SVM123-A IDEALARC DC 1000 - Red-D-Arc.com

IDEALARC DC 1000

SERVICE MANUAL

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

SVM123-AJuly, 1996

Safety Depends on You

Lincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safety can beincreased by proper installation... and thoughtful operation onyour part. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,most importantly, think beforeyou act and be careful.

For use with Machine Code Numbers: 99199920

FOR ENGINEpowered equipment.1.a. Turn the engine off before trou-

bleshooting and maintenance work unless the maintenancework requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated areas or vent the

engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame welding arc or when

the engine is running. Stop the engine and allowit to cool before refueling to prevent spilled fuelfrom vaporizing on contact with hot engine partsand igniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not start engineuntil fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair,clothing and tools away from V-belts, gears, fansand all other moving parts when starting, operat-ing or repairing equipment.

____________________________________________________1.e. In some cases it may be necessary to remove safety guards

to perform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

___________________________________________________1.f. Do not put your hands near the engine fan. Do not attempt to

override the governor or idler by pushing on the throttle con-trol rods while the engine is running.

iSAFETY

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC AND MAGNETICFIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes local-ized Electric and Magnetic Fields (EMF). Welding currentcreates EMF fields around welding cables and weldingmachines.

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have othe healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables togethe.Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the elecrode cable is on your rightside, the work cable should also be on your rightside.

2.d.4. Connect the work cable to the workpiece as closeas possible to the area being welded.

2.d.5. Do not work next to welding power source.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birthdefects, and other reproductive harm.

The engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

Mar ‘95

1.g. To prevent accidentally starting gasoline engines while turn-ing the engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magnetowire as appropriate.

___________________________________________________1.h. To avoid scalding, do not remove the radiator pressure cap

when the engine is hot..

WARNING

i

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and fol low youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

SAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCKcan kill.3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

Mar ‘95

ii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETY

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

SAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres de l’huile, tels que les gants en cuir, chemise épaisse,pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

v

IDEALARC DC - 1000

MASTER TABLE OF CONTENTS FOR ALL SECTIONSPage

Safety .....................................................................................................................................................i - iv

Installation......................................................................................................................................Section ATechnical Specifications ............................................................................................................................A-2Safety Precautions ....................................................................................................................................A-3Select Proper Location ..............................................................................................................................A-3Electrical Input Connections ......................................................................................................................A-3Reconnect Procedures ..............................................................................................................................A-4Output Connections...................................................................................................................................A-8

Operation........................................................................................................................................Section BSafety Precautions ...................................................................................................................................B-2General Description...................................................................................................................................B-3Recommended Processes and Equipment ...............................................................................................B-3Operational Features and Controls ...........................................................................................................B-3Design Features and Advantages .............................................................................................................B-3Welding Capacity.......................................................................................................................................B-4Controls and Settings ................................................................................................................................B-5Operating Steps.........................................................................................................................................B-6Remote Control of Machine Operation ......................................................................................................B-6Welding Proceure Recommendations .......................................................................................................B-6Semi-Automatic and Automatic Wire Feeding with a DC-1000 and Wire Feeders............................B6 - B-8

Accessories....................................................................................................................................Section COptions/Accessories..................................................................................................................................C-2Meters .......................................................................................................................................................C-2Remote Output Control (Optional).............................................................................................................C-2Connections for Wire Feeder Control ...............................................................................................C-2 - C-6

Maintenance ...................................................................................................................................Section DSafety Precautions ....................................................................................................................................D-2Routine and Periodic Maintenance ...........................................................................................................D-2Major Component Locations .....................................................................................................................D-3

Theory of Operation.......................................................................................................................Section EGeneral Description...................................................................................................................................E-2Input Line voltage, Connector, and Main Transformer ..............................................................................E-2Output, Rectification, Control, and Feedback............................................................................................E-3Protection Devices and Circuits (Contactor Hold-In) .................................................................................E-4SCR Operation ..........................................................................................................................................E-5

Troubleshooting.............................................................................................................................Section FHow to Use Troubleshooting Guide...........................................................................................................F-2PC Board Troubleshooting Procedures .....................................................................................................F-3Troubleshooting Guide....................................................................................................................F-4 - F-12Test Procedures............................................................................................................................F-13 - F-37Oscilloscope Waveforms...............................................................................................................F-38 - F-44Replacement Procedures ........................................................................................................................F-45Retest After Repair ..................................................................................................................................F-63

Electrical Diagrams .......................................................................................................................Section G

Parts Manual..........................................................................................................................................P-146

v

IDEALARC DC-1000

A-1

TABLE OF CONTENTS-INSTALLATION SECTION-

INSTALLATION..................................................................................Section ATechnical Specifications........................................................................A-2Safety Precautions ................................................................................A-3Select Proper Location ..........................................................................A-3

Stacking ..........................................................................................A-3Tilting ..............................................................................................A-3

Electrical Input Connections..................................................................A-3Fuses and Wire Sizes .....................................................................A-4Ground Connection.........................................................................A-4Input Power Supply Connections....................................................A-4

Reconnect Procedures..........................................................................A-4Output Connections...............................................................................A-8

Electrode and Work Leads..............................................................A-8Auxiliary Power ...............................................................................A-8Connection for Wire Feeder Control ...............................................A-8Connection for Air Carbon Arc ........................................................A-9

INSTALLATIONA-1

Duty Cycle Amps Volts at Rated Amperes100% 1000 4460% 1140 4455% 1250 44

Mode Current Range Maximum Open AuxiliaryConstant Current 140 to 1250 Amps Circuit Voltage PowerConstant Voltage 140 to 1250 Amps 75 VDC 115 VAC, 8 AmpsConstant Voltage 140 to 625 Amps(@500 Amp Stud)

IDEALARC DC-1000

A-2 INSTALLATION

TECHNICAL SPECIFICATIONS – IDEALARC DC - 1000INPUT - THREE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

Standard Voltage Input Current at Rated Output230/460/575 193/96.5/77

InputVoltage/Frequency

Fuse (Super Lag)or Breaker Size

Input Ampere Rating onNameplate

Type 75C CopperWire in Conduit

AWG (IEC) Sizes

230/60 300 193

430/60 150 96.5

575/60 125 77

000 (85mm2)

3 (26.7mm2)

6 (16mm2)

4 (25mm2)

6 (16mm2)

6 (16mm2)

Type 75C CopperGround Wire in

Conduit AWG (IEC)Sizes

Height Width Depth Weight30.75 in 22.25 in 38.0 in 821 Ibs(781 mm) (567 mm) (965 mm) (372 kg)

PHYSICAL DIMENSIONS

A-2

A-3INSTALLATION

IDEALARC DC-1000

Read entire Installation Section before installingthe IDEALARC DC-1000.

SAFETY PRECAUTIONS

ELECTRIC SHOCK CAN KILL.• Only qualified personnel should install this

machine.• Turn the input power OFF at the discon-

nect switch or fuse box before installing orworking on the equipment.

• Do not touch electrically hot parts.• Always connect the IDEALARC DC-1000

grounding terminal to a good electricalearth ground.

____________________________________________________

SELECT PROPER LOCATION

Place the IDEALARC DC-1000 where clean, dry aircan freely circulate in through the front intake and outthrough the rear louvers. Dirt, dust, or any foreignmaterial that can be drawn into the machine should bekept at a minimum. Not following these precautionscan result in the nuisance shutdown of the machinebecause of excessive operating temperatures.

STACKING

FALLING EQUIPMENT cancause injury.• Do not lift this machine using lift bale if it

is equipped with a heavy accessory suchas trailer or gas cylinder.

• Lift only with equipment of adequate liftingcapacity.

• Be sure machine is stable when lifting.• Do not stack more than two high.• Do not stack the DC-1000 on top of any other machine.

____________________________________________________

Two IDEALARC DC-1000 machines can be stacked.

Follow these guidelines when stacking:

1. Select a firm, level surface capable of supportingthe total weight of two machines (1642pounds/744 kilograms).

2. Set the bottom machine in place.

3. Stack the second machine on top of it by aligningthe two holes in the base rails of the secondmachine with the two pins on top front of the bot-tom machine.

NOTE: The machines must be stacked with the CaseFront of each machine flush with each other. SeeFigure A.1.

TILTING

The IDEALARC DC-1000 must be placed on a stable,level surface so it will not topple over.

ELECTRICAL INPUTCONNECTIONS

Before installing the machine, check that the inputsupply voltage, phase, and frequency are the same asthe machine’s voltage, phase, and frequency as spec-ified on the machine’s rating plate on the Case FrontAssembly Control Panel. Connect input power supplyby removing the rear access panel and connecting tothe three line terminals on the input panel. See FigureA.2 for the location of the machine’s input cable entryopening and reconnect panel assembly for dual volt-age machines.

STACKING HOLE

STACKING PIN

FIGURE A.1 - Stacking IDEALARC DC-1000Machines

WARNING

FIGURE A.2 - Input Power Supply Connection

A-3

WARNING

INSTALLATION

IDEALARC DC-1000

A-4

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses ordelay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machinebeing used. They are also called inverse time or ther-mal/magnetic circuit breakers.

DO NOT use fuses or circuit breakers with a loweramp rating than recommended. This can result in nui-sance tripping caused by inrush current even whenmachine is not being used for welding at high outputcurrents.

Use input and grounding wire sizes that meet localelectrical codes, or see the Technical Specificationspage in this manual.

GROUND CONNECTION

Ground the frame of the machine. A ground terminalmarked with the symbol is located inside the CaseBack of the machine. Access to the rear input panel isat the upper rear of the machine. See your local andnational electrical codes for proper grounding meth-ods.

INPUT POWER SUPPLY CONNECTIONS

A qualified electrician should connect the input powersupply leads.

1. Follow all national and local electrical codes.

2. Follow Input Supply Connection Diagram locatedon the inside of the machine.

3. Use a three-phase line.

4. Remove Input Access Door at upper rear ofmachine.

5. Connect the three-phase AC power supply leadsL1, L2, and L3 to the input terminals on the recon-nect panel. See Figure A.2

RECONNECT PROCEDURE

Multiple voltage machines are shipped connected tothe highest input voltage listed on the machine’s ratingplate. Before installing the machine, check that theReconnect Panel in the Input Box Assembly is con-nected for the proper voltage.

Failure to follow these instructions can cause immedi-ate failure of components within the machine.

____________________________________________________

To reconnect a multiple voltage machine to a differentvoltage, remove input power and follow the InputConnection Diagram located on the inside of CaseBack Input Access Door. These connection diagramsare listed below:

1. For 460 single voltage, 230/460 Dual Voltage,220/440 Dual Voltage, 415 Single Voltage or 575Single Voltage, refer to Figure A.3a.

2. For 380 Single Voltage Machines, refer to FigureA.3b.

3. For 380/500 Dual Voltage Machines, refer toFigure A.3c.

4. For 220/380/440 Triple Voltage Machines, refer toFigure A.3d

CAUTION

A-4

CONNECTION FOR UNDER 300 VOLTS1. Mount the movable reconnect panel to the stationary

reconnect panel studs in the position shown, andsecure firmly with the nine hex nuts provided.

2. Conect L1, L2, and L3 input supply lines and H1 andH2 control transformer leads to the input side of thereconnect panel.

3. Insulate unused H3 lead terminal with adequate tapeto provide at least 600 volt insulation.

4. Connect terminal marked to ground per NationalElectrical Code.

A-5INSTALLATION

IDEALARC DC-1000

CONNECTION FOR OVER 300 VOLTS1. Mount the movable reconnect panel center set of

holes to the stationary reconnect panel in the posi-tion shown, and secure firmly with the six hex nutsprovided. Secure the three remaining hex nuts overthe remaining three studs for future use.

2. Conect L1, L2, and L3 input supply lines and H1 andH3 control transformer leads to the input side of thereconnect panel.

3. Insulate unused H2 lead terminal with adequate tapeto provide at least 600 volt insulation.


CONNECTION FOR 380 VOLTS1. Conect L1, L2, and L3 input supply lines and H1 and

H3 Control Transformer Leads to the InputTerminals as shown.


All input power must be electrically disconnected before touching panel.____________________________________________________


FIGURE A.3b - Input Connection Diagram

WARNING

WARNING

FIGURE A.3a - Input Connection Diagram

A-5

INSTALLATION

IDEALARC DC-1000

A-6

CONNECTION FOR 380 VOLTS1. Mount the movable reconnect panel to the stationary

reconnect panel studs in the position shown, andsecure firmly with the nine hex nuts provided.

2. Connect L1, L2, and L3 input supply lines and H1and H2 control transformer leads to the input side ofthe reconnect panel.

3. Insulate unused H3 and H4 lead terminal with ade-quate tape to provide at least 600 volt insulation.


CONNECTION FOR 500 VOLTS1. Mount the movable reconnect panel center set of

holes to the stationary reconnect panel in the posi-tion shown, and secure firmly with the six hex nutsprovided. Secure the three remaining hex nuts overthe remaining three studs for future use.

2. Connect L1, L2, and L3 input supply lines and H1and H4 control transformer leads to the input side ofthe reconnect panel as shown




WARNING

FIGURE A.3c -Input Connection Diagram

A-6

A-7INSTALLATION

IDEALARC DC-1000


CONNECTION FOR 440 VOLTS 50 Hz (460V, 60 Hz.)1. On reconnect panel, loosen all hex bolts, pull back

movable links, and rotate links to their new positions.Position each link between the wire terminal and hexbolt, push the link completely forward, and securelytighten all hex bolts. Do not remove hex bolts at anytime.

2. Connect L1, L2, and L3 input supply lines and H1and H4 control transformer leads to input terminalsas shown.



CONNECTION FOR 380 VOLTS 50 Hz. 1. On reconnect panel, loosen all hex bolts, pull back





CONNECTION FOR 220 VOLTS 50 Hz. (230V 60 Hz.)1. On reconnect panel, loosen all hex bolts, pull back





FIGURE A.3d - Input Supply Connection Diagram

WARNING

A-7

INSTALLATION

IDEALARC DC-1000

A-8

OUTPUT CONNECTIONS

See Table A.1 for recommended IDEALARC DC-1000cable sizes for combined length of electrode and workcables.

TABLE A.1

Suggested Copper Cable Sizes - 100% Duty CycleCombined Lengths of Electrodes and Work Cables

Amperes Length Cable Size

1000 0 - 250 ft. 3-3/0(76.2m) (3 x 85.0 mm2)

CONNECT ELECTRODE AND WORKLEADS TO OUTPUT TERMINALS

The output terminals are located on the lower casefront and labeled “+” and “-”. See Figure A.4. Thereare 1000 amp rated “+” terminals on the right side,one 500 amp rated “+” terminal near the center and “-”terminals on the left side. They are fully recessed tominimize the possibility of accidental contact by anobject or a person.

The 1000 amp output connections provide the fullrated output range of the machine.

The 500 amp output connections provide enhancedlower current arc characteristics, especially for sub-merged arc and GMAW procedures below 450 amps.

1. Set the ON/OFF PUSH BUTTON to OFF.

2. Insert the electrode lead through the oval openingin the lower shelf of the front case, closest to thedesired polarity (positive or negative). Pull throughenough cable to reach the output terminals.

3. Connect electrode lead to the desired terminal(positive or negative) and tighten the output ter-minal nut with a wrench.

4. Connect the second work lead to the other out-put terminal (positive if negative is attached andvice versa) following steps 2 and 3.

AUXILIARY POWER

This machine supplies the 115 volt, AC power need-ed for operating wire feeding equipment. The poweris available from terminals #31 and #32 on the termi-nal strip. An 8 amp slow blow fuse on the machinecontrol panel protects the auxiliary power fromexcessive overloads. The circuit has a 1000 volt-ampere rating.

CONNECTION FOR SEMI-AUTOMATICOR AUTOMATIC WIRE FEEDERCONTROL

With the DC-1000 turned off, the control cable fromthe semi-automatic or automatic wire feeding equip-ment is connected to the terminal strip. A strain reliefbox connector is provided for access into the termi-nal strip section. A chassis grounding screw is alsoprovided below the terminal strip marked with thesymbol for connecting the wire feeding equip-ment grounding wire. See the appropriate connec-tion diagram for the exact instructions for the wirefeeder being used. A spare plugged hole is providedin case an additional box connector is required.

