)
OUTPUT (See instructions shipped with the kit for installation and
STUD STUD
operation.)
ELECTRODE ELECTRODE
CABLE CABLE
WORK +
STICK AIR/CARBON
WIRE
FEEDER
ELECTRODES
ARC WELDING
EQUIPMENT CONNECTIONS FOR SEMI-AUTOMATIC
WORK
CABLE JUMPER (IF NEEDED
WORK
CABLE
OR AUTOMATIC WIRE FEEDER
SEE INSTRUCTIONS)
CONTROL
12. Connect the left cable from the MULTI-PROCESS SWITCH 1. Set the ON/OFF PUSH BUTTON to OFF.
(facing the front of the machine) to the Idealarc DC-600
negative (-) output terminal. See Figure C.4. 2. Locate and open the hinged access door on the Front Case
Assembly.
13. Connect the wire feeder electrode and work cables. See
Figure C.4. 3. Insert control cable through the strain relief box connector
and pull enough cable through to reach the terminal strip,
a. Insert the wire feeder electrode and work cables through or connect to amphenol plug base.
the strain relief loop on the left side of the Idealarc DC-
600 (facing the front of the machine). 4. Connect the automatic wire feeder control cable to the
amphenol/terminal strip. See corresponding connection
b. Connect the wire feeder electrode and work cables to diagram in this Section of the manual, or the instructions
the electrode and work terminals on the left side of the included with the wire feeder.
MULTI-PROCESS SWITCH.
5. Connect the wire feeder grounding wire to the chassis
Note: When using Dual Process Kits K317 or K318, ground screw marked with the symbol ( ).
connect the electrode and work cables to these terminals
instead of the power source output terminals. See Note: The IDEALARC DC-600 Auxiliary Power Circuit supplies
connection diagrams for details. 42/115-volt AC power to the wire feeding equipment. The circuit
has a 1000 volt ampere rating. An 8-amp slow blow fuse on the
14. Connect wire feeder control cable to the amphenol/terminal machin300/e’s control panel protects the auxiliary power supply
strip of the Idealarc DC-600. from excessive overloads.
Note: Connect the control cable ground lead to the frame
terminal marked ( ).
Note: See the connection diagram for the wire feeder being CONNECTING THE NA-3 IDEALARC DC-600
used for connection instructions. 1. Disconnect main AC input power to the Idealarc DC-600.
15. Connect stick or air/carbon arc electrode and work cable. 2. Set Idealarc DC-600 ON/OFF PUSH BUTTON to OFF.
See Figure C.4.
3. Connect the wire feeder control cable leads to the Idealarc
a. Insert the electrode and work cables through the strain DC-600 amphenol/terminal strip as shown in Figure C.5.
relief loop on the right side (facing the front of the
machine) of the Idealarc DC-600. 4. Connect the wire feeder control cable ground lead to the
frame terminal marked ( ).
b. Connect the electrode cable to the "Positive" terminal on
the right side of the MULTI-PROCESS SWITCH. Note: The Idealarc DC-600 must be properly grounded.

c. Connect the work cable to the "Negative" terminal on

the right side of the MULTI-PROCESS SWITCH. Figure C.5
Note: The instructions above are for connecting the stick Connection to the Idealarc DC-600
polarity positive. To change the polarity, turn the Idealarc NA 3 WIRE
FEEDER
DC-600 OFF, and reverse the cables. CONTROL
CABLE

Note: When it is not necessary to have separate ground

TO
cables for stick and semi-automatic or automatic welding, AUTOMATIC
CONTROL
connect a jumper from the MULTI-PROCESS SWITCH BOX
"Work" terminal to the MULTI-PROCESS SWITCH 77
76
"negative" terminal. See Figure C.4.
75

To operate the MULTI-PROCESS SWITCH, refer to the operating 41 21 4 2 31 32 75 76 77 80 81 32

instructions on the switch nameplate. 31
2
4
21

UNDERCARRIAGE (KA1236, KA1237) – +

GND

The IDEALARC DC-600 is designed for use with the Lincoln NEGATIVE POSITIVE
ELECTRODE
Undercarriage. Complete installation instructions are included CABLE TO
TO WORK AUTOMATIC
with the undercarriage. When any of the undercarriages are EQUIPMENT

Page 16 Idealarc DC-600 IMA 607A

5. Extend wire feeder control cable lead # 21 so it can be 6. Connect NA-5 wire feeder control jumpers on Voltage
connected directly to the work piece. Control Board. See NA-5 Operator's Manual.
a. Make a bolted connection using AWG #14 or larger a. Connect red jumper on Voltage Control Board to pin "S."
insulated wire. Tape the bolted connection with
b. Connect white jumper on Voltage Control Board to pin "B."
insulating tape.
Note: The connection diagram shown in Figure C.6 shows the
b. An S-16586- X remote voltage sensing work lead is
electrode connected for positive polarity.
available for this purpose.
To change polarity:
c. Keep the # 21 lead electrically separate from the work
cable circuit and connection. a. Set the Idealarc DC-600 ON/OFF PUSH BUTTON to
OFF.
d. Tape the # 21 lead to work cable for ease of use.
b. Move the electrode cable to the Negative (-) output
Note: The connection diagram shown in Figure C.5 shows the
terminal.
electrode connected for positive polarity.
c. Move the work cable to the Positive (+) output terminal.
To change polarity:
d. Set the Idealarc DC-600 CONTROL CIRCUIT
a. Set the Idealarc DC-600 ON/OFF PUSH BUTTON to
POLARITY SWITCH to NEGATIVE.
OFF
Note: For proper NA-5 operation, the electrode cables must be
b. Move the electrode cable to the Negative (-) output
secured under the clamp bar on the left side of the NA-5 Control
terminal
Box.
c. Move the work cable to the Positive (+) output terminal.
d. Set the Idealarc DC-600 CONTROL CIRCUIT
POLARITY SWITCH to NEGATIVE. CONNECTING THE LN-8 OR LN-9 TO THE
e. Reverse the leads at the back of the ammeter and IDEALARC DC-600
voltmeter on the wire feeder automatic control box.
1. Disconnect AC input power to the Idealarc DC-600.

CONNECTING THE NA-5 TO THE 2. Set the Idealarc DC-600 ON/OFF PUSH BUTTON to OFF.