NOTE: See the ACCESSORIES Section of this man-ual for specific instructions on connecting the follow-ing semi-automatic and automatic wire feeders:

• LN-7

• LN-8

• LN-9 } Semi-Automatic Wire Feeders

• NA-3

• NA-5 } Automatic Wire Feeders

• LT-7

• LT-56 } Tractors

FIGURE A-4 - Output Terminals

A-8

A-9INSTALLATION

IDEALARC DC-1000

A-9

CONNECTION FOR AIR/CARBON ARCCUTTING OPERATION

THE OUTPUT TERMINALS ARE ENERGIZED ATALL TIMES WHEN THE IDEALARC DC-1000 ISCONNECTED FOR AIR/CARBON ARC CUTTING.

____________________________________________________

1. Set ON/OFF PUSH BUTTON to OFF.

2 . Locate and open the access door on the FrontCase Assembly.

3 . If necessary, disconnect all wire feeder controlcable connections from the DC-1000 terminalstrip.

4 . Remove the leads from the unit by pulling themthrough and out of the strain relief box connector(s).

5. Connect a jumper wire from terminal #2 to termi-nal #4 on the terminal strip.

6. Set the Welding Mode Switch to the CV(I) positionfor air/carbon arc cutting.

WARNING

A-10NOTES

IDEALARC DC-1000

A-10

IDEALARC DC-1000

B-1

TABLE OF CONTENTS-OPERATION SECTION-

OPERATION...................................................................................................................................Section BSafety Precautions..............................................................................................................................B-2General Description ............................................................................................................................B-3

Recommended Processes and Equipment............................................................................B-3Operational Features and Controls........................................................................................B-3Design Features and Advantages..........................................................................................B-3Welding Capacity ...................................................................................................................B-4

Controls and Settings .........................................................................................................................B-5Operating Steps..................................................................................................................................B-6Remote Control of Machine Operation ...............................................................................................B-6Welding Procedure Recommendations ..............................................................................................B-6Semi-Automatic and Automatic Wire Feeding with a DC-1000 and Wire Feeders.............................B-6

NA-3 Automatic Wire Feeder .................................................................................................B-6Good Arc Striking Guidelines....................................................................................B-7Arc Striking with IDEALARC DC-1000 and the NA-3 Start Board ............................B-7

NA-5 Automatic Wire Feeder .................................................................................................B-8LN-8 Semi-Automatic Wire Feeder ........................................................................................B-8LN-7 and LN-9 Semi-Automatic Wire Feeders ......................................................................B-8

OPERATIONB-1

OPERATIONB-2

IDEALARC DC-1000

Read and understand this entire section beforeoperating your machine.

SAFETY INSTRUCTIONS

Only qualified personnel should operate this equip-ment. Observe all safety information throughout thismanual.

FUMES AND GASEScan be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

____________________________________________________

ARC RAYScan burn.

• Wear eye, ear and body protection.

____________________________________________________

WELDING, CUTTING and GOUGING SPARKScan cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on containers thathave held combustibles.

____________________________________________________

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such asoutput terminals or internal wiring.

•Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

____________________________________________________

WARNING

B-2

B-3OPERATION

GENERAL DESCRIPTION

The IDEALARC DC-1000 is an SCR-controlled, threephase, welding and cutting power source. It uses asingle range potentiometer to control:

• Submerged Arc Semi-Automatic or AutomaticWelding

• Open Arc Semi-Automatic or Automatic Welding• Air/Carbon Arc Cutting (Carbon Rod Sizes up to

5/8” [15.9 mm ] Diameter)• With the addition of the 500 ampere output termi-

nal on models code 9500 and above, GMAW pro-cedures can be performed.

The IDEALARC DC-1000 has a three-posit ionWelding Mode Switch to enable the user to operate inone of three modes:

• Constant Voltage (CV) Innershield®• Constant Voltage (CV) Submerged Arc• Variable Voltage (VV) - Constant Current (CC)

Submerged Arc

The IDEALARC DC-1000 can be easily connected towire feeding equipment, including:

• Semi-automatic wire feeders LN-7, LN-8, andLN-9

• Automatic wire feeders NA-3 and NA-5• Tractors LT-56 and LT-7

RECOMMENDED PROCESSES ANDEQUIPMENT

The IDEALARC DC-1000 is recommended for the fol-lowing welding or cutting processes within its outputcapacity of 140 amps to 1250 amps (625 amps at 500amp output stud) in the Constant Voltage mode, and140 amps to 1250 amps in the Variable Voltage(Constant Current) mode:

• Submerged Arc Semi-Automatic or AutomaticWelding

• Open Arc Semi-Automatic or Automatic Welding• Air/Carbon Arc Cutting (Carbon Rod Sizes up to

5/8” [15.9 mm] Diameter)

OPERATIONAL FEATURES AND CONTROLS

The IDEALARC DC-1000 comes with the followingstandard controls:

• DOUBLE ON/OFF PUSH BUTTON (Main Powerand 115V Auxiliary)

• OUTPUT CONTROL POTENTIOMETER• OUTPUT CONTROL SWITCH (Remote or

Machine Control)• WELDING MODE SWITCH• CONTROL CIRCUIT POLARITY SWITCH• POWER SOURCE PILOT LIGHT• DC AMMETER (OPTIONAL)• DC VOLTMETER (OPTIONAL)

DESIGN FEATURES ANDADVANTAGES

The following list of design features will help youunderstand the machine’s total capabilities and howyou can take advantage of them to get maximum useof your machine.

• Excellent arc characteristics for optimum constantvoltage submerged arc and Innershield® weldingperformance.

• A control circuit designed to provide good startingfor a large variety of processes and procedures.

• Output Control Potentiometer that provides easysingle range continuous control.

• Output Control Switch that provides simple switch-ing from local to remote control.

• Red neon pilot light to confirm that the InputContactor is energized.

• Auxiliary power source to provide 115-volt ACpower (1000 VA) to wire feeding equipment.

• Multi-functional terminal strip for easy connectionof wire feeding control cables and switchingbetween CV Innershield® and CV Submerged Arcwelding when using the Dual Process or DualProcedure Kits.

• Recessed output terminals to help prevent anyperson or object from accidentally coming intocontact with the output current. These terminalsare prominently labeled positive and negative foreasy identification.

• Thermostatically protected power source.• Electronic protection circuit to protect power

source against overloads.• Input line voltage compensation to provide an

essentially constant output.• SCR electronically controlled welder output pro-

vides extra long life, especially for highly repetitivewelding applications.

IDEALARC DC-1000

B-3

B-4OPERATIONB-4

• Three circuit solid state control system providesmaximum performance and circuit protection.

• Low profile case provides maximum use of space.• Convenient access to all controls.• Large output lead strain relief openings to prevent

terminal and cable damage.• Easily removed case side, even when stacked.

• Enclosure designed with air intake louvers thatkeep dripping water from entering the unit, allow-ing outdoor operation. Transformer, SCR bridge,and choke have special corrosion resistant paintfor added protection.

IDEALARC DC-1000

WELDING CAPABILITY

The IDEALARC DC-1000 has the following duty cycle ratings.

If the duty cycle is exceeded, the thermal protective thermostat will shut off the output of the machine by keepingthe input contactor open until the machine cools to normal operating temperature. The machine can then berestarted by pushing the ON/OFF push button.

Duty Cycle Amps Volts Hertz

55% (Based on 10 min.) 1250 44 50/60

60% (Based on 10 min.) 1140 44 50/60

100% 1000 44 50/60

B-5OPERATIONB-5

1. ON/OFF PUSH BUTTON: This push button turnsthe machine ON or OFF

2. OUTPUT CONTROL POTENTIOMETER: Thiscontrol provides tapered, continuous control of themachine output. The control can be rotated fromminimum to maximum while machine is underload to adjust the machine output.

3. WELDING MODE SWITCH: This toggle switch isused to select the proper welder performancecharacteristics for the process being used. Thereare three modes: CV (Constant Voltage)Innershield®, CV (Constant Voltage) SubmergedArc, and VV (Variable Voltage) CC (ConstantCurrent) Submerged Arc.

4. OUTPUT CONTROL SWITCH: This toggle switchis used to switch between “Output Control at DC-1000” for local control of machine output and“Output Control Remote” for remote control ofmachine output.

5. CONTROL CIRCUIT POLARITY SWITCH: Thistoggle switch is used to set power source voltagesensing polarity to match the polarity to which theelectrode is connected to the machine. This pro-vides the correct polarity at the terminal strip forcorrect operation of the automatic wire feedingequipment powered by the auxiliary power fromthe power source.

6. POWER SOURCE PILOT LIGHT: The red neonlight glows when the power source input contactoris energized.

7. VOLTMETER: An optional voltmeter is available.

8. AMMETER: An optional ammeter is available.

IDEALARC - DC 1000

FIGURE B.1 - Control Panel Keys

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the Case Front Assembly of the IDEALARC DC-1000. SeeFigure B.1 for the location of each control.

B-6OPERATIONB-6

OPERATING STEPSThe following procedures are for using the IDEALARCDC-1000 in the local control mode of operation. Forremote control of the machine, see the RemoteControl of Machine Operation section.

Before operating the machine, make sure you have allmaterials needed to complete the job. Be sure you arefamiliar with, and have taken all possible safety pre-cautions before starting work. It is important that youfollow these operating steps each time you use themachine.

1. Turn on the main AC power supply to themachine.

2. Set the CONTROL CIRCUIT POLARITY SWITCHto the appropriate position.

- Set toggle to “Electrode Negative” position if theelectrode is connected to the negative (-) outputterminal.

- Set toggle to “Electrode Positive” position if theelectrode is connected to the positive (+) outputterminal.

3. Set the WELDING MODE SWITCH to weldingprocess being used.

- CV Innershield®

- CV Submerged Arc

- VV (CC)

4. Push the ON/OFF PUSH BUTTON to the ONposition.

- The red neon light glows.

- The fan starts.

5. Set Output Control Potentiometer to desired volt-age or current.

6. Make the weld (NOTE: Terminal #2 and #4 mustbe connected together to energize the machineoutput).

REMOTE CONTROL OF MACHINEOPERATION

The toggle switch on the control panel labeled “OutputControl at DC-1000” - “Output Control Remote” givesthe operator the option of controlling the machine out-put from a remote location. If in the Remote position, awire feeder with remote control capabilities or aremote control device such as a K775, must be con-nected to terminals #75, #76, and #77 to operate.Refer to Accessories Section for wire feeder remoteinformation.

WELDING PROCEDURERECOMMENDATIONSSelect Welding Mode Switch position based on type ofwelding to be done.

1 Innershield® Welding/Other Open Arc Processes:Use the CV Innershield® mode.

2. Submerged Arc Welding: Use the CV SubmergedArc mode. If performing high speed welding,switch between the CV Submerged Arc and theCV Innershield® mode and use the mode thatproduces the best welding results. High Current,Large Puddle Submerged Arc Welding: Use theVV (CC) mode.

3. When the IDEALARC DC-1000 is used forAir/Carbon Arc cutting, use the CV (I) mode andinitially set the OUTPUT CONTROL POTEN-TIOMETER to “9”. Based on the size of the car-bon being used, turn the potentiometer to a lowersetting as required to obtain the best results. Youcan use carbon rods up to 5/8” (15.9 mm) in diam-eter. The welder protection circuit protects themachine from extremely high short circuiting puls-es.

SEMI-AUTOMATIC ANDAUTOMATIC WIRE FEEDING WITHIDEALARC DC-1000 AND WIREFEEDERS

NA-3 AUTOMATIC WIRE FEEDER

1. Set the DC-1000 Output Control Switch toRemote.

NOTE: Later model NA-3 automatic wire feeders arecapable of cold starts when the NA-3 Mode switch isin the CV or VV (CC) mode position. Some earliermodels are capable of cold starting only in the VV(CC) mode position. Cold starting enables you toinch the wire down to the work, automatically stop,and automatically energize the flux hopper valve.

2. Set the DC-1000 welding mode switch for thedesired process: CV Submerged Arc, CVInnershield® mode or VV (CC) mode.

3. Set the NA-3 mode Switch Position to either CV orVV (CC) to match the DC-1000 mode selected instep 2.

4. Refer to the NA-3 operators manual for instruc-tions on how to use the NA-3 in conjunction withthe DC-1000.

5. Follow the following guidelines for good arc strik-ing detailed below for each welding mode.

IDEALARC DC-1000

B-7OPERATIONB-7

GOOD ARC STRIKING GUIDELINES FOR THENA-3 WITH THE IDEALARC DC-1000 IN THE CVINNERSHIELD®, CV SUBMERGED ARC OR VV(CC) WELDING MODES.

Following are some basic arc striking techniques thatapply to all wire feed processes. Using these proce-dures should provide trouble-free starting. These pro-cedures apply to single, solid wires and Innershield®wires.

1. Cut the electrode to a sharp point.

2. Set the NA-3 Open Circuit Voltage Control to thesame dial setting as the Arc Voltage Control. Ifthis is a new welding procedure, a good startingpoint is to set the Open Circuit Voltage Control to#6.

NOTE: The open circuit voltage of the IDEALARCDC-1000 varies from approximately 25 volts to 75volts in the CV Innershield or CV Submerged Arcmodes. The open circuit voltage is constant in theVV (CC) mode.

3. Run a test weld. Set proper current, voltage, andtravel speed.

a. For the best starting performance, theNA-3 Open Circuit Voltage Control andVoltage Control setting should be thesame. Set the Inch Speed Control for theslowest inch speed possible.

b. To adjust the Open Circuit Voltage Controlto get the best starting performance, makerepeated starts observing the NA-3 volt-meter.

When the voltmeter pointer swings smoothly up to thedesired arc voltage, without undershooting or over-shooting the desired arc voltage, the Open CircuitVoltage Control is set properly.

If the voltmeter pointer overshoots the desired voltageand then returns back to the desired voltage, theOpen Circuit Voltage Control is set too high. This canresult in a bad start where the wire tends to “Blast off.”

If the voltmeter pointer hesitates before coming up tothe desired voltage, the Open Circuit Voltage Controlis set too low. This can cause the electrode to stub.

4. Start and make the weld.

a. Cold starts. For cold starts, be sure thework piece is clean and the electrodemakes positive contact with the workpiece.

b. Hot “On the Fly” starts. For hot starts, trav-el should begin before the wire contactsthe work piece.

ARC STRIKING WITH IDEALARC DC-1000 ANDTHE NA-3 START BOARD

When electrical strikeouts exceed 1 3/4” (44.4 mm) anNA-3 Start Board may be required to improve arcstriking. When the NA-3 Start Board is used toimprove arc striking, use the following procedures:

1. Set start time at 0.

2. Set NA-3 start current and start voltage at midrange.

3. Set the NA-3 output current and voltage to theproper settings for the welding procedure to beused.

4. Turn the Start Board Timer to maximum.

5. Set Start Board current and voltage control.

a. Set the Start Board current control to 1-1/2 dial numbers below that set on theNA-3 current control.

b. Set the Start Board voltage control equalwith the NA-3 voltage control setting

NOTE: These Start Board current and voltage set-tings result in a start-up current that is lower thanthe NA-3 current setting and approximately equalwith the NA-3 voltage setting for the desired weld-ing procedure.

6. Establish the correct arc striking procedure withthe NA-3 Start Board timer set at maximum.

a. For the best starting performance, theNA-3 Open Circuit Voltage Control andVoltage Control setting should be thesame. Set the Inch Speed Control for theslowest inch speed possible.

b. To adjust the Open Circuit Voltage Controlto get the best starting performance, makerepeated starts observing the NA-3 volt-meter.

When the voltmeter pointer swings smoothly up to thedesired arc voltage, without undershooting or over-shooting the desired arc voltage, the Open CircuitVoltage Control is set properly.

If the voltmeter pointer overshoots the desired voltageand then returns back to the desired voltage, theOpen Circuit Voltage Control is set too high. This canresult in a bad start where the wire tends to “Blast off.”

If the voltmeter pointer hesitates before coming up tothe desired voltage, the Open Circuit Voltage Controlis set too low. This can cause the electrode to stub.

IDEALARC DC-1000

B-8OPERATIONB-8

c. Set NA-3 Start Board current and voltageas close to the welding procedure currentand voltage as possible.

NOTE: The Start Board current and volt-age should be as close as possible to thewelding procedure current and voltage,while sti l l gett ing satisfactory starts.

d. Set the start time to as low a time as possi-ble while still getting satisfactory starts.

7. Start and make the weld.

IDEALARC DC-1000 POWER SOURCESETTING WHEN CONNECTED TO NA-5AUTOMATIC WIRE FEEDER

When using the IDEALARC DC-1000 with the NA-5automatic wire feeder, set the controls on the IDE-ALARC DC-1000 as follows for the best performance:

1. Turn OFF main AC input power supply to the IDE-ALARC DC-1000.

2. Connect the electrode cables to terminal polarity to be used.

3. Set the CONTROL CIRCUIT POLARITY SWITCHto the same polarity as the electrode cable con-nection.

4. Set the OUTPUT CONTROL SWITCH toREMOTE.

5. Set the IDEALARC DC-1000 WELDING MODESWITCH to the position that matches the weldingprocess being used.

a. For submerged arc welding, set WELDINGMODE SWITCH TO CV SUBMERGEDARC position.

b. For all open arc welding processes setWELDING MODE SWITCH TO CVINNERSHIELD® position.

6. Set the Open Voltage Control four volts higherthan the welding voltage, and the inch speed at1/2 the welding wire feed speed for the initial testweld.

7. Refer to NA-5 Operator’s Manual for instructionson how to use the NA-5.

LN-8 SEMI-AUTOMATIC WIRE FEEDER

To use the LN-8 Semi-Automatic Wire Feeder withIDEALARC DC-1000

1. Set the IDEALARC DC-1000 WELDING MODESWITCH to either CV Innershield® mode or CVSubmerged Arc mode depending on the weldingprocess being used.

2. Set the IDEALARC DC-1000 OUTPUT CONTROLSWITCH to the REMOTE position.

3. Set the LN-8 Welding Mode Switch to the CVposition. The LN-8 Welding Mode Switch is locat-ed on the variable voltage VV (CC) board.

4. Refer to the LN-8 Operator’s Manual for instruc-tions on how to use the LN-8.

LN-7 AND LN-9 SEMI-AUTOMATIC WIREFEEDERS OR OTHER CONSTANT WIREFEEDERS

To use the LN-7, LN-9, or other constant wire feedspeed semi-automatic wire feeders with IDEALARCDC-1000

1. Set the IDEALARC DC-1000 WELDING MODESWITCH to either CV Innershield® mode or CVSubmerged Arc mode depending on the weldingprocess being used.

NOTE: These semi-automatic wire feeders cannot beused in the VV (CC) mode.

2. Set the IDEALARC DC-1000 OUTPUT CONTROLSWITCH.

a. LN-7: Use either an optional K775 RemoteControl Box Assembly or set the IDE-ALARC DC-1000 OUTPUT CONTROLSWITCH in the Local position.

b. LN-9: Refer to the LN-9 Operator’s Manualfor instructions on how to use the LN-9.

IDEALARC DC-1000

C-1ACCESSORIESC-1

IDEALARC DC-1000

TABLE OF CONTENTS-ACCESSORIES SECTION-

ACCESSORIES ........................................................................................................................Section COptions/Accessories ....................................................................................................................C-2Meters ..........................................................................................................................................C-2Remote Output Control ................................................................................................................C-2Connections for Wire Feeder Control ..........................................................................................C-2

NA-3, or LT-7 ..................................................................................................................C-2NA-5 ................................................................................................................................C-3LN-8 ................................................................................................................................C-4LN-9 ................................................................................................................................C-5LN-7 ................................................................................................................................C-6

C-2ACCESSORIESC-2

OPTIONS/ACCESSORIES• Remote Control Box Assembly (K775)• LN-7• LN-8 }Semi-Automatic Wire Feeders• LN-9 • NA-3• NA-5 } Automatic Wire Feeders

• LT-7 and LT-56 Tractors

METERS

Optional factory-installed voltmeter and ammeter areavailable.

REMOTE OUTPUT CONTROL -(OPTIONAL)

The K775 Remote Output Control consists of a controlbox with 28 ft. (8.4 m) four conductor cable. This con-nects to terminals #75, #76, #77 on the terminal strip,and the case grounding screw marked with the sym-bol on the machine. These terminals are madeavailable by opening the terminal access cover on thecase front. This control will give the same control asthe output control on the machine.

CONNECTIONS FOR SEMI-AUTO-MATIC OR AUTOMATIC WIREFEEDER CONTROL

1. Set the ON/OFF PUSH BUTTON to OFF.

2. Locate and open the hinged access door on theFront Case Assembly.

3. Insert control cable through the strain relief boxconnector and pull enough cable through to reachthe terminal strip.

4. Connect the automatic wire feeder control cable tothe terminal strip. See corresponding connectiondiagram in this section of the manual, or theinstructions included with the wire feeder.

5. Connect the wire feeder grounding wire to thechassis ground screw marked with the symbol .

NOTE: The IDEALARC DC-1000 Auxiliary PowerCircuit (at #31 and #32 on the terminal strip) supplies115-volt AC power to the wire feeding equipment. Thecircuit has a 1000 volt ampere rating. An 8-amp slowblow fuse on the machine’s control panel protects theauxiliary power supply from excessive overloads orshort circuits.

CONNECTING THE NA-3 OR LT-7 TOIDEALARC DC-1000

1. Disconnect main AC input power to the IDE-ALARC DC-1000.

2. Set IDEALARC DC-1000 ON/OFF PUSH BUT-TON to OFF.

3. Connect the wire feeder control cable leads to theIDEALARC DC-1000 terminal strip as shown inFigure C.1.

4. Connect the wire feeder control cable ground leadto the frame terminal marked .

5. Extend wire feeder control cable lead #21 so itcan be connected directly to the work piece.

a. Make a bolted connection using AWG #14or larger insulated wire.

b. Tape the bolted connection with insulatingtape.

NOTE: An S-16586-X remote voltage sensing worklead is available for this purpose.

c. Keep the #21 lead electrically separatefrom the work cable circuit and connection.

IDEALARC DC-1000

FIGURE C.1 - NA-3 or LT-7 Wire FeederConnection to the IDEALARC DC-1000

CAUTIONThe IDEALARC DC-1000 must be properly grounded.

____________________________________________________

C-3ACCESSORIESC-3

d. Tape the #21 lead to work cable for easeof use.

6. Connect the welding cables as shown in FigureC.1.

NOTE: Welding cables must be of proper capacity forthe current and duty cycle for immediate and futureapplications.

NOTE: The connection diagram shown in Figure C.1shows the electrode connected for positive polarity.To change polarity:

a. Set the IDEALARC DC-1000 ON/OFFPUSH BUTTON to OFF.

b. Move the electrode cable to the Negative(-) output terminal.

c. Move the work cable to the Positive (+)output terminal.

d. Set the IDEALARC DC-1000 CONTROLCIRCUIT POLARITY SWITCH to NEGA-TIVE.

e. Reverse the leads at the back of theammeter and voltmeter on the wire feederautomatic control box.

CONNECTING THE NA-5 TO THEIDEALARC DC-1000

NOTE: For optimum performance, use the NA-5 withIDEALARC DC-1000 codes 8288 and above.


2. Set the IDEALARC DC-1000 ON/OFF PUSHBUTTON to OFF.

3. Connect the wire feeder control cable leads to theIDEALARC DC-1000 terminal strip as shown inFigure C.2.

NOTE: If using a K215 control cable, connect con-trol cable leads #75 to #75 on the terminal strip,#76 to #74 on the terminal strip, and #77 to #73on the terminal strip.


5. Extend wire feeder control cable lead #21 so itcan be connected directly to the work piece.





d. Tape the #21 lead to work cable for easeof use.

6. Connect NA-5 wire feeder control jumpers on theVoltage Control Board. See NA-5 Operator’sManual.

a. Connect red jumper on Voltage ControlBoard to pin “S.”

b. Connect white jumper on Voltage ControlBoard to pin “B.”



IDEALARC DC-1000

FIGURE C.2 - NA-5 Wire Feeder Connection tothe IDEALARC DC-1000


____________________________________________________

C-4ACCESSORIESC-4






e. Refer to NA-5 operator’s manual for propercontrol box polarity connections.

NOTE: For proper NA-5 operation, the electrodecables must be secured under the clamp bar on theleft side of the NA-5 Control Box.

CONNECTING THE LN-8 TO THEIDEALARC DC-1000

1. Set the ON/OFF PUSH BUTTON to the OFF pos-tion.

2. Disconnect AC input power to the IDEALARC DC-1000.

3. Connect the wire feeder control cable leads to theDC-1000 terminal strip. See Figure C.3.


5. Extend the wire feeder control cable #21 lead so itcan be connected directly to the work piece.





d. Tape the #21 lead to the work cable forease of use.

IDEALARC DC-1000

FIGURE C.3 - LN-8 Wire Feeder Connectionto the IDEALARC DC-1000

6. Connect lead #75(A) to #75 on the terminal strip.

7. Connect lead #76(B) to #76 on the terminal strip.

8. Connect lead #77(C) to #77 on the terminal strip.



10. Set the DC-1000 output control switch to the”Output Control Remote” position.

NOTE: The connection diagram shown in figure C-3shows electrode connected positive. To change polari-ty:





e. Refer to LN-8 operator’s manual for propercontrol box polarity connections.


____________________________________________________

C-5ACCESSORIESC-5

CONNECTING THE LN-9 WIRE FEEDERTO THE IDEALARC DC-1000

1. Set the ON/OFF PUSH BUTTON to the OFF pos-tion.

2. Disconnect AC input power to the IDEALARC DC-1000.

3. Connect the wire feeder control cable leads to theDC-1000 terminal strip. See Figure C.4.


5. Extend the wire feeder control cable #21 lead so itcan be connected directly to the work piece.




c. Keep the #21 lead elecrically separatefrom the work cable circuit and connection.

d. Tape the #21 lead to the work cable forease of use.

6. Connect lead #75(A) to #75 on the terminal strip.

7. Connect lead #76(B) to #74 on the terminal strip.

8. Connect lead #77(C) to #73 on the terminal strip.


Note: Welding cables must be of proper capacity forthe current and duty cycle for immediate and futureapplications.

10. Connect LN-9 wire feeder jumpers on voltageboard as follows: See LN-9 operator’s manual.

a. White jumper on voltage board to pin “S”

b. Blue jumper on voltage board (later mod-els) or on start board (earlier models) topin “B”.

11. Set the DC-1000 output control switch to the”Output Control Remote” position.

NOTE: The connection diagram shown in figure C-4shows electrode connected for positive polarity. Tochange polarity:




d. Position the positive-negative switch onthe power source to correspond to thepolarity of the electrode cable connection.

e. Refer to LN-9 operating manual forrequired polarity connections.

IDEALARC DC-1000

FIGURE C.4 - LN-9 Wire Feeder Connectionto the IDEALARC DC-1000


____________________________________________________

C-6ACCESSORIESC-6

CONNECTING THE LN-7 WIRE FEEDER TOTHE IDEALARC DC-1000

1. Set the IDEALARC DC-1000 ON/OFF PUSHBUTTON to OFF.


3 Connect the wire feeder control cable leads to theIDEALARC DC-1000 terminal strip as shown inFigure C.5.


5. PERFORM THIS STEP ONLY IF THE LN-7 ISEQUIPPED WITH A METER KIT.

Extend wire feeder control cable lead #21 so it can beconnected directly to the work piece.



NOTE: If the work cable length is less than 25 feetand the connections to the work piece are secure,then wire feeder control cable lead #21 can be con-nected directly to the DC-1000 terminal strip.


b. Keep the #21 lead electrically separatefrom the work cable circuit and connection.

c. Tape the #21 lead to work cable for easeof use.







d. Set the IDEALARC DC-1000 CONTROLPOLARITY SWITCH to NEGATIVE.

IDEALARC DC-1000

FIGURE C.5 - LN-7 Wire Feeder Connection tothe IDEALARC DC-1000


____________________________________________________

D-1MAINTENANCED-1

IDEALARC DC - 1000

TABLE OF CONTENTS-MAINTENANCE SECTION-

MAINTENANCE ...................................................................................................Section DSafety Precautions ....................................................................................................D-2Routine and Periodic Maintenance ...........................................................................D-2Major Component Locations .....................................................................................D-3

3. Inspect the electrode cables for any slits or punc-tures in the cable jacket, or any condition thatwould affect the proper operation of the machine.

Perform Periodically:

Clean the inside of the machine with low pressure airstream. Clean the following parts. Refer to FigureD.1.

• Main transformer and choke

• Electrode and work cable connections.

• SCR rectifier bridge and heat sink fins.

• Control board.

• Firing board.

• Fan Assembly.

.....................................................................................NOTE: The fan motor has sealed bearings whichrequire no maintenance.

ROUTINE AND PERIODICMAINTENANCE

1. Disconnect input AC power supply lines to themachine before performing periodic maintenance,tightening, cleaning, or replacing parts. SeeFigure D.1

Perform the following daily:

1. Check that no combustible materials are in thewelding or cutting area or around the machine.

2. Remove any debris, dust, dirt, or materials thatcould block the air flow to the machine for cooling.

D-2MAINTENANCED-2

IDEALARC DC - 1000

Only qualified personnel shouldperform this maintenance.

Turn the input power OFF at the disconnect switch orfuse box before working on this equiptment.

Do not touch electrically hot parts.

____________________________________________________

SAFETY PRECAUTIONS

ELECTRIC SHOCKCAN KILL

WARNING

D-3MAINTENANCED-3

IDEALARC DC-1000

FIGURE D.1 - Major Component Locations

D-4NOTES

IDEALARC DC-1000

D-4

E-1THEORY OF OPERATIONE-1

IDEALARC DC-1000

TABLE OF CONTENTS-THEORY OF OPERATION SECTION-

THEORY OF OPERATION SECTION. ................................................................Section EGeneral Description............................................................................................E-2Input Line Voltage, Contactor, and Main Transformer .......................................E-2Output Rectification, Control, and Feedback......................................................E-3Protection Devices and Circuits (Contactor Hold-In) ..........................................E-4SCR Operation. ..................................................................................................E-5

FIGURE E.1 Block Logic Diagram


INPUT LINE VOLTAGE, CONTAC-TOR, AND MAIN TRANSFORMER

The desired three phase power is connected to theDC-1000 through an Input Contactor located in theinput box at the rear of the machine. Two phases of theinput l ines are also connected to the ControlTransformer which supplies power to the ContactorHold-In Circuit. The Contactor Hold-In Circuit will dis-able the Input Contactor if the DC-1000 is overloadedor overheated.

A Reconnect Panel allows the user to configure themachine for the desired input voltage. This AC inputvoltage is applied to the primary of the MainTransformer. The transformer changes the high volt-

age, low current input power to a low voltage, highcurrent output. The finishes or “neutrals” of themain secondary coils are connected together andthe six starts of the secondary windings are con-nected to the rectifier assembly. In addition, themain transformer also has an isolated 115 VACauxiliary winding that supplies 115 VAC to operatethe cooling fan and offers 8 amps of auxiliary powerto operate wire feeding equipment. The three 75VAC phase angle windings are also housed in theMain Transformer assembly. These windings pro-vide power and “timing” to the Firing Board.

FIGURE E.2 - Input Line Voltage, Contactor and Main Transformer

IDEALARC DC-1000

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.

GENERAL DESCRIPTION

The DC 1000 is an SCR - controlled DC powersource. It is designed to be controlled with a single

range potentiometer ouptut control. It can be usedfor submerged arc or open arc automatic and semi-automatic welding.

THEORY OF OPERATION E-3

OUTPUT RECTIFICATION,CONTROL, AND FEEDBACK

The neutrals of the Main Transformer secondarywindings are connected together and the six startsare connected to the six SCR assemblies to form asix phase output. This six phase AC output from theMain Transformer secondary is rectified and con-trolled through the SCR bridge. Output current issensed at the shunt, and output voltage is moni-tored at the welding output terminals. This feedbackinformation is processed in the control board. Thecontrol board compares the commands of the Modeswitch and the Output Control Potentiometer (orRemote Control) with the feedback information andsends the appropriate signal to the Firing Board.