IDEALARC DC-600 3. Connect the wire feeder control cable leads to the Idealarc
DC-600 amphenol/terminal strip as shown in Figure C.7.
Note: For optimum performance use the NA-5 with Idealarc DC-
600 codes 8288 and above. 4. Connect the wire feeder control cable ground lead to the
frame terminal marked ( ).
1. Disconnect main AC input power to the Idealarc DC-600.
Note: The Idealarc DC-600 must be properly grounded.
2. Set the Idealarc DC-600 ON/OFF PUSH BUTTON to OFF.
5. Extend wire feeder control cable lead #21 so it can be
3. Connect the wire feeder control cable leads to the Idealarc
connected directly to the work piece.
DC-600 amphenol/terminal strip as shown in Figure C.6.
a. Make a bolted connection using AWG #14 or larger
Figure C.6 insulated wire. Tape the bolted connection with
NA-5 Wire Feeder Connection to the Idealarc DC-600 insulating tape.
b. An S-16586- X remote voltage sensing work lead is
LN8 OR LN 9
WIRE
available for this purpose.
FEEDER
CONTROL
CABLE
c. Keep the #21 lead electrically separate from the work
cable circuit and connection.
TO INPUT
CABLE
d. Tape the #21 lead to work cable for ease of use.
C
B
Note: Using the extended #21 lead eliminates the need to use the
A LN-9's remote work lead accessory which has a direct work lead
41 21 4 2 31 32 75 76 77 80 81 32
jack.
31
2
6. Connect LN-9 wire feeder control jumpers on Voltage
4 Control board. See LN-9 Operator's Manual.
21
GND a. White jumper on Voltage Control Board to pin "S."
– +
NEGATIVE POSITIVE b. Blue jumper on Voltage Control Board to pin "B."
ELECTRODE
TO WORK
CABLE TO WIRE
FEEDER
Note: On earlier units, the blue jumper on Voltage Control Board
is connected to Pin "B" on Start Board.
Note: The connection diagram shown in Figure C.7 shows the
Note: If using a K215 control cable, connect control cable leads
electrode connected for positive polarity.
#75, #76, and #77 to the matching #75, #76, and #77 terminals on
the terminal strip of the Idealarc DC- 600. To change polarity:
4. Connect the wire feeder control cable ground lead to the a. Set the Idealarc DC-600 ON/OFF PUSH BUTTON to
frame terminal marked ( ). OFF.
Note: The Idealarc DC-600 must be properly grounded. b. Move the electrode cable to the Negative (-) output
terminal.
5. Extend wire feeder control cable lead # 21 so it can be
connected directly to the work piece. c. Move the work cable to the Positive (+) output terminal.
a. Make a bolted connection using AWG #14 or larger d. Set the Idealarc DC-600 CONTROL CIRCUIT
insulated wire. Tape the bolted connection with POLARITY SWITCH to NEGATIVE.
insulating tape.
b. An S-16586- X remote voltage sensing work lead is
available for this purpose.
c. Keep the # 21 lead electrically separate from the work
cable circuit and connection.
d. Tape the # 21 lead to work cable for ease of use.

IMA 607A Idealarc DC-600 Page 17

 Figure C.7 Note: The Idealarc DC-600 must be properly grounded.
LN-8 or LN-9 Wire Feeder Connectionto the Idealarc DC-600 5. PERFORM THIS STEP ONLY IF THE LN-7 IS EQUIPPED
LN8 OR LN 9
WITH A METER KIT.
WIRE
FEEDER
CONTROL
CABLE
Extend wire feeder control cable lead #21 so it can be
connected directly to the work piece.
TO INPUT
CABLE
a. Make a bolted connection using AWG #14 or larger
C
B
insulated wire. Tape the bolted connection with
A
insulating tape.
41 21 4 2 31 32 75 76 77 80 81 32
31 Note: If the work cable length is less than 25 feet and the
2
4
connections to the work piece are secure, then wire feeder control
21 cable lead #21 can be connected directly to the DC-600 terminal
GND
– + strip.
NEGATIVE POSITIVE
ELECTRODE b. An S-16586- X remote voltage sensing work lead is
CABLE TO WIRE
TO WORK FEEDER available for this purpose.
c. Keep the #21 lead electrically separate from the work
cable circuit and connection.
LN-7 IDEALARC DC-600 d. Tape the #21 lead to work cable for ease of use.
1. Disconnect main AC input power to the Idealarc DC-600.
Note: The connection diagram shown in Figure C.8 shows the
2. Set the IDEALARC DC-600 ON/OFF PUSH BUTTON to electrode connected for positive polarity.
OFF.
To change polarity:
3. Connect the wire feeder control cable leads to the Idealarc
a. Set the Idealarc DC-600 ON/OFF PUSH BUTTON to
DC-600 amphenol/terminal strip as shown in Figure C.8.
OFF.
4. Connect the wire feeder control cable ground lead to the
b. Move the electrode cable to the Negative (-) output
frame terminal marked ( ).
terminal.
Figure C.8 c. Move the work cable to the Positive (+) output terminal.
LN-7 Wire Feeder Connection to the Idealarc DC-600
LN -7 WIRE
d. Set the IDEALARC DC-600 CONTROL CIRCUIT
FEEDER
CONTROL POLARITY SWITCH to NEGATIVE.
CABLE