The Firing Board is a three phase circuit. Eachphase provides two firing pulses, one for each ofthe two Silicon Controlled Rectifiers (SCR) con-trolled by that phase. The firing circuit supplies the

proper amount of energy to the gates of the powerSCRs. When this gate signal is applied, at the cor-rect time, the SCR will turn “ON”. The amount of“ON” time versus “OFF” time determines the outputof the machine. See SCR Operation.

The Pilot Relay signals the Firing Board circuit tosupply gate pulses to the SCR Bridge. Closing ofthe Pilot Relay (a “dry” closure of leads #2 and #4)also brings the Latching Resistor into the machineoutput circuit. The Latching Resistor provides apre-load for the SCR Bridge.

In later models (above code 9500) a Choke andseparate 500 amp output terminal is provided toenhance lower current arc characteristics, espe-cially for submerged arc and GMAW proceduresbelow 450 amps.

FIGURE E.3- Output, Rectification, Control and Feedback

IDEALARC DC-1000


E-3


PROTECTION DEVICES ANDCIRCUITS (CONTACTOR HOLD-IN)Two thermostats protect the DC-1000 from exces-sive operating temperatures. Excessive operatingtemperatures may be caused by a lack of cooling airor operating the machine beyond the duty cycle andoutput rating. If excessive operating temperatureshould occur, the thermostat(s) will deactivate theinput contactor, turning the machine off. The inputcontactor will remain open until the machine cools.The machine can then be restarted by operating thestart push button.

Upon restart, if the fan does not turn or the air intakelouvers are obstructed, then the input power mustbe removed and the fan problem or air obstructionbe corrected.

The DC-1000 is also protected against high currentoverloads. This electronic protection circuit sensesan overload on the power source and opens theinput contactor should the overload remain for apredetermined time. If the overload is great themachine will shut down immediately. The input con-tactor will remain open until the start push button isoperated.

The Remote Control circuit is also protected fromÒgroundsÓ or voltage intrusions. If the #73, #74, #75,#76 or #77 leads come in contact with either of themachineÕs output cables, the DC-1000 will onlyoperate at a minimum output or the input contactorwill open.

FIGURE E.4 - Protection Devices and Circuits (Contactor Hold-In)

IDEALARC DC-1000



SCR OPERATION

A silicon controlled rectifier (SCR) is a three termi-nal device used to control rather large currents to aload. An SCR acts very much like a switch. When agate signal is applied to the SCR it is turned ON andthere is current flow from anode to cathode. In theON state the SCR acts like a closed switch. Whenthe SCR is turned OFF there is no current flow fromanode to cathode thus the device acts like an openswitch. As the name suggests, the SCR is a rectifi-er, so it passes current only during positive halfcycles of the AC supply. The positive half cycle isthe portion of the sine wave in which the anode ofthe SCR is more positive than the cathode.

When an AC supply voltage is applied to the SCR,the device spends a certain portion of the AC cycletime in the on state and the remainder of the time inthe off state. The amount of time spent in the ONstate is controlled by the Gate.

An SCR is fired by a short burst of current into thegate. This gate pulse must be more positive thanthe cathode voltage. Since there is a standard PNjunction between gate and cathode, the voltagebetween these terminals must be slightly greaterthan 0.6 V. Once the SCR has fired it is not neces-sary to continue the flow of gate current. As long ascurrent continues to flow from anode to cathode theSCR will remain on. When the anode to cathodecurrent drops below a minimum value, called hold-ing current, the SCR will shut off. This normallyoccurs as the AC supply voltage passes throughzero into the negative portion of the sine wave. Ifthe SCR is turned on early in the positive half cycle,the conduction time is longer resulting in greaterSCR output. If the gate firing occurs later in thecycle the conduction time is less resulting in lowerSCR output.

FIGURE E.5 - SCR Operation

IDEALARC DC-1000

E-6NOTES

IDEALARC DC-1000

E-6

IDEALARC DC-1000

F-1TROUBLESHOOTING & REPAIRF-1

TABLE OF CONTENTS -TROUBLESHOOTING AND REPAIR SECTION-

TROUBLESHOOTING AND REPAIR SECTION...............................................................Section FHow to Use Troubleshooting Guide.......................................................................................F-2Safety Precautions.................................................................................................................F-3PC Board Troubleshooting Procedures .................................................................................F-3Troubleshooting Guide ..........................................................................................................F-4

Output Problems .............................................................................................................F-4Function Problems ..........................................................................................................F-9Welding Problems .........................................................................................................F-11

Test ProceduresControl Transformer (T2) Voltage Test .........................................................................F-13Main Transformer (T1) Voltage Test .............................................................................F-16Firing Board Test...........................................................................................................F-20Control Board Test ........................................................................................................F-25Static SCR Test.............................................................................................................F-30Active SCR Test ............................................................................................................F-34

Oscilloscope WaveformsNormal Open Circuit Voltage Waveform Constant Current Mode ..................................F-38

No LoadNormal Open Circuit Voltage Waveform Constant Voltage............................................F-39

Innershield - Maximum Output Setting - No LoadNormal Open Circuit Voltage Waveform Constant Voltage............................................F-40

Innershield - Minimum Output Setting - No LoadTypical Output Voltage Waveform - Machine Loaded Constant Voltage........................F-41

Innershield ModeTypical Output Voltage Waveform - Machine Loaded ....................................................F-42

500 Amp Output Terminal Constant Voltage Innershield ModeTypical SCR Gate Voltage Waveform Constant Voltage................................................F-43

Innershield Maximum Output Setting - No LoadAbnormal Open Circuit Voltage Waveform Constant Voltage ........................................F-44

Innershield One Output SCR Not Functioning Maximum Output SettingReplacement Procedures

Input Contactor Cleaning and or Replacement .............................................................F-45SCR Output Bridge Replacement .................................................................................F-49

SCR Output Bridge Removal..................................................................................F-50Removal of Individual SCR Heat Sink Assemblies.................................................F-52SCR Heat Sink Installation .....................................................................................F-53SCR Output Bridge Installation...............................................................................F-53

Removal and Reassembly of Lift Bail ...........................................................................F-55Removal of Lift Bail.................................................................................................F-56Reassembly of Lift Bail ...........................................................................................F-57

Main Transformer Removal and Installation .................................................................F-58Main Transformer Disassembly and Assembly ......................................................F-59Main Transformer Disassembly ..............................................................................F-60Coil Removal and Replacement .............................................................................F-60Transformer Reassembly .......................................................................................F-61

Retest After Repair ..............................................................................................................F-63

IDEALARC DC-1000


This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.

STEP 1 LOCATE PROBLEM(SYMPTOM).

Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describespossible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.Symptoms are grouped into the followingcategories: output problems, function prob-lems, and welding problems.

STEP 2 PERFORM EXTERNALTESTS.

The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.

STEP 3. RECOMMENDEDCOURSE OF ACTION

The last column labeled “RecommendedCourse of Action” lists the most likely com-ponents that may have failed in yourmachine. It also specifies the appropriatetest procedure to verify that the subjectcomponent is either good or bad. If thereare a number of possible components,check the components in the order listed toeliminate one possibility at a time until youlocate the cause of your problem.

All of the referenced test proceduresreferred to in the Troubleshooting Guide aredescribed in detail at the end of this chap-ter. Refer to the Troubleshooting and RepairTable of Contents to locate each specificTest Procedure. All of the specified testpoints, components, terminal strips, etc. canbe found on the referenced electrical wiringdiagrams and schematics. Refer to theElectrical Diagrams Section Table ofContents to locate the appropriate diagram.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid elec-trical shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

If for any reason you do not understand the test procedures or are unable to perform thetests/repairs safely, contact the Lincoln Electric Service Department for technical trou-bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353._____________________________________________________________

WARNING

CAUTION

IDEALARC DC-1000


_______________________________

CAUTION: Sometimes machine failures appear tobe due to PC board failures. These problems cansometimes be traced to poor electrical connections.To avoid problems when troubleshooting andreplacing PC boards, please use the following pro-cedure:

1. Determine to the best of your technical abilitythat the PC board is the most likely componentcausing the failure symptom.

2. Check for loose connections at the PC board toassure that the PC board is properly connect-ed.

3. If the problem persists, replace the suspect PCboard using standard practices to avoid staticelectrical damage and electrical shock. Readthe warning inside the static resistant bag andperform the following procedures:

P.C. Board can be damaged by static electricity.

- Remove your body’s staticcharge before opening thestatic-shielding bag. Wear ananti-static wrist strap. Forsafety, use a 1 Meg ohmresistive cord connected to agrounded part of the equip-ment frame.

- If you don’t have a wriststrap, touch an unpainted,grounded, part of the equip-ment frame. Keep touchingthe frame to prevent staticbuild-up. Be sure not to touchany electrically live parts atthe same time.

- Tools which come in contact with the P.C. Boardmust be either conductive, anti-static or static-dissi-pative.

ELECTRIC SHOCK can kill.

Have an electrician install andservice this equipment. Turnthe input power OFF at thefuse box before working onequipment. Do not touch elec-trically hot parts.

- Remove the P.C. Board from the static-shieldingbag and place it directly into the equipment. Don’tset the P.C. Board on or near paper, plastic orcloth which could have a static charge. If the P.C.Board can’t be installed immediately, put it back inthe static-shielding bag.

- If the P.C. Board uses protective shortingjumpers, don’t remove them until installation iscomplete.

- If you return a P.C. Board to The Lincoln ElectricCompany for credit, it must be in the static-shield-ing bag. This will prevent further damage andallow proper failure analysis.

4. Test the machine to determine if the failuresymptom has been corrected by the replace-ment PC board.

NOTE: It is desirable to have a spare (knowngood) PC board available for PC board trou-bleshooting.

NOTE: Allow the machine to heat up so that allelectrical components can reach their operatingtemperature.

5. Remove the replacement PC board and sub-stitute it with the original PC board to recreatethe original problem.

a. If the original problem does not reap-pear by substituting the original board,then the PC board was not the prob-lem. Continue to look for bad connec-tions in the control wiring harness,junction blocks, and terminal strips.

b. If the original problem is recreated bythe substitution of the original board,then the PC board was the problem.Reinstall the replacement PC boardand test the machine.

6. Always indicate that this procedure was fol-lowed when warranty reports are to be submit-ted.

NOTE: Following this procedure and writing on thewarranty report, “INSTALLED AND SWITCHED PCBOARDS TO VERIFY PROBLEM,” will help avoiddenial of legitimate PC board warranty claims.

PC BOARD TROUBLESHOOTING PROCEDURES

ATTENTIONStatic-SensitiveDevicesHandle only atStatic-SafeWorkstations

Reusable ContainerDo Not Destroy

WARNING

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln ElectricService Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.


IDEALARC DC-1000

Observe all Safety Guidelines detailed throughout this manual

OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENT(S)

RECOMMENDEDCOURSE OF ACTION

Major Physical or ElectricalDamage is Evident.

The Machine is dead - The Inputcontactor does not operate.

Input contactor (1CR) chatters.

1. The.Start/Stop button (S1)may be faulty- Check for prop-er operation. See wiring dia-gram.

2. The Control Transformer (T2)may be faulty. Perform theControl Transformer Test.

3. The primary or secondarythermostats may be open.Check or replace. Also checkthe associated wiring. Seewiring diagram.

4. The pilot relay (2CR) may befaulty. Check or replace. Seewiring diagram.

5. The input contactor coil maybe open. See wiring diagram.

6. The Control board may befaulty - Replace.

1. The pilot relay (2CR) mayhave bad contacts. Check orreplace relay.

2. Check for loose or faultywiring between pilot relay(2CR) and input contactor(1CR) coil connections.

3. The input contactor (1CR)may be faulty - Replace.

Contact the Lincoln ElectricService Dept. (216) 383-2531or 1-800-833-9353 (WELD)

1. Check for blown or missingfuses in input lines.

2. Check the three-phase inputline voltage at the machine.The input voltage must matchthe rating plate and reconnectpanel.

1. The input line voltage may below. Check all three phases.

2. Make sure input line voltagematches machine rating andreconnect panel.

CAUTION

F-5TROUBLESHOOTING & REPAIR

IDEALARC DC-1000



OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)



Input contactor pulls in when startbutton is pressed but immediatelydrops out when start button isreleased.

1. Make sure input voltagesmatch machine rating andreconnect panel.

2. Remove all external wiresattached to terminal strip (2, 4,31, 32, 73, 74, 75, 76, 77). Ifcontactor (1CR) functions cor-rectly, there may be a groundor negative intrusion on theremote control leads (73, 74,75, 76, or 77). There may alsobe a short at the welder outputterminals.

3. If the problem persists afterperforming steps #1 and #2,the problem is in the DC-1000.

1. The 1CR interlock may befaulty. Replace if necessary.

2. The Start/Stop button may befaulty. Check or replace.

3. Check internal remote controlcircuit (leads 73, 74, 75, 76and 77) and switch SW3 forgrounds or shorts.

4. The control board may befaulty - Replace.

CAUTION

F-5

TROUBLESHOOTING & REPAIRF-6

IDEALARC DC-1000



OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)



Machine input contactor operatesbut machine has no weld output.Fan runs and pilot light glows.

1. Install a jumper from #2 to #4on machine terminal strip. Ifmachine weld output isrestored, the problem is in thewire feeder or control cable.

2. If remote control is not beingused, make certain the outputcontrol switch (SW3) is in the“OUTPUT CONTROL AT DC1000” position.

3. Check 8 AMP fuse in the frontpanel. Replace if blown.

4. Check for loose or faulty weldcable connections.

1. Check operation of outputpilot relay (4CR). Thereshould be 115 VAC presenton leads #31 and #4 at (4CR)when #2 and #4 are jumperedtogether at the terminal strip.

a. If the correct voltage is pre-sent and the relay does notactivate, the relay may befaulty - Replace.

b. If the 115 VAC is missing,check the associated wiringfor loose or faulty connec-tions. See wiring diagram.

2. Check the output controlpotentiometer (R1) and asso-ciated circuitry for loose orfaulty connections. See wiringdiagram.

3. Perform Main TransformerTest

4. Perform Firing Board Test.

5. Perform Control Board Test.

6. Perform SCR Output BridgeTest.

CAUTION

F-6


IDEALARC DC-1000



OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)



Machine has maximum weld out-put and no control.

Machine has minimum outputand no control.

1. If remote control is beingused, put output control switch(SW3) in “OUTPUT CON-TROL AT DC-1000” positionand control weld output withthe output control (R1) at DC-1000. If the problem is solved,check the remote control unit(or wire feeder) and associat-ed control cable.

1. If a remote control unit is NOTconnected to the terminal strip#73, #74,#75, #76, and/or #77terminals, the output controlswitch must be in the “OUT-PUT CONTROL AT DC-1000”position.

2. If a remote control cable isconnected to terminals #73,#74, #75, #76, and/or #77, theleads may be shorted to thepositive weld output.

3. Make certain the three phaseinput voltage is correct andmatches the machine ratingand the reconnect panel.

1. Check output control switch(SW3) and associated wiring.

2. Check feedback leads #222(negative output terminal) and#215, #210(output shunt) forloose or faulty connections.See wiring diagram.

3. Check the #75 lead for conti-nuity (zero ohms) from theoutput control potentiometer(R1) to the control board plug10J1. See wiring diagram.




1. Check the output controlpotentiometer (R1) and asso-ciated wiring.

2. Check the output controlswitch (SW3) the weldingmode switch (SW4) and asso-ciated wiring.

3. Perform the Control BoardTest.

4. Perform the Firing BoardTest.

5. Perform the SCR OutputBridge Test..

6. Perform Main TransformerTest.

CAUTION

F-7


IDEALARC DC-1000


OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)



The machine does not have max-imum weld output.

1. Check all three-phase inputlines at the DC-1000. Makesure input voltages matchmachine rating and reconnectpanel.

2. Put output control switch(SW3) in “OUTPUT CON-TROL AT DC-1000” position.If problem is solved, thencheck remote control unit orwire feeder.

1. Check the output controlpotentiometer (R1) and asso-ciated circuitry for loose orfaulty connections. See wiringdiagram.


3. Perform Firing Board test.

4. Perform Main TransformerTest.



CAUTION


IDEALARC DC-1000



FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)



Machine shuts off (input contac-tor drops out) when the welderoutput terminals are electricallyenergized. (#2 to #4 closure atterminal strip.)

The DC-1000 will NOT shut offwhen the Stop button is pushed.

1. Remove all welding cablesand control cables from theDC-1000. Jumper #2 to #4 atthe terminal strip. If themachine does NOT shut offand normal open circuit volt-age is present at the welderoutput terminals, the problemis external to the DC-1000.Either the remote leads #73,#74, #75, #76 or #77 aregrounded to the negative out-put cable, or there is a shorton the welding output termi-nals.

2. If the machine still shuts offwhen all control and weldingcables are removed, then theproblem is internal to the DC-1000.

1. Contact your local LincolnAuthorized Field ServiceFacility.

1. Check for grounds and orshorts in the #73, #74, #75,#76, #77 circuit. See wiringdiagram.

2. Check for grounds and shortsin the welder output terminalsand associated leads. Seewiring diagram.

3. Check the output shunt andassociated leads. See wiringdiagram.

4. Perform the Control BoardTest.

1. The input contactor (1CR)contacts may be stuck closed.Check and replace if neces-sary.

2. The Interlock contacts (part of1CR) may be faulty. Replaceif necessary.

3. The Start/Stop button may befaulty. Check or replace.

CAUTION


IDEALARC DC-1000

Observe all Safety Guidelines detailed througout this manual


FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)



The weld output terminals arealways electrically “hot”.

1. Remove any external leadshooked to #2 and #4 on theterminal strip. If the problemdisappears, the fault is in thecontrol cable or wire feeder.

2. If some open circuit voltage ispresent (over 3 VDC.) afterperforming Step #1, then theproblem is within the DC-1000.

1. Check for an internal shortbetween leads #2 and #4. Seewiring diagram.

2. The Pilot Relay (4CR) may bestuck closed. Check orreplace.



5. Perform the SCR OutputBridge Test.

6. The SCR Snubber(s) may be“leaky”. Check or replace. Seewiring diagram.

CAUTION


IDEALARC DC-1000



WELDING PROBLEMS

PROBLEMS(SYMPTOMS)



Poor arc starting when the DC-1000 is in the CV Sub-Arc or CVInnershield Modes.

Poor arc characteristics in allprocesses.

1. Make sure the proper weldingprocedures are being used(wire feed speed, arc voltageand wire size).

2. Check weld cables for looseor faulty connections.

1. Check for the correct inputvoltages on the three phaseinput lines at the DC-1000.

2. Make sure the proper weldingprocedures are being used(wire feed speed, arc voltageand wire size).

3. Check the welding cables forloose or faulty connections.

1. Check the 3CR reed switch.The voltage from lead #215 tolead #220 should be 8 VDCwhen the DC-1000 is in anidle condit ion (on but notwelding). When the machineis producing welding current,the reed switch (3CR) shouldclose and the voltage from#215 to #220 should drop tozero.


3 Perform the SCR OutputBridge Test.


1. Check the Mode Switch(SW4) and the associatedwiring for loose or faulty con-nections. See wiring diagram.

2. Check the 3CR reed switch.The voltage from lead #215 tolead #220 should be 8 VDCwhen the DC-1000 is in anidle condit ion. When themachine is producing weldingcurrent, the reed switch (3CR)should close and the voltagefrom #215 to #220 shoulddrop to zero.


4. Perform the SCR OutputBridge Test.


CAUTION


IDEALARC DC-1000



WELDING PROBLEMS

PROBLEMS(SYMPTOMS)



Poor performance (including arcoutages) while welding at lowcurrent (less than 450 amps)when connected to 1000 amp (+)output terminals.

The machine frequently shuts offwhile using the 500 amp (+) out-put terminal (later models only).

1. Change the welding cable(s)to the 500 amp terminal (latermodels only).

1.The output current demandmay be over 500 amps, caus-ing the choke to overheat.Change the welding cable(s)to the 1000 amp output termi-nals.

1. The choke thermostat may befaulty - Replace.

CAUTION

IDEALARC DC-1000


TEST DESCRIPTION

This test will determine if the correct voltage is being:a. applied to the primary of the control transformer.b. induced on the secondary winding of the control transformer.

MATERIALS NEEDED

Volt/Ohm Meter (Multimeter)IDEALARC DC-1000 wiring diagrams (See Electrical Diagram Section of Manual).

CONTROL TRANSFORMER (T2) VOLTAGE TEST

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment could result in danger to the technician orthe machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe all safety notes and precautions detailed throughout thismanual.

If for any reason you do not understand the test procedures or are unable to perform thetests/repairs safely, contact the Lincoln Electric Service Department for technical trou-bleshooting assistance before you proceed.

Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

WARNING


TEST PROCEDURE

1. Disconnect main AC input power tothe machine.

2 . Remove the Top and Case Sides.

3. Locate the Control Transformer (T2)on the left side of the Input Box (fac-ing the back of the machine). SeeFigure F.1.

4 . Locate the Control Transformerprimary leads (H1, H2, H3, etc.).See wiring diagram.

NOTE: Unused leads should betaped. Check for loose or faultyconnections.


IDEALARC DC-1000

FIGURE F.1 - Control Transformer Lead Location


5. Locate Control Transformer leadsX1 and X2 at in line connectors.See Figure F.2.

6. Apply power and test for 115 VACbetween leads X1 to X2.


IDEALARC DC-1000

FIGURE F.2 - Control Transformer X1 and X2 Test Points

7. If 115 VAC is not present betweenleads X1 and X2, test for correctmain AC input power to the ControlTransformer primary windings (H1,H2, H3, etc.) See wiring diagram.

If the correct main AC input power tothe Control Transformer is present, andthe secondary voltage is not correct,the Control Transformer may be faulty.Replace.


If for any reason you do not understand the test procedures or are unable to perform thetests/repairs safely, contact the Lincoln Electric service department for technical troubleshoot-ing assistance before you proceed.

Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________


MAIN TRANSFORMER (T1) VOLTAGE TEST

IDEALARC DC-1000

TEST DESCRIPTION

This test will determine if the correct voltages are being:a. applied to the primary windings of the Main Transformer (T1).b. induced on the secondary winding, auxillary windings, and phase angle windings.

MATERIALS NEEDED

Volt/Ohm Meter (Multimeter)IDEALARC DC-1000 wiring diagrams (See Electrical Diagram Section of Manual).

WARNING


TEST DESCRIPTION

1. Disconnect main AC input power tothe machine.

2 . Inspect the Input Contactor,Reconnect Panel, and primary leadsto the Main Transformer for loose orfaulty connections. See Figure F.3.

3. Apply input power, push start button,and make sure the Input Contactor(1CR) energizes.

4. Test with an AC voltmeter for propermain AC input voltage to the lineside of the Input Contactor (1CR).See wiring diagram.

L1 to L2.

L2 to L3.

L1 to L3.

a . If proper voltage is not pre -sent in any or all of the threephases, check input fusesand leads.

5 . Test with an AC voltmeter forproper main AC input voltage fromthe output side of the InputContactor. (1CR). See wiring dia-gram.

T1 to T2.

T2 to T3.

T1 to T3.

a . If correct voltage is pre-sent, the Contactor isworking properly.

b. If the correct voltage is notpresent for any or all of thethree phases, the contac -tor may be faulty.

6 . Test with an AC voltmeter forapproximately 60 VAC from eachof the six main transformer sec -ondary leads to the common bussconnected to the negative outputterminal. See Figure F.4.


IDEALARC DC-1000

FIGURE F.3 - Input Contactor, Reconnect Panel, and Primary Leads toMain Transformer Locations


a. If one or more of the abovevoltage tests are incorrect,check for loose or faultywiring. If the wiring is good,then the Main Transformermay be faulty.

NOTE: A long wire with clip or along probe may be required toreach the lower middle lead.

7 . Test for 115 VAC between leads#31 to #32 on the terminal strip.These can be accessed throughthe front panel assembly door.

a . If the 115 VAC is not pre-sent, check for loose orfaulty wiring or blown fuse.If necessary, untape andtrack the continuity of leads#31 and #32 through theentire harness.

b. If the wiring is good, then theMain Transformer may befaulty.

8. Remove the screws from the controlbox cover. It does not have to becompletely removed to perform thistest.

9 . Test with an AC voltmeter for 75VAC for each phase angle windingas shown. See Figure F.5.

NOTE: If the main supply voltagevaries, the Main Transformer volt -ages will vary proportionately. SeeFigure F.5.


IDEALARC DC-1000

FIGURE F.4 - Main Secondary Lead Test Points



IDEALARC DC-1000

From To Expected VAC

Plug Pin Lead Plug Pin Lead

J5 2 #203 J5 4 #204 75 VAC

J5 7 #205 J5 3 #206 75 VAC

J5 9 #207 J5 8 #208 75 VAC

FIGURE F.5 - Phase Angle Windings Test Points and Firing Board PinLocation


FIRING BOARD TEST

IDEALARC DC-1000



Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION

This test determines whether or not the Firing Board is receiving the correct voltages andgate signals. The LED’s (Light Emitting Diodes) will help you determine if the Firing Board isgenerating gate signals to the main SCR’s.

MATERIALS NEEDED

Volt/Ohm Meter (Multimeter)IDEALARC DC-1000 Wiring Diagram and Firing Board Schematic Diagram (See ElectricalDiagram Section of Manual).

WARNING


TEST PROCEDURE FORNORMAL FIRINGBOARD OPERATION1. Disconnect main AC input power to

the machine.

2. Remove screws, loosen and lowerthe front panel to access the FiringBoard on the left side of ControlBox facing the machine.

3 . Visually inspect the Firing Boardfor loose or faulty connections.

4 . Reconnect the input power andturn the DC-1000 on.

5 . Locate LEDs 7, 8, and 9 on theFiring Board. See Figure F.6. EachLED should be ON and equallybright. Use Table F.1 to check LEDoperation.

6. Connect a jumper wire from termi-nal #2 to terminal #4 on the termi-nal strip. These can be accessedthrough the Front Panel Assemblydoor. See Figure F.7.

7 . Locate LEDs 1 thru 6. Each LEDshould glow with equal brightness.

NOTE: LEDs 1 through 6 indicate thatthe gate firing signals are being gener-ated to send to each of the outputSCRs.

8. Set the output control switch (SW3)in the ÒOutput Control at DC-1000Óposition.

9 . Set the welding mode switch(SW4) in either of the ÒCVÓ posi-tions.

FIRING BOARD TEST

IDEALARC DC-1000

FIGURE F.6 - Firing Board LED and Molex Plug Locations

WARNING

JUMPERING LEADS 2 AND 4 ELEC-TRICALLY ENERGIZES MACHINEÕSOUTPUT TERMINALS. DO NOTTOUCH ELECTRICALLY HOT COM -PONENTS.______________________________________


1 0 . Rotate the output control poten -tiometer (R1). As the potentiometeris turned clockwise, the LEDsshould glow brighter. As the poten-tiometer is turned counter-clock-wise, the LEDs should dim.

a . If the LEDs glow andchange in brightness equal-ly as the potentiometer isturned and the problemcontinues, then the SCRbridge may be faulty.Perform the SCR BridgeTest.

b . If any or all of LEDs 1through 6 do not glow, ordo not change in brightnessequally as the potentiome -ter is turned, continue tonext step.

c . If one or two LEDs staybright or dim while the oth-ers change, this could indi-cate either an open orshorted gate or a faultysnubber on the related SCRassembly. Perform SCRBridge Test.

1 1 . Locate and test for 6 to 15 VDCbetween leads #231 and #215 onthe Firing Board in the CV mode.When the output control poten -tiometer (R1) is rotated, the DCvoltage between leads #231 and#215 should vary from 6 to 15 VDC.

1 2 . If an LED continues to be lit andshould not be, a circuit may befaulty on the Firing Board betweena Molex plug and LED. ReplaceFiring Board.

1 3 . If the DC voltage does NOT vary,as potentiometer (R1) is rotated,the Control Board may be faulty.

1 4 . Locate and test for approximately5.8 VDC between leads #231 and#215 on the Firing Board in VV(CC) mode. When the output con-trol potentiometer (R1) is rotated,the DC voltage between leads #231and #215 should NOT vary andshould remain at a constant approx-imate 5.8 VDC.

NOTE: The DC voltage may varyslightly at the lower portion of therange.

FIRING BOARD TEST

IDEALARC DC-1000

FIGURE F.7 - Terminal Strip Jumper Wire Connections


15. Test the Output Pilot Relay (4CR)for operation by removing andreplacing the jumper wire repeat-edly from terminal #2. See FigureF.7. This should cause the relaycontacts to open and close. Thecontacts can be seen closing andopening through the clear plasticrelay case or can be heard opening

FIRING BOARD TEST

IDEALARC DC-1000

FIGURE F.8 - Output Pilot Relay 4CR Location

and closing. If the Output PilotRelay (4CR) does not close whenenergized, check for loose or faultywiring. See Wiring Diagram andFigure F-8.

16. Replace the Firing Board if theabove voltage and control relaytests are passed. It may be faulty.


FIRING BOARD TEST

IDEALARC DC-1000

TABLE F.1 - LED 7, 8 and 9 Check List

IFLED 7 is ON

LED 7 is OFF or is DIM-MER than other LEDs

LED 8 is ON


LED 9 is ON


THENAC power is being supplied to the Firing Board fromleads #203 and #204 connected to the phase angle wind-ing in the Main Transformer.

The proper AC voltage may not be reaching Firing Board.Check for loose or faulty connections. Perform MainTransformer Test.

AC power is being supplied to the Firing Board fromleads #205 and #206 connected to the phase angle wind-ing in the Main Transformer.


AC power is being supplied to the Firing Board fromleads #207 and #208 connected to the phase angle wind-ing in the Main Transformer.



IDEALARC DC-1000

CONTROL BOARD TEST


If for any reason you do not understand the test procedures or are unable to perform thetests/repairs safely, contact the Lincoln Electric service department for technical trou-bleshooting assistance before you proceed.

Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION

This test will determine if the Control Board is receiving the correct voltages and feedbacksignals.

MATERIALS NEEDED

Volt/Ohm Meter (Multimeter)IDEALARC DC-1000 Wiring Diagram and Control Board Schematic (See Electrical DiagramSection of Manual).

WARNING


TEST PROCEDURE FORNORMAL CONTROL BOARDOPERATION

1. Remove main supply power to theDC-1000.

2. Remove screws, loosen and lowerthe Front Panel to access andinspect the Control Board locatedin the right front control box. SeeFigure F.9.

3. Apply the correct three-phase inputpower to the DC-1000. Turn on themachine.

4. Connect a jumper wire from termi-nal #2 to terminal #4 on the termi-nal strip. These can be accessedthrough the front panel assemblydoor. See Figure F.7.

5 . LED 1 should be lit indicating thepresence of 115 VAC at leads#255 to #256 Plug J1.

6 . LED 3 should be l i t indicatingpower is being applied to the faultprotection relay (2CR).

7 . LED 4 should NOT be lit. LED 4should light only if there is a ÒfaultÓcondition.

8. LED 2 should be lit indicating outputvoltage feedback is being suppliedto the Control Board. With theOutput Control Switch (SW3) in theÒOutput Control At DC-1000Ó(Panel) position and the WeldingMode Switch (SW4) in a CV posi -tion, LED 2 should change in bright-ness as the Output ControlPotentiometer is rotated. As theopen circuit voltage is increased,LED 2 should get brighter and viceversa.

9 . LED 5 indicates a control signal(lead #231) is being supplied to thefiring circuit. As the output is varied,LED 5 should change in brilliancyfrom bright (at low output) to dim (athigh output). When the Weld ModeSwitch (SW4) is in the CC (Stick)position, the open circuit voltage isat maximum, and LED 5 will be verydim or not lit.

CONTROL BOARD TEST

IDEALARC DC-1000

FIGURE F.9 Control Board LED and Pin Locations.

WARNING

JUMPERING LEADS 2 AND 4 ELEC-TRICALLY ENERGIZES MACHINEÕSOUTPUT TERMINALS. DO NOTTOUCH ELECTRICALLY HOT COM -PONENTS.______________________________________


POSSIBLE PROBLEMSPERTAINING TO THECONTROL BOARD

IF LED 1 does not light, when thestart switch is ON.