TO LN-7
INPUT
CABLE
PLUG
77
76
75

41 21 4 2 31 32 75 76 77 80 81 32
31
2
4
21
GND
– +
NEGATIVE POSITIVE
ELECTRODE
CABLE TO LN
TO WORK CONDUCTOR
BLOCK

Page 18 Idealarc DC-600 IMA 607A

 GROUND TEST PROCEDURE
WARNING
8. Jumper volt & amp meter terminals, set local / remote
switch to local and CV / CC to cc position.
9. Input circuit test: Connect one lead of the mega tester to
This procedure is only suitable for applications using DC the frame of the machine and the other lead to the input
mega testers up to 500V. contactor jumper. Apply the test. (Min. resistance 1MΩ).
10. Welding circuit test: Connect one lead of the mega tester
Note: This procedure is for ‘machines as built’ many modifications to the frame of the machine and the other lead to the
could have taken place over the life of a particular machine, so positive output stud. Apply the test. (Min. resistance 1MΩ).
details of this procedure may need to be ‘adjusted’ to suit these
modifications. 11. Input circuit to welding circuit test: Connect one lead of
the mega to the input contactor jumper and the other to the
For prompt service contact your local authorised Lincoln field positive output stud. Apply the test/s. (Min. resistance
service shop. 10MΩ).
The insulation resistance values listed below are from Australian 12. Auxiliary circuit test: Connect one lead of the mega tester
Standard AS1966.2. to the frame of the machine and the other lead to terminal
1. Disconnect input power mains supply. No32A. Apply the test. (Min. resistance 1MΩ).
2. Remove welding leads (electrode cables, control cables 13. Input circuit to auxiliary circuit test: connect one lead of
and work lead) from the machine before any tests are the mega to the input contactor jumper and the other lead
carried out. to terminal No32A. Apply the test. (Min. resistance 1MΩ).
3. Remove plugs from all PCB’s, install a shorting socket into 14. Welding circuit to auxiliary circuit test: Connect one
the harness plugs. (shorting all pins together. The firing lead of the mega tester to the positive output stud and the
board harness shorting plugs must have leads connecting other lead to terminal No32A. Apply the test. (Min.
the plugs to the SCR heat sinks. The control board harness resistance 1MΩ).
shorting plugs must be connected together, shorting plugs 15. Control board harness test: Connect one lead of the
or machine wiring harness must not touch any part of pcb mega tester to the control board harness plugs and the
or pcb mountings during mega testing. other lead to the frame of the machine.Apply the test. (Min.
4. On each of the 6 power SCR's, connect a jumper to both resistance 1MΩ)
heat sinks anode and cathode, also connect a jumper from 16. Control board harness to input circuit test: connect one
each gate lead to one of the heatsinks. lead of the mega tester to the control board harness
5. Disconnect the ground lead on the by - pass capacitor shorting plugs and the other lead to terminal No32A. Apply
mounted on the front panel. the test. (Min. resistance 1MΩ).
6. Jumper all input and output lead connections on the input 17. Remove all shorting plugs, and jumpers and reconnect all
contactor (1cr). plus and leads.
7. Disconnect leads 222, 210 and 256 from transient If any problems are encountered refer to your nearest authorised
suppressor assy. (if equipped). Lincoln Field Service Shop.

MAINTENANACE
ROUTINE AND PERIODIC

ELECTRIC SHOCK can kill

• Only qualified personnel should perform this
maintenance.
• Turn the input power OFF at the disconnect
switch or fuse box before working on this
equipment.
• Do not touch electrically hot parts.

MAINTENANCE Perform Periodically:

Clean the inside of the machine with low pressure air stream.
1. Disconnect input AC power supply lines to the machine Clean the following parts. Refer to Figure D.1.
before performing periodic maintenance, tightening,
cleaning, or replacing parts. See Figure D.1 • Main transformer and choke.

Perform the following daily: • Electrode and work cable connections.

1. Check that no combustible materials are in the welding or • SCR rectifier bridge and heat sink fins.
cutting area or around the machine. • Control board.
2. Remove any debris, dust, dirt, or materials that could block • Firing board.
the air flow to the machine for cooling.
• Fan Assembly.
3. Inspect the electrode cables for any slits or punctures in the
Note: The fan motor has sealed bearings which require no
cable jacket, or any condition that would affect the proper
maintenance.
operation of the machine.

IMA 607A Idealarc DC-600 Page 19

 NOTES

Page 20 Idealarc DC-600 IMA 607A

 TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorised repairs performed on this equipment may result in danger to the technician
and machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.

This Troubleshooting Guide is provided to help you locate Step 3. RECOMMENDED COURSE OF ACTION
and repair possible machine malfunctions. Simply follow This column provides a course of action for the Possible
the three-step procedure listed below. Cause, generally it states to contact your local Lincoln
Step 1. LOCATE PROBLEM (SYMPTOM). Authorized Field Service Facility.
Look under the column labeled “PROBLEM If you do not understand or are unable to perform the
(SYMPTOMS)”. This column describes possible Recommended Course of Action safely, contact your local
symptoms that the machine may exhibit. Find the listing Lincoln Authorised Field Service Facility.
that best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the
obvious external possibilities that may contribute to the
machine symptom.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorised Field Service Facility for technical troubleshooting assistance before you proceed.

IMA 607A Idealarc DC-600 Page 21

 TROUBLESHOOTING
PC BOARD TROUBLESHOOTING PROCEDURES

WARNING
- If you don’t have a wrist strap, touch an unpainted,
grounded, part of the equipment frame. Keep touching
the frame to prevent static build-up. Be sure not to touch
any electrically live parts at the same time.
- Tools which come in contact with the P.C. Board must be
ELECTRIC SHOCK can kill
either conductive, anti-static or static-dissipative.
Have an electrician install and service this
- Remove the P.C. Board from the static-shielding bag
equipment. Turn the input power OFF at the
and place it directly into the equipment. Don’t set the
fuse box before working on equipment. Do not
P.C. Board on or near paper, plastic or cloth which could
touch electrically hot parts.
have a static charge. If the P.C. Board can’t be installed

CAUTION
immediately, put it back in the static-shielding bag.
- If the P.C. Board uses protective shorting jumpers, don’t
remove them until installation is complete.

Sometimes machine failures appear to be due to PC board - If you return a P.C. Board to The Lincoln Electric
failures. These problems can sometimes be traced to poor Company for credit, it must be in the static-shielding
electrical connections. To avoid problems when bag. This will prevent further damage and allow proper
troubleshooting and replacing PC boards, please use the failure analysis.
following procedure: 4. Test the machine to determine if the failure symptom has
1. Determine to the best of your technical ability that the PC been corrected by the replacement PC board.
board is the most likely component causing the failure Note: It is desirable to have a spare (known good) PC board
symptom. available for PC board troubleshooting.
2. Check for loose connections at the PC board to assure that Note: Allow the machine to heat up so that all electrical
the PC board is properly connected. components can reach their operating temperature.
3. If the problem persists, replace the suspect PC board using 5. Remove the replacement PC board and substitute it with
standard practices to avoid static electrical damage and the original PC board to recreate the original problem.
electrical shock. Read the warning inside the static
a. If the original problem does not reappear by substituting
resistant bag and perform the following procedures:
the original board, then the PC board was not the
problem. Continue to look for bad connections in the
P.C. Board can be damaged by static control wiring harness, junction blocks, and terminal
electricity. strips.
b. If the original problem is recreated by the substitution of
ATTENTION
the original board, then the PC board was the problem.
Static-Sensitive
Remove your body’s static charge before Reinstall the replacement PC board and test the
Devices opening the static-shielding bag. Wear an machine.
Handle only at anti-static wrist strap. For safety, use a 1 Meg
Static-Safe ohm resistive cord connected to a grounded 6. Always indicate that this procedure was followed when
Workstations
part of the equipment frame. warranty reports are to be submitted.
Reusable Note: Following this procedure and writing on the warranty report,
Container “INSTALLED AND SWITCHED PC BOARDS TO VERIFY
Do Not Destroy PROBLEM,” will help avoid denial of legitimate PC board warranty
claims.