1. Check for 115 VAC at leads #255to #256 plug J1

a. If the correct voltage is notpresent, check leads #255and #256 and associatedwiring for loose or faultyconnections. See wiring dia-gram and Figure F.10.

b. Remove main supply powerto the DC-1000. Test forcontinuity (zero ohms) fromlead #255 plug J1 at theControl Board to lead #212at the Start/Stop Button.

c . Test for continuity (zeroohms) from lead #256 plugJ1 at the Control Board tothe pilot light. See wiring dia-gram.

d. If the 115 VAC is present atleads #255 to #256 at plugJ1 and LED 1 does not light,the Control Board may befaulty. Replace.

CONTROL BOARD TEST

IDEALARC DC-1000

FIGURE F.10 - LED 1 Test Points


IF LED 2 does not light when #2 and#4 are jumpered together.

1. Check for the presence of open cir-cuit voltage at the weld output ter-minals (27 to 75 VDC in constantvoltage mode, 75 VDC in constantcurrent mode).

a . If open circuit voltage ISpresent at the output termi-nals, then check for opencircuit voltage from lead#222 (-) plug J1 to lead#215 (+) plug J2 on theControl Board See FigureF.11.

b . If open circuit voltage isNOT present at the ControlBoard, then check leads#222 and #215 and associ-ated wiring for loose orfaulty connections. Seewiring diagram. Removemain supply power to theDC-1000.

2 . Test for continuity (zero ohms)from the output shunt to lead #215at plug J2 on the Control Board.

See wiring diagram and FigureF.11.

3. Test for continuity (zero ohms) fromthe negative output terminal to lead#222 at plug J1 on the ControlBoard. See wiring diagram.

4 . If the previous tests do not revealthe problem then the Control Boardmay be faulty. Replace.

5. If open circuit voltage is NOT mea-sured at the weld output terminals,then check the Output Choke andassociated heavy current carryingleads for loose or faulty connec -tions.

¥ Perform the Main TransformerTest.

¥ Perform the Firing Board Test.¥ Perform the SCR Output Bridge

Test.

If the previous tests do not reveal theproblem then the Control Board may befaulty. Replace.

CONTROL BOARD TEST

IDEALARC DC-1000

FIGURE F.11 - LED 2 Open Circuit Voltage Test Points


IF LED 3 does not light when theStart Button is depressed (but LED 1does light).

The Fault Protection Relay (2CR) is notreceiving supply voltage (24 VDC) andthe Input Contactor (1CR) will not stayclosed. Check to see if LED 4 lights orÒflickersÓ when the Start Button is heldin.

If LED 4 lights,

1 . There may be a ÒshortÓ at thewelder output terminals or theremote control circuit (leads #73,#74, # 75, #76 and #77) may beshorted to the negative weldingvoltage. Check the weld output ter-minals and associated leads andalso the remote control circuitry.See wiring diagram.

2 . If the above procedures do notreveal the problem, then theControl board may be faulty-Replace.

IF LED 5 does not light and varies inbrightness when #2 and #4 arejumpered together, while the OutputControl Potentiometer is rotated .

The Control Board may be faulty -Replace.

NOTE: The Weld Mode Switch (SW4)must be in the CV position and theOutput Control Switch (SW3) in theÒOutput Control at DC -1000Ó position.Also check the Output ControlPotentiometer and associated circuitry.

CONTROL BOARD TEST

IDEALARC DC-1000


IDEALARC DC-1000



Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

STATIC SCR TEST

TEST DESCRIPTION

The Static SCR Test is a quick check to determine if an SCR is shorted or “leaky”. Seemachine waveform section for normal and abnormal SCR waveforms.

MATERIALS NEEDED

Analog ohmeter Volt/Ohm Meter (Multimeter)DC-1000 Wiring Diagrams (See Electrical Diagram Section of Manual).

WARNING


TEST PROCEDURE

1 . Remove main supply power to theDC-1000.

2 . Remove all Molex plugs from thefiring board and control board. SeeFigure F.12.

STATIC SCR TEST

IDEALARC DC-1000

FIGURE F.12 - Firing and Control Board Molex Plug Locations.

CONTROL BOARD

FIRING BOARD


3 . Remove the red insulating paintfrom heat sink test points. SeeFigure 13.

NOTE: DO NOT DISASSEMBLE THEHEAT SINKS.

4. Using an analog ohmmeter, test theresistance from anode to cathode ofSCR 1. Reverse the meter leadsand check from cathode to anode ofSCR 1. (R x 1000 SCALE)

a. If a low resistance is indicat-ed in either direction, dis-connect the snubber circuit(See wiring diagram) andretest SCR 1. If a low resis-tance is still indicated, SCR1 is faulty - Replace. If avery high or infinite resis -tance is indicated withoutthe snubber circuit, thenreplace the snubber circuit,See Figure F.14.

STATIC SCR TEST

IDEALARC DC-1000

FIGURE F.13 - SCR Heat Sink Assembly Test Points.


5. Repeat Step 4 testing SCR 2, SCR3, SCR 4, SCR 5, and SCR 6.

To further check the SCRs’ functionsuse an SCR tester and proceed toActive SCR Test.

STATIC SCR TEST

IDEALARC DC-1000

FIGURE F.14 - Snubber Location and Circuit


IDEALARC DC-1000



Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

ACTIVE SCR TEST

TEST DESCRIPTION

The Active SCR Test will determine if the device is able to be gated “ON” and conduct currentfrom anode to cathode.

MATERIALS NEEDED

An SCR tester as outlined in this procedure.DC-1000 Wiring Diagram (See Electrical Diagrams Section of this manual).

WARNING


1 . Remove main supply power to theDC-1000.

2 . Remove all Molex plugs from theFiring Board and Control Board.See Figure F.15.

ACTIVE SCR TEST

IDEALARC DC-1000

FIGURE F.15 - Firing Board and Control Board Molex Plug Locations

FIRING BOARD

CONTROL BOARD


3 . Remove the red insulating paintfrom heat sink test points. SeeFigure F.16.

4 . Perform test procedure as follows.Refer to Figure F.17. Repeat testfor all six SCRs.

NOTE: Do not disassemble the heatsinks.

ACTIVE SCR TEST

IDEALARC DC-1000

FIGURE F.16 - Heat Sink Assembly Test Points


5 . To test SCRs, construct the circuitoutlined in Figure F.17. Use one 6Vlantern battery. Resistor values arein ohms ± 10%. The voltmeter scaleshould be low, approximately 0-5 or0-10 volts.

BATTERY TEST

Check the battery by shorting leads (A)and (C) and then close switch SW1.Replace battery if voltage is less than4.5 volts.

A. Connect SCR into the test circuit asshown (A) lead to anode (C) lead tocathode and (G) lead to the gate.

B . Close switch SW1 (switch SW2should open), voltmeter should readzero. If the voltmeter reads higherthan zero the SCR is shorted.

NOTE: Do not disassemble the heatsinks.

6 . With switch SW1 closed, closeswitch SW2 for two seconds andrelease. The voltmeter should read3 to 6 volts before and after switchSW2 is released. If the voltmeterdoes not read, or reads only whileSW2 is depressed, the SCR or bat-tery is defective (repeat BatteryTest Procedure).

7 . Open switch SW1, disconnect thegate lead (G) and reverse the (A)and (C) leads on the SCR. Closeswitch SW2. The voltmeter shouldread zero. If the voltage is higherthan zero, the SCR is shorted.

8 . Replace any SCR assembly thatdoes not pass test in Step 4.

ACTIVE SCR TEST

IDEALARC DC-1000

FIGURE F.17- Silicon Controlled Rectifier (SCR) Test Setup


NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMCONSTANT CURRENT MODE - NO LOAD

IDEALARC DC-1000

Volts/Div . . . . . . . . . . . . . 50 V/Div.Horizontal Sweep . . . . . 2 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigger . . . . . . . . . . . . . . . Internal

SCOPE SETTINGS

F-38

This is the typical DC open circuit volt-age waveform generated from a proper-ly operating machine. Note that eachvertical division represents 50 volts andthat each horizontal division represents2 milliseconds in time.

Note: Scope probes connected atmachine output terminals: (+) probe topositive 1000 Amp terminal, (-) probe tonegative terminal.


NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMCONSTANT VOLTAGE INNERSHIELD - MAXIMUM

OUTPUT SETTING - NO LOAD

IDEALARC DC-1000

Volts/Div . . . . . . . . . . . . . 50 V/Div.Horizontal Sweep . . . . . 2 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigger . . . . . . . . . . . . . . . Internal

SCOPE SETTINGS


Note: Scope probes connected atmachine output terminals: (+) probe topositive 1000 Amp terminal, (-) probe tonegative terminal.


NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMCONSTANT VOLTAGE INNERSHIELD

MINIMUM OUTPUT SETTING - NO LOAD

IDEALARC DC-1000

Volts/Div. . . . . . . . . . . . . 50 V/Div.Horizontal Sweep . . . . . 2 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigger . . . . . . . . . . . . . . . Internal

SCOPE SETTINGS


Note: Scope probes connected atmachine output terminals: (+) probe topositive 1000 Amp terminal, (-) probe tonegative terminal


TYPICAL OUTPUT VOLTAGE WAVEFORM -MACHINELOADED CONSTANT VOLTAGE INNERSHIELD MODE

IDEALARC DC-1000


SCOPE SETTINGS

F-41

This is the typical DC open circuit volt-age waveform generated from a proper-ly operating machine. Note that eachvertical division represents 20 volts andthat each horizontal division represents2 milliseconds in time. The machinewas loaded with a resistance grid bank.The grid bank meters read 600 amps at44 VDC.

Note: Scope probes connected atmachine ouput terminals: (+) probe topositive 1000 Amp terminal, (-) probe tonegative terminal.


TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINELOADED - 500 AMP OUTPUT TERMINAL

CONSTANT VOLTAGE INNERSHIELD MODE

IDEALARC DC-1000


SCOPE SETTINGS

This is the typical DC open circuit volt-age waveform generated from a proper-ly operating machine. Note that eachvertical division represents 20 volts andthat each horizontal division represents2 milliseconds in time. The machinewas loaded with a resistance grid bank.The grid bank meters read 400 amps at36 VDC.

Note: Scope probes connected atmachine ouput terminals: (+) probe topositive 500 amp terminal, (-) probe tonegative terminal.


TYPICAL SCR GATE VOLTAGE WAVEFORMCONSTANT VOLTAGE INNERSHIELD

MAXIMUM OUTPUT SETTING - NO LOAD

IDEALARC DC-1000

SCOPE SETTINGS

Volts/Div. . . . . . . . . . . . . . 1 V/Div.Horizontal Sweep . . . . . .5 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigger . . . . . . . . . . . . . . . Internal

This is the typical SCR gate pulse volt-age waveform. The machine was in anopen circuit condition (no load) andoperating properly. Note that each verti-cal division represents 1 volt and thateach horizontal division represents 5milliseconds in time.

Note: Scope probes connected at SCRgate and cathode: (+) probe to gate, (-)probe to cathode.


ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORMCONSTANT VOLTAGE INNERSHIELD

ONE OUTPUT SCR NOT FUNCTIONINGMAXIMUM OUTPUT SETTING

IDEALARC DC-1000

SCOPE SETTINGS


This is NOT the typical DC output volt-age waveform. One output SCR is notfunctioning. Note the “gap” in the wave-form. One SCR gate is disconnected tosimulate an open or nonfunctioning out-put SCR. Each vertical division repre-sents 50 volts and each horizontal divi-sion represents 2 milliseconds in time.

Note: Scope probes connected atmachine ouput terminals: (+) probe topositive 1000 amp terminal, (-) probe tonegative terminal.


IDEALARC DC-1000



Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

INPUT CONTACTOR (1CR) CLEANING AND/OR REPLACEMENT

MATERIALS NEEDED

7/16” socket wrench1/2” open end wrench11/16” socket wrenchPhillips head screwdriverFlat head screwdriverLow pressure air source

WARNING


CLEANING PROCEDURE

1. Remove main input supply power tothe DC-1000 and remove case topand sides.

2. Locate the input contactor. Using a1/2Ó wrench, remove the cover plate

from the input contactor. Mark,label, and remove leads as neces-sary to access the two nuts andwashers on the studs. See FiguresF.18 and F.19.


IDEALARC DC-1000

FIGURE F.18 - Input Contactor Cover Removal

FIGURE F.19 - Input Contactor Removal


DO NOT APPLY INPUT POWER TOTHE DC-1000 WITHTHE CONTACTORCOVER PLATEREMOVED. POWERAPPLIED WITHOUTCOVER PLATE IN

POSITION MAY CAUSE SEVEREARCING RESULTING IN BODILYINJURY.________________________________________

3. Blow out any dirt or dust from inand around contacts.

4. Examine contacts for signs of wear.

5. If contacts are stuck together oroverheated, parts of the contactor,or the entire assembly, should bereplaced.

CONTACTOR REPLACEMENT

REMOVAL

1. Using a 11/16” wrench, removeleads L1, L2, L3 and output powerleads from 1CR contactor. Markand label all leads for proper recon-nection. See Figure F.19.

2. Remove lead #257 at secondarythermostat. See Figure F.20 andrefer to Wiring Diagram. Removeany cable t ies and/or harnesslooms as necessary.

3. Remove the contactor interlockleads from quick disconnects (leads211 and 212) and from resistor R3.See Figure F-21 and refer to WiringDiagram.

4. Remove input contactor using a7/16” socket wrench. Remove thefour mounting bolts, nuts, and asso-ciated washers (or loosen the twobottom bolts and nuts, and removethe top two).

IDEALARC DC-1000


WARNING

FIGURE F.20 - Lead #257 atSecondary Thermostat

FIGURE F.21 - Lead #211 and #212Quick Disconnects


INSTALLATION

1. Install input contactor using a 7/16”socket wrench. Attach the fourmounting bolts, nuts, and associat-ed washers (or tighten the two bot-tom bolts and nuts, and attach thetop two).

2. Attach leads to contactor interlock.Connect quick connects on leads#211 and #212. See Figure F.21.

3. Attach leads from contactor coil.Attach any cable ties and/or har-ness looms cut at removal. Attachlead #257 at secondary thermostat.See Figure F.20.

4. Using a 11/16” wrench, attachleads L1, L2, L3 and output powerleads to 1CR contactor. See FigureF.19.

NOTE: Ensure all leads are connectedcorrectly. See Wiring Diagram.

IDEALARC DC-1000

F-48


TROUBLESHOOTING & REPAIR F-49

IDEALARC DC-1000



Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

SCR OUTPUT BRIDGE REPLACEMENT

MATERIALS NEEDED9/16” socket wrench9/16” open end wrench1/2” long-handled flat rachet wrench1/2” socket wrench1/2” open end wrench3/8” socket wrench5/16” socket wrenchLincoln E1868 (Dow Corning #340) heat sink compound

WARNING

F-49

F-50 TROUBLESHOOTING & REPAIR

SCR OUTPUT BRIDGEREMOVAL

1. Remove input power to machine.

2. Using a 5/16 (8mm) nut driver or flathead screw driver, remove 20screws (ten per side) to removecase sides and 2 screws to removetop.

3. Using a 5/16 (8mm) nut driver or flathead screw driver, remove 6screws, then lower the front controlpanel.

4. Remove the J4 gate lead Molexplug from firing board, and feed theplug down through the hole in bot-tom of the PC board compartment.

5. Using a 9/16” socket and open-endwrench, remove the two bolts andnuts holding the shunt assembly tothe two positive buss leads con-nected to the SCR bridge. SeeFigure F.22.

6. Using a 5/16” socket remove thescrew and small reed switch lead(#210) from the left, top rear SCRheat sink.

NOTE: It may be necessary to move orremove the output choke to gain accessto the bottom anode leads. For accessto the bottom middle screw, nut, andassociated washers, a long handled flatratchet is recommended.

7. Identify and label the six trans-former secondary (heavy alu-minum) leads that connect to theanodes of the SCR heat sinkassemblies. Using a 1/2” socketand open-end wrench, remove thesecondary leads (see Figure F.22).

8. Support the SCR bridge assemblywith a lift hook or rope.

9. Using a 3/8” socket wrench,remove the two screws (one oneach side) holding the SCR assem-bly rails to the front panel assem-bly.

IDEALARC DC-1000

FIGURE F.22 - Preparation For SCR Output Bridge Removal


F-50


10. Cut any necessary cable ties toallow for the SCR bridge assemblyremoval.

11. Using a 1/2” socket wrench, removethe four screws (2 on each side)holding the transformer side panelsand SCR assembly rails to the maintransformer. See Figure F.23.

12. Remove leads #217 and #222 fromresistor R2 located on the lift bailassembly. Remove resistor R2using a 7/16” wrench.

13. With the 5/16” socket wrench,remove the bottom six screws hold-ing the front panel assembly to thebase. Carefully pull the front panelforward to allow room to remove theSCR bridge assembly.

14. Clear all leads and carefully removethe SCR bridge assembly.

NOTE: Upon reassembly, apply a thinlayer of Lincoln E1868 (Dow Corning340) heat sink compound to all boltedelectrical connections on the aluminumheat sinks.

UPON REASSEMBLY, THE SCRBRIDGE ASSEMBLY MUST BE ELEC-TRICALLY ISOLATED FROMGROUND. _______________________________________

15. Place insulators between SCRbridge assembly and the outputrectif ier mounting bracket (seeFigure F.23). Check for electricalisolation with an analog ohmmeter.

MINIMUM ACCEPTABLE RESIS-TANCE TO GROUND IS 500,000OHMS._______________________________________


IDEALARC DC-1000

FIGURE F.23 - SCR Output Bridge Removal

F-51

CAUTION

CAUTION


REMOVAL OF INDIVIDUALSCR HEAT SINK ASSEMBLIES

1. Using a 9/16” wrench, remove twonuts, flat washers, and lock wash-ers from the SCR assembly mount-ing studs. See Figure F.24.

2. Using a 5/16 (8mm) nut driver orflat head screw driver, removesnubber ground wire attachment.The snubber assembly can now beremoved. Replace if necessary.

3. Carefully remove the positive bussbar from the heat sink in question.It may be necessary to remove thebuss bar completely.

4. Carefully slide the SCR assemblyfrom the mounting studs.Replacement will be made with anew SCR assembly.

DO NOT DISASSEMBLE THE SCRFROM THE HEAT SINK. MACHINEDAMAGE MAY RESULT. REPLACETHE SCR ONLY AS AN ASSEMBLY._______________________________________


IDEALARC DC-1000

FIGURE F.24 - Individual SCR Assembly Heat Sink Removal

CAUTION

F-52


SCR HEAT SINKINSTALLATION

NOTE: Upon reassembly, apply a thinlayer of Lincoln E1868 (Dow Corning#340) heat sink compound to all boltedelectrical connections on the aluminumheat sinks, including positive buss bar.

1. Slide a new SCR assembly onto themounting studs.

2. Carefully attach the positive bussbar onto the heat sink which hadbeen removed. If it had been nec-essary to remove the buss bar,replace it at this time.

3. Align snubber assembly in positionon SCR output bridge assembly.

4. Using a 9/16” wrench, secure theSCR output bridge and snubberassemblies with two nuts, flat wash-ers, and lock washers.

5. Using a 5/16 (8mm) nut driver or flathead screw driver, attach snubberassembly ground wire with screwspreviously removed.

SCR OUTPUT BRIDGEINSTALLATION

NOTE: Upon reassembly, apply a thinlayer of Lincoln E1868 (Dow Corning#340) heat sink compound to all boltedelectrical connections on the aluminumheat sinks.

1. Support the SCR bridge assemblywith a lift hook or rope.

2. Clear all leads and carefully posi-tion the SCR bridge assembly inplace.

3. Place insulators between SCRbridge assembly and the outputrectifier mounting bracket. SeeFigure F.23. Check for electricalisolation with an analog ohmmeter.Minimum acceptable resistance toground is 500,000 ohms.

4. With the 5/16” socket wrench,attach bottom six screws securingthe front panel assembly to thebase. Carefully push the front panelrearward into position.

5. Attach resistor R2 to the unit usinga 7/16” wrench Secure leads #217and #222 to resistor R2.

6. Using a 1/2” socket wrench, attachthe four screws (2 on each side)holding the transformer side panelsand SCR assembly rails to the maintransformer.


IDEALARC DC-1000

F-53


7. Using a 3/8” socket wrench, attachthe two screws (one on each side)holding the SCR assembly rails tothe front panel assembly. SeeFigure F-23.

NOTE: It may have been necessary tomove or remove the output choke togain access to the bottom anode leads.For access to the bottom middle screw,nut, and associated washers, a longhandled flat ratchet is recommended.

8. Using a 1/2” socket and open-endwrench, attach the secondary leadsthat connect the anodes of the SCRheat sink assemblies to the sixtransformer secondary (heavy alu-minum) leads as labeled during dis-assembly.

9. Using a 5/16” socket attach thesmall reed switch lead (#210) to theleft, top rear SCR heat sink usingthe screw previously removed.

10. Using a 9/16” socket and open-endwrench, attach the two bolts andnuts holding the shunt assembly tothe two positive buss leads con-nected to the SCR bridge.

11. Feed the J4 gate lead Molex plugup through the hole in bottom of thePC board compartment. Attach theplug onto the firing board.

12. Secure any cable ties removed pre-viously to allow for the SCR bridgeassembly removal.

13. Using a 5/16 (8mm) nut driver orflat head screw driver, attach 20screws (ten per side) to attach thecase sides. Attach the top using 2similar screws.

14. Raise the front control panel intoposition, and, using a 5/16 (8mm)nut driver or flat head screw driver,secure in position using 6 screws.


IDEALARC DC-1000

F-54


IDEALARC DC-1000



Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

REMOVAL AND REASSEMBLY OF LIFT BAIL

MATERIALS NEEDED3/8” socket wrench9/16” socket wrench

WARNING

F-55


REMOVAL OF LIFT BAIL

1. Remove input power to machine.

2. Using a 5/16 (8mm) nut driver or flathead screw driver, remove 20screws (ten per side) to removecase sides and 2 screws to removetop.

3. Remove two leads, #217 and #222from resistor R2.

4. Using a 3/8” socket wrench, removethe two screws holding the inputcontactor bracket to the lift bail.

5. Using a 9/16” socket wrench,remove the four bolts mounting thelift bail to the main transformerassembly.

6. Using a 9/16” socket wrench,remove the four bolts and associat-ed washers mounting the lift bail tothe base assembly. See FigureF.25.

7. Loosen or remove any cable or wireties necessary for lift bail removal.

8. Carefully remove the lift bail by lift-ing straight up and clear.


IDEALARC DC-1000

FIGURE F.25 - Lift Bail Removal

F-56


REASSEMBLY OF LIFTBAIL

1. Place the lift bail onto the IDE-ALARC DC-1000 from the top, low-ering straight onto the unit.

2. Using a 9/16” socket wrench, attachthe four bolts and associated wash-ers mounting the lift bail to the baseassembly.

3. Using a 9/16” socket wrench, attachthe four bolts mounting the lift bailto the main transformer assembly.

4. Using a 3/8” socket wrench, attachthe two screws holding the inputcontactor bracket to the lift bail.

5. Reattach leads #217 and #222 toresistor R2.

6. Reattach or reconnect any cablesor wire ties previously removed.

7. Using a 5/16 (8mm) nut driver orflat head screw driver, attach 20screws (ten per side) to securecase sides, and 2 screws to securetop.


IDEALARC DC-1000

F-57


IDEALARC DC-1000



Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

MAIN TRANSFORMER REMOVAL AND INSTALLATION

MATERIALS NEEDED

3/8” socket wrench1/2” socket wrench3/4” socket wrench

WARNING

F-58


MAIN TRANSFORMER DISASSEMBLY AND ASSEMBLY

IDEALARC DC-1000

FIGURE F.26 - Main Transformer Disassembly

F-59


MAIN TRANSFORMERDISASSEMBLY

1. Perform Lift Bail RemovalProcedure.

2. Remove lead #271 from resistor R3(located near the input contactor).

3. Separate the in-line connectorsfrom leads #211 and #212. SeeFigure F.21.

4. Remove lead #256 from the chokethermostat.

5. Remove lead #220 from the reedswitch (3CR).

6. Cut any necessary cable ties orrestraints and clear the leads nec-essary for the removal of the toptransformer iron.

7. Using a 3/8” socket wrench, removetwo screws mounting the input con-tactor bracket to the case backassembly. With leads attached,carefully pull assembly up and outof the way. Set assembly aside.

8. Using a 1/2” socket wrench, move16 screws (8 on each side) from thetransformer side brackets. Takingnote of placement, remove the fourbrackets and two bottom spacers.See Figure F.26.

9. Using a 3/4” wrench, remove the sixnuts and lock washers from thetransformer threaded rods. It maybe necessary to hold the threadedrods to keep them from turning.

10. Using a hoist, carefully lift the topiron from the assembly. Note theplacement of shims and insulators.

NOTE: Some prying and jolting may benecessary to free the iron from the coils.Replace any coils that may be faulty. Ifany heavy aluminum secondary coilsare to be replaced, identify and label allleads to the transformer. The leads willhave to be cut and then TIG weldedupon reassembly.

COIL REMOVAL ANDREPLACEMENT

1 Label and disconnect leads to thecoils that are being removed orreplaced (see Wiring Diagram).

2 Refer to Figure F.26 for proper coillocations (top, bottom, left, right,and center) of primary and sec-ondary coils. If secondary coils areto be replaced, it will be necessaryto cut the leads and TIG weld uponreassembly.

3. Remove the coils:

a. Some prying and jolting may benecessary to free the coils fromthe iron.

b. Note placement of insulationand wedges for reassembly(especially primary coil to lami-nation insulation and secondaryto primary insulation).

4. Replace the coils:

a. Be sure to replace all insulationand wedges that were removed(lamination to coils, and primaryto secondary coils).

b. Using a high temperatureindustrial epoxy, such asLincoln E1603, glue the coils inplace by applying the epoxy tothe coil sides along the lamina-tion, cell insulation, andwedges.

c. Glue the secondary coils inplace from the iron to the coilsides.

5. Re-TIG weld the secondary coilleads (if previously cut).

6. When reconnecting any aluminumleads, apply a thin layer of DowCorning 340 Heat Sink Compoundto mating surfaces.

IDEALARC DC-1000

MAIN TRANSFORMER DISASSEMBLY

F-60


TRANSFORMERREASSEMBLY

1. Using a hoist, carefully lift the topiron onto the assembly. Lightly tapon the top of the iron.

2. Position the transformer threadedrods securing the transformer.Using a 3/4” wrench, secure the sixnuts and lock washers. It may benecessary to hold the threaded rodsto keep them from turning. Tightennuts to 39 - 41 Ft.-Lbs.

3. The primary coils should be groundtested at 2700 VAC for one second.The secondary coils should beground tested at 1500 VAC for onesecond. The primary to secondaryinsulation should be tested at 2700VAC for one second.

4. Install the four brackets and twobottom spacers in the posit ionnoted at disassembly. Using a 1/2”socket wrench, secure in positionwith 16 screws (8 on each side)onto the transformer side brackets.

5. With leads still attached, carefullyreposition the input contactor brack-et onto the case back assembly.Using a 3/8” socket wrench, securein posit ion using two screwsremoved previously.

6. Attach lead #220 onto the reedswitch (3CR).

7. Attach lead #256 onto the chokethermostat.

8. Reconnect lead #211 and #212 tothe in-line connectors.

9. Attach lead #271 onto resistor R3.

10. Perform Lift Bail InstallationProcedure.

11. Replace any cable ties or restraintswhich were cut to remove the toptransformer iron.

TRANSFORMER INSTALLATION

IDEALARC DC-1000

F-61

NOTES

IDEALARC DC-1000

F-62


OPEN CIRCUIT VOLTAGES

Mode Input Hertz Open Circuit Volts

Variable Voltage 60 74/76 DC

Auxiliary Output (#31-#32) 60 122/124 AC

RETEST AFTER REPAIR

IDEALARC DC-1000

Testing is required after the removal of any mechanical part that could affect the machine’selectrical characteristics, or if any electrical components are repaired or replaced.

INPUT IDLE AMPS AND WATTS

Input Volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW

230/3/60 14.0 2.0

460/3/60 7.0 2.0

575/3/60 5.6 2.0

MAXIMUM ACCEPTABLE OUTPUT VOLTAGE - AT MINIMUM OUTPUTSETTINGS

Mode Input Hertz Load

Constant Voltage Innershield 60 140 Amps @ 14/18 VDC

MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUTSETTINGS

Mode Input Hertz Load

Variable Voltage 60 1250 Amps @ 47/52 VDC

Constant Voltage Submerged Arc 60 1250 Amps @ 47/52 VDC

Constant Voltage Submerged Arc 60 625 Amps @ 53/58 VDCat 500 Amp Terminal

F-63

F-64NOTES

IDEALARC DC-1000

F-64

G-1ELECTRICAL DIAGRAMSG-1

IDEALARC DC-1000

TABLE OF CONTENTS-ELECTRICAL DIAGRAMS SECTION-

DIAGRAMS........................................................................................Section GWiring Diagram (Codes 9919, 9920) ...........................................................G-2Operating Schematic ...................................................................................G-3Control PC Board (G1585) Layout ..............................................................G-4Firing PC Board (G1486-5 and above) Layout ............................................G-5Control PC Board (G1585) Schematic ........................................................G-6Firing PC Board (G1486-5 and above) Schematic ......................................G-7Output Snubber (M14312) Schematic .........................................................G-8

NOTES

IDEALARC DC-1000

G-2ELECTRICAL DIAGRAMS

IDEALARC DC1000

Wiring Diagram (Codes 9919, 9920)

9008 C

h'g

e.

Sh

t. N

o.

2-1

9-93

G

3-1

9-93

D

11-

19-9

3C

t

UN

LE

SS

OT

HE

RW

ISE

SP

EC

IFIE

D T

OL

ER

AN

CE

ON

HO

LE

SIZ

ES

PE

R E

20

56

ON

2 P

LA

CE

DE

CIM

AL

S I

S

.0

2

WIT

H P

UB

LIS

HE

D S

TA

ND

AR

DS

.

ON

3 P

LA

CE

DE

CIM

AL

S I

S

.0

02

ON

AL

L A

NG

LE

S I

S

.5

OF

A D

EG

RE

EM

AT

ER

IAL

TO

LE

RA

NC

E (

" "

) T

O A

GR

EE

THE

LIN

CO

LN E

LEC

TRIC

CO

.T

HIS

SH

EE

T C

ON

TA

INS

PR

OP

RIE

TA

RY

IN

FO

RM

AT

ION

OW

NE

D B

YA

ND

IS

NO

T T

O B

E R

EP

RO

DU

CE

D,

DIS

CL

OS

ED

OR

US

ED

THE

LIN

CO

LN E

LEC

TRIC

CO

.

LW

ITH

OU

T T

HE

EX

PR

ES

S P

ER

MIS

SIO

N O

F

4

5

69

8

71

2

3

L2

L1

H1

H2

TO GROUND PERNATIONAL ELECTRICALCODE

SUPPLYPOWER

TO3 PHASE TO

PRIMARYCOILS

SINGLE OR DUAL VOLTAGE INPUT PANEL

SHOWN CONNECTED FOR LOW VOLTAGE

9

8

71

2

3

L2

L1

H1

H3


SUPPLYPOWER

TO3 PHASE

SHOWN CONNECTED FOR 380 VOLTS

380 VOLTS OR TRIPLE VOLTAGE INPUT PANEL

L3

L3

6

4

5

6

12

10

11

TO PRIMARY COILS

TO T2

TO1CR

4

5

6 15

14

137

8

9

L2

L1

H1

H2


SUPPLYPOWER

TO3 PHASE TO

PRIMARYCOILS

SHOWN CONNECTED FOR LOW VOLTAGE

L3

380/ 500 VOLTS OR 460/ 575 VOLTS

INPUT PANEL

TO T2TO1CR

1S

413

7

S10

T1S

203

S

204

2S

S

S

S

S

SS

S

514

8

11

205

206

3

615

9

12

207

208

S32A

31

N.A.

N.B.

1CR

FANMOTOR

31

32A

STOPSTART

212

211211

SW1

R3

5 7

A B2CRPILOTLIGHT

271

R

271

256

257 257A

SECONDARYTHERMOSTAT

CHOKETHERMOSTAT

X2

255

X1 T2

H4

H3

H2

H1

N.C.