Page 22 Idealarc DC-600 IMA 607A

 TROUBLESHOOTING
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical Contact the Lincoln Electric Service
Damage is Evident

The machine is dead - the Input 1. Check for blown or missing fuses
contactor does not operate. in input lines.
2. Check the three-phase input line
voltage at the machine. The input
voltage must match the rating plate
and reconnect panel.

Input contactor (CR1) chatters. 1. The input line voltage may be low.
Check all three phases.
2. Make sure input line voltage
matches machine rating and the
reconnect panel is connected
correctly for the line voltage.

Input contactor pulls in when start 1. Make sure input line voltage
button is pressed but immediately matches machine rating and the
drops out when start button is reconnect panel is connected
released. correctly for the line voltage.
2. Remove all external wires
attached to terminal strip or.
amphenol plug.(2,4,31,32,75,76,77).
If contactor (CR1) functions correctly If all recommended possible areas of
there may be a “ground” or misadjustment have been checked and
negative intrusion on the remote the problem persists, contact your
control leads (75,76 or 77). There local Lincoln Authorised Field Service
may also be a “short”at the welder Facility.
output terminals.
3. If the problem persists after
performing steps #1 and #2 the
problem is in the DC-600.

Machine input contactor operates 1. Install a jumper from #2 to #4 on

but machine has no weld output. machine terminal strip. If machine
Fan runs and pilot light glows. weld output is restored the problem
is in the wire feeder or control
cable.
2. If remote control is not being used
make certain the OUTPUT
CONTROL SWITCH (SW3) is in the
“Panel” position.
3.Check 8AMP fuse in the front panel.
Replace if blown.
4. Check for loose or faulty weld
cable connections.

Machine has maximum weld 1. If remote control is being used set

output and no control. OUTPUT CONTROL SWITCH
(SW3) in “Panel” position and
control weld output with the
OUTPUT CONTROL
POTENTIOMETER (R1) at DC-600.
If the problem is solved check the
remote control unit (or wire feeder)
and associated control cable.

IMA 607A Idealarc DC-600 Page 23

 TROUBLESHOOTING

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine has minimum output and 1. If a remote control unit is NOT
no control. connected to the temrinal strip
#75, #76 and #77 terminals, the
OUTPUT CONTROL SWITCH
must be in the “Panel” position.
2. If a remote control cable is
connected to terminals #75, #76
and #77 the leads may be "shorted"
to the positive weld output.
3. Make certain the Three Phase
input voltage is correct and
matches the machine rating and
the reconnect panel.

The machine does not have 1. Check all Three-Phase input lines
maximum weld output. at the DC-600. Make sure input
voltages match machine rating and
reconnect panel.
2. Put OUTPUT CONTROL SWITCH
(SW3) in "Panel" position. If
problem is solved then check
remote control unit or wire feeder.

Machine shuts off (input 1. Remove all welding cables and If all recommended possible areas of
contactor drops out) when the control cables from the DC-600. misadjustment have been checked
welder output terminals are made Jumper #2 to #4 at the terminal and the problem persists, contact
electrically “hot”. strip. If the machine does NOT shut your local Lincoln Authorised Field
(#2 to #4 closure at terminal strip). off and normal open circuit voltage Service Facility
is present at the welder output
terminals the problem is external to
the DC-600. Either the remote leads
#75,#76 or #77 are grounded to
the negative output cable or there
is a short on the welding output
terminals.
2. If the machine still shuts off when
all control and welding cables are
removed then the problem is
internal to the DC-600.

The DC-600 will NOT shut off 1. Contact your local Lincoln
when the Stop button is pushed. Authorised Field Service Facility.

The weld output terminals are 1. Remove any external leads hooked
always electrically “hot”. to #2 and #4 on the terminal strip.
If the problem disappears the fault
is in the control cable or wire feeder.
2. If some open circuit voltage is
present (over 3VDC) after
performing Step #1, then the
problem is within the DC-600.

Page 24 Idealarc DC-600 IMA 607A

 TROUBLESHOOTING

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Poor arc starting when the DC-600 1. Make sure the proper welding
is in the CV Sub-Arc or CV procedures are being used (wire
Innershield modes. feed speed, arc voltage and wire
size).
2. Check weld cables for loose or
faulty connections.
If all recommended possible areas of
misadjustment have been checked
Poor arc characteristics in all 1. Check for the correct input voltages and the problem persists, contact your
processes. on the three-phase input lines at local Lincoln Authorised Field Service
the DC-600. Facility
2. Make sure the proper welding
procedures are being used (wire
feed speed, arc voltage and wire
size).
3. Check the welding cables for loose
or faulty connections.

IMA 607A Idealarc DC-600 Page 25

 Figure D.1
General Assembly Exploded View

Page 26 Idealarc DC-600 IMA 607A

 AP- 216
Operative: May 2003

DC-600
Supersedes: NEW

(For Codes 1272 to 1633)

Model Index
DO NOT attempt to use this Parts List for machine if its code
NUMBERS IN THE TABLE BELOW INDICATE WHICH number is not listed. Contact the Service Department for any
COLUMN TO USE IN EACH PARTS LIST FOR EACH code numbers not listed. (Only those suffixes which require
INDIVIDUAL CODE NUMBER. distinction from the basic codes are shown.)

K804-1 Multi-Process Switch

Life Bale & Choke Assembly
Case Front panel Assembly

Case Rear Panel Assembly

Remote Control (Optional)

Base, Fan, Sides & Roof
Transformer Assembly

SCR bridge Assembly

Control Box Assembly
PARTS
Miscellaneous Items
Optional Equipment

LIST
TITLES

Assembly
PARTS LIST AP216-B.1 AP216-B.2 AP216-C AP216-D AP216-E AP216-F AP216-G AP216-H AP216-J AP239 AP84-J
NO.

CODE NO.

1272 1 1 1 1 1 1 1 1 1
1273 2 1 1 2 2 1 1 1 1 1
1311 1 1 1 1 1 1 1 1 1 1
1312 2 1 1 2 2 1 1 1 1 1
1318 2 1 1 2 2 1 1 1 1 1
1319 1 1 1 1 1 1 1 1 1 1
1322 1 1 1 1 1 1 1 1 1 1
1323 2 1 1 2 2 1 1 1 1 1
1327 1 1 1 1 1 1 1 1 1 1
1329 1 1 1 1 1 1 1 1 1 1
1334 2 1 1 2 2 1 1 1 1 1
1435 1 1 1 1 1 1 1 1 1 1
1434 2 1 1 2 2 1 1 1 1 1
1485 1 1 1 1 1 1 1 1 1 1
1503 1 1 1 1 1 1 1 1 1 1
1548 1 2 1 1 1 1 1 1 1 1
1549 2 2 1 2 2 1 1 1 1 1
1622 3 2 1 2 3 1 1 1 1 1
1623 4 2 1 2 4 1 1 1 1 1
1633 5 2 1 2 5 1 1 1 1 1

# Indicates a change this printing

IMA607A Idealarc DC-600 Page 27

 AP216-B.1
Operative: May 2003
Supersedes: NEW

OPTIONAL EQUIPMENT LISTING

Miscellaneous Options Available for your machine are listed below:
# Indicates a change this printing

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Hand Amptrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K812

Arc Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K812
Undercarriage without Gas Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KA1236
Undercarriage with Gas Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KA1237
Twist Mate Plug Kit (25mm-95mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KA1346
Remote Output Control (8.5m suits terminal strip connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K775
Remote Output Control 6 pin Connector (8.5m req K864 Adapter) . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K857
Remote Output Control 6 pin Connector (20m req K864 Adapter) . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K857-20
Remote Output Control 14 pin Connector (20m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K857A20
Remote Control Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K864
Universal Adapter for 14 Pin Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K867
Foot Amptrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K870
DC TIG Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K900-1
Multi Process Switch (8.5m req K864 Adapter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KA1237
Paralleling Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KA1010

Page 28 Idealarc DC-600 IMA 607A

 AP216-B.2
Operative: May 2003
Supersedes: NEW

MISCELLANEOUS ITEMS
(These items are not illustrated)

# Indicates a change this printing. Use only the parts marked “X” in the column under the
heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Input Connection Diagram:

414/3/50 AT3164-1 1 x
Input Connection Diagram
220/380/440/3/50 AM3237 x
Input Connection Diagram
200/3/50 AT3164-11 x
Input Connection Diagram
380/550/575/3/50 AT3164-12 x
Input Connection Diagram
380/550/3/50 AT3164-9 x
Wiring Diagram
415/3/50 AL2331
220/380/440/3/50 AL2331
200/3/50 AL2331
380/550/575/3/50 AL2331
380/500/3/50 AL2331
Ground Decal T13259 1 X
Identification Sticker (CR1) T14798-1 1 X
Caution Decal S16307 1 X
Warning Decal AS4244 1 X
Instruction Decal T14446 1 X
Ground Decal T13259 1 X
Caution Decal (Case Front) T13086-20 1 X
Reed Switch (3CR) S12334-32 1 X

IMA 607A Idealarc DC-600 Page 29

 AP-216-C
Operative: May 2003
Supersedes: NEW

Case Front Panel Assembly

(Control Box Assembly shown)

16
17
15A

15

15B

14A 14 14B
18
11 13
1C
1B

6
10 12
6B 12A 19

20

9 8 7

6A 4
5 5A
3 2 1
1A

13A

Page 30 Idealarc DC-600 IMA 607A

 AP-216C.1
Operative: Dec 2005
Supersedes: May 2003

# Indicates a change this printing. Use only the parts marked “X” in the column under the
* Items not illustrated. heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Pushbutton switch with light AS4208 1 X

2 Pilot Light Part of switch
3 Output Control Switch (SW3) T10800-24 1 X
4 Welding Mode Switch (SW4) T13381-3 1 X
5 Fuse Holder S10433-1 1 X
5A* Fuse T10728-16 1 X
6 Output Control Potentiometer T10812-97 1 X
6A Knob T10491 1 X
6B Potentiometer Insulation T12792-1 1 X
7 Control Circuit Polarity Switch (SW2) T13562 1 X
(10 Amp,250 Vac: 15 Amp, 125 Vac)
8 DC Ammeter M10485-5 1 X
9 DC Voltmeter M10486-3 1 X
10 Control Box Cover AM3176A 1 X
11 Nameplate AM3292A 1 X
12 Bottom Cover (Push Button) Part of AS4208
13 Front Panel Welded Assy AL1978 X
(Use AL1978-1 + AS4450 plug)
13 Front Panel Welded Assembly (14 pin ) AL1978-1 1 X
13A Self Tapping Screw S8025-71 7 X
14 Relay (Fault) S15122-11 1 X #
14A Self Tapping Screw S8025-62 2 X
14B Identification Sticker T12286-2 1 X
15 Relay (Pilot) S14293-8 1 X
15A Self Tapping Screw S8025-62 2 X
15B Identification Sticker T12286-4 1 X
16 Firing Circuit PC Board G1486-[ ] 1 X
17 Control PC Board G1504-[ ] 1 X
18 PC Board Support S19300-3 11 X
19 Bushing T14614-1 1 X
20 Bushing T12380-1 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board
that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any
necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so
as to eliminate errors, confusion and updates.

IMA 607A Idealarc DC-600 Page 31

 AP-216-D
Operative: May 2003
Supersedes: NEW

Control Box Assembly

(Case Front Panel Assembly shown)

1A

20 2
20A

2A 7

19

17 16
3
18A 15

18 4

4A

4B
6A
6 4C
5 4D

Page 32 Idealarc DC-600 IMA 607A

 AP-216D.1
Operative: May 2003
Supersedes: NEW

# Indicates a change this printing. Use only the parts marked “X” in the column under the
* Items not illustrated. heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1A Thread Cutting Screw S9225-36 1 X

2 Terminal Strip S14530-11 1 X
3 Air Bafflle (part of Front Panel Welded Assy (14 pin ) NSS 1 X
4 Capacitor Assembly, Includes: S17222 1 X
4A Capacitor T11577-47 2 X
4B Clamp T12563-8 2 X
4C Thread Cutting Screw S9225-36 1 X
4D Plain Washer S9262-136 1 X
5 Thread Cutting Screw S9225-8AZ 1 X
6 Moulded Output Stud AM2464-1 3 X
6A Flange Nut T3960 3 X
7 14 pin Amphenol Plug Base (code 1548 & above) S12021-40 1 X
15 Box Connector T9639-1 1 X
16 Plug Button T13597-1 1 X
17 Number Plate AS4236 1 X
18 Door and Welded Assembly S17750 1 X
18A Self Tapping Screw S8025-71 2 X
19 Decal T13260-3 1 X
20 Terminal Strip S8542-7 1 X
20A Self Tapping Screw S8025-15 2 X

IMA 607A Idealarc DC-600 Page 33

 AP-216-E
Operative: May 2003
Supersedes: NEW

Case Rear Panel Assembly

2 3
3B 4A

4
2A 2B
3A 2D

2C
2E
5

5A
1

1A

7A

Page 34 Idealarc DC-600 IMA 607A

 AP-216E.1
Operative: May 2003
Supersedes: NEW

# Indicates a change this printing. Use only the parts marked “X” in the column under the
* Items not illustrated. heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Input Box Assembly AL1890 1 X X

1A Self Tapping Screw S8025-71 3 X X
2 Reconnect Panel AS3745 1 - X
2A Self Tapping Screw S8025-71 2 - X
2B Reconnect Panel Link T14190 As Req’d - X
2C Reconnect Panel Link T14190 As Req’d - X
2D 1
/4-20 Heavy Hex Nut AM3055-90 As Req’d - X
2E 1
/4-20 Brass - Hex Nut AM3055-90 As Req’d - X
2F Grommet Strip (Not Shown) T12823-4 1 X X
3 Contactor (see note below) M18712 1 X X
3A Relay S15122-10 1 • X
3B Self Tapping Screw S8025-71 3 X X
4 Input Access Door AM3257 1 X X
4A Self Tapping Screw S8025-71 3 X X
5 Control Transformer (Aux.Pilot Transformer)
415 Volt (50/60HZ) AM2681- 2 1 X
220/380/440 Volt AM2681- 1 1 X
200 (50 HZ) PT0063 1 X X
380/500 Volt AM2681-2 1 X X
575 Volt (60HZ) 380/500/575 PT0064 1 X X
5A Self Tapping Screw S8025-71 3 X X
6 Bushing T12380-2 1 X X
7 Rear Panel AL2375 1 X
7A Self Tapping Screw S8025-71 12 X X
8 1
/4 - Whit Hex Nut AM3055-90 2 X X

* Codes below 1503 require Contactor Kit G3146

IMA 607A Idealarc DC-600 Page 35

 AP-216-F
Operative: May 2003
Supersedes: NEW

Transformer Assembly

1A
1B

1A

1C

1D

2A 1E

2B 2
2C

1F

1G

Page 36 Idealarc DC-600 IMA 607A

 AP-216F.1
Operative: May 2003
Supersedes: NEW

# Indicates a change this printing. Use only the parts marked “X” in the column under the
* Items not illustrated. heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Transformer Assembly (1A thru 1H)

415V AL2335-1 1 X
220/380/440/3/0 AL2335-3 1 X
200/3/50 AL2335-4 1 X
380/500/3/50 AL2335-2 1 X
380/500/575/50 AL2335-5 1 X
1A Left Primary Coil
415V 9356L 1 X
220/380/440/3/50 9363
200/ 9355L 1 X
380/500 9359L 1 X
380/500/575 9384LX 1 X
Right Primary Coil
415V/3/50 9356R
220/380/440/3/50 9363R
200/3/50 9355R
380/500/3/50 9359R
380/ 500/575/3/50 9384RX
1B Center Primary Transformer Coils 415V
415V 9356C 1 X
220/380/440/3/50 9363C 1 X
200/3/50 9355C 1 X
380/500/3/50 9359C 1 X
380/500/575/3/50 9384CX 1 X
1C Top Secondary Transformer Coil M13904-1 3 X
1D Bottom Secondary Transformer Coil M13904-2 3 X
1E Threaded Rod AS4324-6 4 X
1F Washer S9262-120 12 X
1G 3/8-16 Hex Nut AM3055-115 8 X
1H Transformer Lamination Assembly L3841-29 2 X
2 Thermostat (Secondary) T13359-7 1 X
Thermostat (Primary) M17192-2 1 X

IMA 607A Idealarc DC-600 Page 37

 AP-216-G
Operative: May 2003
Supersedes: NEW

SCR Bridge Assembly

(Lift Base Assembly shown)

3 3A
2A
1A 3B
2B
4
2C
5
6 9A
7
10
8 9B
11
9C
1 14
9 9D
13
10
3B
3C
11

12

2C
2

Page 38 Idealarc DC-600 IMA 607A

 AP-216G.1
Operative: May 2003
Supersedes: NEW

# Indicates a change this printing. Use only the parts marked “X” in the column under the
* Items not illustrated. heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Three Phase Bridge Assembly, Includes: AL1899-2 1 X

1A Stiffener S16818 1 X
2 5
/16-18 x 2.50 Hex Head Cap Screw T9447-44 12 X
2A 5
/16-18 Hex Nut AM3055-104 12 X
2B Lock Washer E106A14 12 X
2C Plain Washer S9262-121 18 X
3 Self tapping Screw S8025-73 4 X
3A Plain Washer S9262-120 4 X
3B Insulating Washer S10773-23A 4 X
3C Insulating Tube T7028-176 4 X
4 5
/16” 18 Hex Nut AM3055-104 12 X
5 Lock Washer E106A14 12 X
6 Plain Washer S9262-121 18 X
7 Thread Forming Screw S9225-8AZ 1 X
8 Snubber P.C. Board Assembly AL1898B 6 X
9 Snubber P.C. Board Assembly S16182-2 6 X
9A 1
/4-20 x .625 Hex Head Cap Screw 1 X
9B Plain Washer S9262-98 1 X
9C Lock Washer E106A2 1 X
9D 1
/4-20 Hex nut AM3055-90 1 X
10 Bridge Tie Bar S16181-4 4 X
11 Insulation S13330-6 2 X
12 Aluminum Heat Sink M12314-3 6 X
13 Bridge Tie Bar S16181-6 2 X
14 Bridge Tie Bar S16181-5A 2 X
15 SCR* M12283-10 6 X
16 Plug & Lead Assembly (Not Shown) S18250-213 1 X
17* Cathode Heat Sink AM2435-1 6 X
18A Mounting Clamp Spring S14724A 6 X
18B Mounting Clamp, S14724B 6 X
19 Shunt Assembly M19044 1 X

IMA 607A Idealarc DC-600 Page 39

 AP-216-H
Operative: May 2003
Supersedes: NEW

Lift Bale, Choke Assembly

(SCR bridge Assembly shown)

4
3A 4A
3
4B
3A 4C

3B 5
2 3C 5A

2A 5A
5B
1
5C
1A

2A
6
1

1A

8A 8B
8C
6A
8

8C
7
9C 7A
8B 8D
9D 8E
9B
9E
9
9F 9A

10A 10B
10

Page 40 Idealarc DC-600 IMA 607A

 AP-216H.1
Operative: May 2003
Supersedes: NEW

# Indicates a change this printing. Use only the parts marked “X” in the column under the
* Items not illustrated. heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Choke Side Baffle AT3760 2 X

1A Self Tapping Screw S8025-79 2 X
2 Choke Top Baffle S16642 1 X
2A Thread Forming Screw S9225-17 2 X
3 3
/8-16 x 1.00 Hex Head Screw 1 X
3A Plain Washer 2 X
3B Lock Washer 1 X
3C 3
/8-16 Hex Nut 1 X
4 Choke & Lamination Assembly, Includes: AM2866 1 X
Edge Wound Coil NSS 1 X
4A 3/8-16 Hex Nut NSS 4 X
4B Lock Washer NSS 4 X
4C Plain Washer NSS 4 X
5 3
/8-16 x 1.25 Hex Head Cap Screw NSS 1 X
5A Plain Washer NSS 2 X
5B Lock Washer NSS 1 X
5C 3
/8-16 Hex Nut NSS 1 X
6 Lift Bale Assembly AL1822 1 X
6A Self Tapping Screw S8025-58 4 X
7 Transformer Insulating Baffle T11357-18 2 X
7A Self Tapping Screw S8025-79 4 X
8* Resistor S10404-79 1 X
8A #10-24 x 7.50 Round Head Screw NSS 1 X
8B Plain Washer NSS 2 X
8C Insulating Washer T4479A 2 X
8D Lock Washer NSS 1 X
8E #10-24 Hex Nut NSS 1 X
9* Reed Switch Assy S12334-32 1 X
9A Clamp T8970-17 2 X
9B #8-32 x .50 Round Head Screw NSS 2 X
9C Reed Switch Plate S11797-15 1 X
9D Lock Washer 2 X
9E #8-32 Hex Nut 2 X
9F Identification Sticker T14798-3 1 X
10 Shunt Assembly includes: M19044 1 X
10A 3
/8-16 x 1.00 Hex Head Cap Screw 3 X
10B 3
/8-16 Hex Nut 3 X
10C Shunt (500 amp) S6602-20 1 x

IMA 607A Idealarc DC-600 Page 41

 AP-216-J
Operative:
Supersedes:

Base, Fan, Sides & Roof Assembly

1A
2

4
1
5

1B
6

3A
3B
3C

9A
9 10

9B

Page 42 Idealarc DC-600 IMA 607A

 AP-216J.1
Operative:
Supersedes:

# Indicates a change this printing. Use only the parts marked “X” in the column under the
* Items not illustrated. heading number called for in the model index page.

Recommended Spare Parts are highlighted in bold

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Roof Assembly (Red) AM2805-7 1 X

1A Self Tapping Screw S8025-79 2 X
1B Self Tapping Screw S8025-65 2 X
2 Cover Seal S12934 1 X
3 Fan Motor M9983-4 1 X
4 Fan Baffle L6247 1 X
5 Self Tapping Screw S8025-65 7 X
6 Fan M6819-9 1 X
7&8 Fan Bracket Brace (Left & Right) M16525 2 X
9 Side Panel AL2098-2 2 X
9A Self Tapping Screw S8025-65 4 X
9B Self Tapping Screw S8025-79 6 X
10 Base L5928-3 1 X

IMA 607A Idealarc DC-600 Page 43

 Wiring Diagram (Various Single, Dual and Triple Voltage Machines)

Page 44
Idealarc DC-600
DIAGRAMS

AL2331
Note: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The

IMA 607A
specific diagram for your particular machine is pasted inside the machine on one of the enclosure panels.
 NOTES

IMA 607A Idealarc DC-600 Page 45

 NOTES

Page 46 Idealarc DC-600 IMA 607A

 NOTES

IMA 607A Idealarc DC-600 Page 47

 LIMITED WARRANTY IMAWS1 (5/06)

STATEMENT OF LIMITED WARRANTY CONDITION OF WARRANTY

The Lincoln Electric® Company (Australia) Pty Limited ("Lincoln") warrants all new TO OBTAIN WARRANTY COVERAGE:
machinery and equipment ("goods") manufactured by Lincoln® against defects in The purchaser must contact Lincoln® or Lincoln's Authorised Service Facility about any
workmanship and material subject to certain limitations hereinafter provided. defect claimed under Lincoln's warranty.
This warranty is void if Lincoln® or its Authorised Service Facility finds that the equipment Determination of warranty on welding and cutting equipment will be made by Lincoln® or
has been subjected to improper installation, improper care or abnormal operations. Lincoln's Authorised Service Facility.
PERIOD OF WARRANTY "LINCOLN BRANDED GOODS" WARRANTY REPAIR
The period from the commencement of the warranty in respect of goods covered by If Lincoln® or Lincoln's Authorised Service Facility confirms the existence of a defect
this warranty shall be as follows: covered by this warranty, the defect will be corrected by repair or replacement at
Lincoln's option.
Three Years
All Lincoln® welding machines, wire feeders and plasma cutting machines unless listed At Lincoln's request, the purchaser must return, to Lincoln® or its Authorised Service
below. Facility, any "Goods" claimed defective under Lincoln's warranty.

Two Years FREIGHT COSTS

All Weldanpower®, Ranger®, Italian Invertec® welders, PC65 and PC105 Plasmas. The purchaser is responsible for shipment to and from the Lincoln® Authorised Service
Facility.
One Year
• PC60 & PC100 Plasmas WARRANTY LIMITATIONS
• All water coolers (internal and external). Certain conditions warranties and obligations are implied by law (for example under the
• Arc welding and cutting robots and robotic controllers. Trade Practices Act 1974) and cannot be excluded or modified ("the statutory
• All stick electrodes, welding wires and fluxes. warranties").
• All Environmental Systems equipment, including portable units, central units and Where the statutory warranties do apply then any express warranties given by Lincoln®
accessories. (Does not include consumable items listed under 30-day warranty). (the "express warranties") are given in addition and without derogation from the statutory
• All welding and cutting accessories including wire feed modules, undercarriages, field warranties. Apart from the express warranties and (in cases where they apply by law but
installed options that are sold separately, unattached options, welding supplies, not otherwise) the statutory warranties Lincoln® gives no warranties whether express or
standard accessory sets, replacement parts. (Does not include expendable parts and implied by operation of law or otherwise in respect of any goods manufactured or
guns/torches listed under 90 and 30 day warranties). supplied by Lincoln® or by its authorised distributor.

90 Days Any warranty whether express or statutory and the term of any such warranty as set out
• All Gun and Cable Assemblies (manufactured by Lincoln®) and Spool guns. herein commences on the date Lincoln® or Lincoln's authorised distributorship forwards
• All MIG, TIG and Plasma Torches. the goods from the premises of Lincoln® or Lincoln's authorised distributor to the
• All “Pro Torch” TIG Torches. purchaser.
30 Days In respect of any claim under the warranty herein provided a purchaser must furnish
• All consumable items that may be used with the environmental systems described Lincoln® with written notice of any claim under the warranty within the time period of the
above. This includes hoses, filters, belts and hose adapters. warranty as further specified herein.
• Expendable Parts - Lincoln® is not responsible for the replacement of any expendable The extent of Lincoln's warranty whether express or statutory is limited to a liability to
part that is required due to normal wear. repair, replace or pay to the purchaser an amount equal to:
ENGINE WARRANTY a) The cost of replacing the goods;
To the extent permitted by law Lincoln® shall be entitled to in its absolute discretion repair b) The cost of obtaining equivalent goods; or
all engines and engine accessories however Lincoln® shall not be held responsible for c) cost of having the goods repaired whichever remedy in its absolute discretion
any such repair which shall be the sole responsibility of the engine manufacturer which Lincoln® chooses.
provides for warranties for the period and subject to any limitations provided for by those Upon request by Lincoln® the purchaser must permit Lincoln® to inspect the goods the
manufacturers of the respective engines and engine accessories. subject of any claim under this warranty and Lincoln® may at its absolute discretion repair
Three Years* or replace the goods F.O.B. at its own premises or at such other premises as Lincoln®
Deutz 912 Engine and Accessories *Subject to conditions may designate provided that all freight charges to and from Lincoln's premises or such
(Warranty service can only be carried out an imposed by Deutz. other premises as Lincoln® may designate shall be paid by the purchaser.
authorised Deutz service dealer) Subject to the express and statutory warranties hereinbefore provided Lincoln® provides
Cummins B3.3 Engine and Accessories *Subject to conditions no other warranties in respect of the manufacture or sale of goods and in particular
(Warranty service can only be carried out an imposed by Cummins Lincoln® shall have no responsibility or liability in respect of:
authorised Cummins service dealer) a) Repairs done to Lincoln's goods and undertaken by the purchaser outside
Two Years Lincoln's premises without written authority from Lincoln® obtained prior to any
Perkins Engines and Accessories such repair;
(The Perkins Distributor Organisation *Subject to conditions b) Any damage or failure of the goods as a result of normal wear and tear or the
provides all warranty service (accessories imposed by Perkins neglect misuse abuse or failure to properly service goods by any purchaser.
included) for the Perkins Engines powering The liability of Lincoln® is limited as hereinbefore provided and Lincoln® shall not be liable
goods manufactured by Lincoln. for any incidental special or consequential damage suffered by a purchaser whether or
not arising out of circumstances known or foreseeable known by Lincoln® and in
Briggs & Stratton Vanguard Engines *The Magnetron ignition particular arising out of the supply of goods to a purchaser or the use of goods by a
and Accessories. (Warranty service can only system is warranted by purchaser whether based on breach of contract negligence or tort.
be carried out by an authorised Briggs & Stratton Briggs & Stratton for 5 years.
service dealer). CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality
Kubota Engines and Accessories *Subject to conditions welding equipment, consumables, and cutting equipment. Our challenge is to meet the
(Warranty service can only be carried out an imposed by Kubota. needs of our customers and to exceed their expectations. On occasion, purchasers may
authorised Kubota service dealer) ask Lincoln Electric® for advice or information about their use of our products. We
One Year* respond to our customers based on the best information in our possession at that time.
Ruggerini Engines and Accessories Lincoln Electric® is not in a position to warrant or guarantee such advice and assumes no
(Warranty service can only be carried out by liability, with respect to such information or advice. We expressly disclaim any warranty
authorised Lincoln Field Service Shop or of any kind, including any warranty of fitness for any customer's particular purpose, with
the engine distributors authorised by the respect to such information or advice. As a matter of practical consideration, we also
Lincoln® branch office). cannot assume any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information or advice create,
BATTERY WARRANTY expand or alter any warranty with respect to the sale of our products.
Lincoln® supplies certain batteries in connection with its supply of goods and the
purchaser acknowledges that any such battery is warranted by its manufacturer and Lincoln Electric® is a responsive manufacturer, but the selection and use of specific
any claim in respect of such a battery whether as to a defect in the battery or as to products sold by Lincoln Electric® is solely within the control of, and remains the sole
damage consequential upon a defect in a battery shall be made by the purchaser to responsibility of the customer. Many variables beyond the control of Lincoln Electric®
the manufacturer of the battery and the purchaser shall not hold Lincoln® in any way affect the results obtained in applying this type of fabrication methods and service
requirements.
liable for the operation, non-operation or malfunction of any such battery.

In Australia, Lincoln Technical Sales Representatives are located in,

Mackay, Brisbane, Newcastle, Sydney, Melbourne, Adelaide and Perth. To
contact your local Lincoln Technical Sales Representative, call 1300 728
720 (for the cost of a local call). Lincoln products are sold primarily
The Lincoln Electric Company through its distributors. Our Regional Office locations are:

(Australia) Pty. Ltd. A.B.N. 36 000 040 308 Northern Region: Unit 1/15 Westgate St, Wacol, QLD, 4076 (07) 3271 3000
Central Region: 35 Bryant Street, Padstow, NSW, 2211 (02) 9772 7222
35 Bryant Street, Padstow, Sydney 2211, Australia Southern Region: Unit 8/2 Sarton Rd, Clayton, VIC, 3168 (03) 9590 0143
Western Region: 25 Barker Street, Belmont, WA, 6104 (08) 9277 8744
Telephone: (02) 9772 7222 Fax: (02) 9792 2420
New Zealand: 7B/761 Great South Rd, Penrose, Auckland (9) 580 4008
International: Ph: +61 2 9772-7222 Fax: +61 2 9792 2420 Singapore: 11 Pandan Crescent, Singapore (65) 6773 6689

THE LINCOLN ELECTRIC CO.

Cleveland, Ohio, U.S.A. - Subsidiary companies established in Australasia, Asia, Canada, Europe, North and South America.