256

255

235

233

+

+

-

-

VM

AM

216

215210

222

216

222

SW2

21 4 2 31 32

2

32A

F1

32

31NEG

21

T.S.2

METER KIT(OPTIONAL)

CENTER TERMINALON FUSE HOLDER

73 74 75 76 77

T.S.3

B

A

314

7 8

5 6

9

4CR

215214

4 215

217R2

SEC

SEC

SCR SCR SCR

SCR SCR SCR

31 5

2 4 6

G1G3G5

GATE LEADSTO FIRING CIRCUITP.C. BOARD

SCR SNUBBERS

G6G4G2

GATE LEADSTO FIRING CIRCUITP.C. BOARD

OUTPUT SHUNT50 MV

215 210+ -

2103CR

222

222

222

220OUTPUTSNUBBER

+

-

1000 AMPOUTPUT

L1

500 AMPOUTPUT

216

226SW3

76 77

OUTPUT CONTROL

R1

75236 237

229224

266221

215

CCCVICVS

SW4238

230

226

123456789

1011121314

221222230

220

23374

23175

226235255256

12345678

12

J1

J2

J3

CONTROLP.C. BOARD

266

229215224

73238

210215

123456789

101112

214203206

215

205

207

123456

1J5

J4

J7

P.C. BOARD

1234

204

215

208

231

YXZ

G1

G2

G3

G4G5

G6

FIRINGCIRCUIT

2345678

J6

A

A'

B

B'CC'

LEGEND

SW1 INPUT POWER

SW4 WELDING MODE

SW2 ELECTRODE POLARITYSW3 OUTPUT CONTROL

F1 8 AMP SLOW BLOW FUSER1 10K OHM POTENTIOMETERR2 30 OHM, 300 WR3 10 OHM, 50 W (20W ON EARLIER MODELS)

2CR FAULT PROTECTION RELAY3CR CURRENT ACTIVATED REED SWITCH4CR OUTPUT PILOT RELAY

T1 MAIN POWER TRANSFORMER

L1 LOW CURRENT WELDING CHOKET2 CONTROL TRANSFORMER

1CR INPUT CONTACTOR

ELECTRICAL SYMBOLS PER E1537

NOTES:

N.A. 13, 14, AND 15 CONNECTIONS PRESENT

ONLY.ON 380/500 AND 460/575 MACHINES

N.B. 10,11, AND 12 CONNECTIONS NOT

VOLTAGE MACHINES.PRESENT ON 380V. OR TRIPLE

N.C. CONNECTIONS TO H2, H3, OR H4 DEPENDS ON INPUT VOLTAGE. SEEINPUT SUPPLY CONNECTION

APPEARS ON 380V AND TRIPLEINSTRUCTIONS. H4 CONNECTION

VOLTAGE MACHINES ONLY.

J3 J1

CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF BOARD)

J6 J4 J2, J7 J5

IDEA

LAR

C D

C-1

000

W

IRIN

G D

IAG

RA

M

DA

D

NO

NE

9008

L823

4

J.J

.

7-3

0-92

TH

E L

INC

OL

N E

LE

CT

RIC

CO

.C

LE

VE

LA

ND

, O

HIO

U.S

.A.

EQ

UIP

.

TY

PE

SC

AL

ES

UB

JE

CT

DR

DA

TE

CH

KR

EF

.S

UP

'S'D

'G

SH

T.

NO

.L

POS

TO T

1 A

UXI

LIA

RY

WIN

DIN

G

P.C. BOARD

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.


IDEALARC DC1000

Operating Schematic

TS 2

21

4

2

31

32

TS 3

R1

S4-A

S4-C

CVI

CVI

CVS

CVS

S3

2CR

L1

L2L3

1CR

STARTSTOP

R1CR

2CR

SECONDARY PRIMARY

SHUNT215

215 210210

226

238

75

3CR

220

215

CURRENT REED SW.CLOSED WITH OUTPUT CURRENT

235

236

236

235

210 215

222

222

231

204

203

206

205

208

207

G1

G2

G3

G4

G5

G6

215

215

X

Y

Z

AA'

C

BB'

C'

75 VAC

75 VAC

75 VAC

SET POINT

POWER SUPPLY

VOLTAGE FEEDBACK

CURRENT FEEDBACK

FAULT DETECT.

SHUTDOWN

CONTROL AMP

OVERLOAD DETECT.

4CR

FAN MOTOR

F1

8A

31

32A

S2

222

216

216214

R24CR

4CR

4CR

215256 255

OU

TPU

T C

HO

KE

1J5

5J5

6J5

4J5

2J5

3J5

7J5

10J5

2J6

1J7

8J7

1J6

2J7

5J7

8J5

9J5

3J6

6J7

5J7

CONTROL PCB

2J4

5J4

4J4

1J4

6J4

3J4

FIRING PCB

120VAC

120VAC

FIRING CIRCUIT

FIRING CIRCUIT

FIRING CIRCUIT

231

231

231

FIRING BD. ENABLE

SCR1 & SCR2

SCR3 & SCR4

SCR5 & SCR6

GATE DRIVE

GATE DRIVE

GATE DRIVE

GATE DRIVE

GATE DRIVE

GATE DRIVE

FIRING SIGNAL

OUTPUTSNUBBER

SCR1

SCR2

SCR3

SCR4

SCR5

SCR6

500 AMP OUTPUT

50mV @ 1300Amps

2J3

6J2

5J11

10J1

11J1

8J2

3J1

1J2

4J2

2J11 1J3

77

76

75

74

73

CVICVS

S4-B

266230

73

74

7J2

8J1

14J1

13J1

5J2

CVICVS

S4-B

2211J1

215

STARTING LOGIC

12J1

7J1

9J1

214

R3

"+" OUTPUT STUD

"-" OUTPUT STUD

CC

CC

CC

CC

229

224

++16V

- 6.2V- 10V

55V

2147

4-27-90

2-19-93L

3-19-93D

TRANSFORMER WELDERS OPERATING SCHEMATIC

C.S.

NONE

2147 3-1-90 J.J. 7-31-92 t

UNLESS OTHERWISE SPECIFIED TOLERANCEON HOLE SIZES PER E2056ON 2 PLACE DECIMALS IS .02

WITH PUBLISHED STANDARDS.

ON 3 PLACE DECIMALS IS .002ON ALL ANGLES IS .5 OF A DEGREEMATERIAL TOLERANCE (" " ) TO AGREE

THE LINCOLN ELECTRIC CO.CLEVELAND, OHIO U.S.A.

EQUIP.

TYPE

SCALE

DR DATE CHK REF.

SUBJECT

SUP'S'D'G

SHT.

NO.

THE LINCOLN ELECTRIC CO.THIS SHEET CONTAINS PROPRIETARY INFORMATION

OWNED BY AND IS

NOT TO BE REPRODUCED, DISCLOSED OR USED

THE LINCOLN ELECTRIC CO. GG

WITHOUT THE EXPRESS PERMISSION OF

PCB

OUTPUT

271

257

255

212211H3

H2

H1

T2

1CR 1CR 1CR

TO GROUND

TI

1

4

7

10

203

204

2

5

8

11

205

206

3

6

9

12

31

32A

207

208

256

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


IDEALARC DC1000

Control PC Board (G1585) Layout

IDENTIFICATIONPART No.REQ'D.ITEM

C3

C15

D1,D2,D3,D4

1N4004

DZ2

DZ3

DZ4

DZ7

R1,R113

R13

R34

R39

R48

20K 1/2W

R80,R94,R98

R84

D36

31

4

1

4

1

21

2

4

1

9

S16668-5 S13490-48

T11577-38

S13490-35

S13490-67 T11577-28

T12199-2

S13490-27

S13490-63

.047/100

50/16

.22/100

T12199-130

1N4007

T12702-3311112

14

T12702-18 T12702-27 T12702-31

T12702-29 T12702-30

IN5353 1N5347B

1N4740 1N5237B

1N4744A 1N5225B

1

26

5 T12218-4

T13657-2

T12704-68 2N4401 T12704-36

2 T12707-4

11

2

5

52

9

2

T12300-47

T14648-15

S19400-1004

S19400-1001

S19400-2213

200 15W

3143311

2

5

16

4

24

2

8

3

1 S19400-3010

S19400-4752

S19400-4751

S19400-1502

S19400-4750 S19400-20R0

1

3

313

332

S19400-3320 S19400-4753

S19400-1301

S19400-8252

1K 1/2W

S19400-1501

DC1000 CONTROL

R113 R1

DZ3

DZ1

4

DZ8

L1

C10

C26

C16

C1

C20

C18

C24

C28

C13

C25

C7

C30

C29

C5

C6

C17

+

C3

C4

C11

C8

C22

C15

C27

C21

C23

C14

C9

C19

DZ5

D

Z11

DZ1

0

DZ7

DZ1

2

DZ1

3

DZ1

5

DZ4

DZ6

DZ9

D34

D6

D36

D19

D20

D31

D16

D11

D10

D15

D14

D30

D25

D13

D32

D27

D33

D29

D4

D3

D2

D1

D5

D18

D17 D7

D9

D8

D28

D35

D24

D26

D23

D12

DZ2

X2

X1

LED5

LED2

LED1 LED3

LED4

TP1

J1

J

3

J2

R54

R10

2

R114

R73

R10

R63

R34

R26

R39

R38

R3

R4

Q8

Q9

Q6

Q2 Q7

Q5

SCR1

QU2 QU1 Q4

Q3

Q1 C

12

R37

R

27

R82

R13

3

R74

R

148

R11

2

R14

2

R83

R14

3

R84

R85

R18

R19

R17

R24

R16

R5

R6

R22

R20

R

25

R23

R

147

R70

R71

R2 R146

R13

R78

R87

R30

R29

R14

5

R77

R11

1

R13

6

R11

5 R99

R10

6

R10

7

R56

R79 R50

R55 R46

R28

R31

R15

R14

R32

R86

R

104

R10

5 R

100 R40

R41

R66

R64

R65

R48

R7

R8

R9

R11

R12

R52

R53

R62

R61

R59

R21

R60

R35

R81

R58

R47

R

76

R57

R97

R95

R96

R93

R98

R10

8

R90

R91

R92

R89

R88

R

80

R94

R110

R10

3

C2 DZ1

C1,C18,C20 .022/50C2

C4,C8,C11,C12

C9,C14,C19,C23

C10

C16,C26

C17C21,C27

1 S13490-42 1.0/35C22

S13490-19

S13490-39

S13490-102

47/160 1.8/20

18/15

.02/600

2.7 MFD 75V .47/50

2/50

D5,D6,D7,D8,D9,D10,D11,D12,D13,D14,D15, D16,D17,D18,D19,D20,D23,D24,D25,D26,D27,D28,D29,D30,D31,D32,D33,D34,D35,

DZ1

DZ5,DZ11 DZ6,DZ9,DZ12,DZ13

DZ8,DZ14 DZ10 DZ15

T12702-34

2

11

T12702-12 T12702-15 T12702-19

1N5253B 1N5231B 1N4742A

1N821

L1 LED1,LED2,LED3,LED4,LED5 RED LED

33 mH

Q4 1 T12704-69 2N4857 2N4403 2N6027

Q1,Q3 Q2,Q5,Q6,Q7,Q8,Q9

QU1,QU2

R2,R146 R3

R4 R5,R15,R24,R103,R115

R7,R8 R9,R76,R90,R95,R96

1 S19400-2673R10,R63 R11R12,R35,R53,R91,R92,R93

R14

R17,R20

R16,R28,R30,R31,R32,R62,R71,R77

R18,R25,R29,R57,R88 R19,R78,R79,R100R21,R61,R85R23,R147

S19400-1503

T14648-7

S19400-2671

T10812-39

S19400-6812

S19400-3922

S19400-1003

700 5W 470 5W

50K 1/2W

R26,R38 R27,R37,R58,R81

R40,R64,R65 R41,R47,R97

T10812-68

S19400-2211 T10812-67

T10812-77

S19400-2670

100K 1/2W

R46,R70,R74,R148

R50,R83,R143 R52,R99,R110 R54 R55,R56,R104R66,R111,R136 R73,R102,R114

R82,R133

S19400-2212 T12732-3

S19400-47R5 T14231-3

S19400-1002 S19400-1620

S19400-6810

27K 1W

15 .5W

R89R108R112,R142R145

SCR1TP1X1,X2

1121

112

S19400-6811S19400-1000S19400-75R0S19400-2432

S15161-17T13640-11S15128-4

45J

XXXX

XX

X

XX

XX

XXX

XXXX

XX

X

XX

XX

XXX

R105,R106,R107 R6,R22,R59,R60,R86,R87,

150K 1/4W

1M 1/4W

1K 1/4W

2.67K 1/4W

221K 1/4W

267K 1/4W

301 1/4W

100K 1/4W 475K 1/4W 20.0 1/4W

68.1K 1/4W

47.5K 1/4W 4.75K 1/4W 39.2K 1/4W 15.0K 1/4W

1.5K 1/4W 267 1/4W 332 1/4W

475K 1/4W 1.3K 1/4W

22.1K 1/4W

22.1K 1/4W

47.5 1/4W

10K 1/4W 1.3K 1/4W 1.3K 1/4W

100 1/4W

75.0 1/4W

82.5K 1/4W

6.81K 1/4W

24.3K 1/4W

C5,C6,C7,C13,C24,C25,C28,C29,C30

G1585-[ ]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are notavailable from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may resultin danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.


IDEALARC DC1000

Firing PC Board (G1486-5 and above) Layout

1/4W 150

1/2W 5.1

1/4W 475

FIR

ING

BO

AR

D

G14

86-5

R1

R2

R3

R4

R5

R6

R46

R47

R48

R64

R65

R66

R54

R53

R52

R42

R45

R41

R

44

R43

R

40

R21 R27 R39

R33

R19 R25 R37

R31

R16 R22 R34

R28

R20 R26 R38

R32

R55

R56

R57

R17 R23 R35

R30

R24 R36

R29

R18

C25

C26

C16

C22

C13

C19

C17

C23

C14

C20

C15

C21

C27

C18

C24

C1

C3

C4

C5

C6

C7

C8

C9

C10

C12

C11

C2

DZ1

DZ3

DZ2

D31

D32

D33

D37

D

34

D38

D39

D1

D

4

D5

D

2

D6

D3

D7

D

8

D35

D36

D19

D10

D

16

D13

D20

D11

D14

D17

D21

D12

D15

D18

D9

D30

D28

D29

D24

D27

D23

D26

D22

D

25

LED

2 LE

D1

LED

7 LE

D8

LED

9

LED

3

LED

5

LED

4

LED

6

TP

1

TP

2

TP

3

J5

J6

J4

J7

R10

R58

R14

R62

R11

R59

R12

R60

R

63

R15

R61

R13

R51

R50

R

49

R7

R9

R8

SC

R4

SC

R1

SC

R5

SC

R2

SC

R3

SC

R6

QU

1

QU

2

QU

3



IDEALARC DC1000

Control PC Board (G1585) Schematic

1.00K

R22

J110

100V.047

C6

162

R133

75.0

R142

100V.047C29

10K

J18

15.0KR25

1N4004D35

J28

1N4004D24

LED3

J27

1N4004D26

50V.022C18

1N4004D18

2.21K

R27

1K

CW

R38

77

74

75

SW.3 226

1N4004D12

332R74

1815V

C4

2N6027QU2

224

"N"

R1

73

233

75

C.V.I. MIN.TRIM

"N"

-6.2V

-6.2V-6.2V

"N"

2.21K

R37

100V.047C5

1W15VDZ9

1/2W15

R731K

CW

R26

332R148

-10V

T.S.3

76

VV

CVI

CVS

73

238

OUTPUT TRIM CIRCUIT

J17

75.0

R112

250V

C17

500mW3VDZ7

162

R82

1N4004

D23

15.0K

R18

1.3K

R83

VOLTAGE FEEDBACK

1N4004D8

2.21K

R81

1W15V

DZ13

1.00K

R59

2N4857Q9

681

R84

100V.22C21

"L"

-10V

+16V1.00K

R61N4004

D28

2N6027QU1LED4

1N4004D7

4.75K

R16

39.2K

R20

1.3K

R143

1.00M

R24

100K

R19

1W15V

DZ6

600mA40V

Q4

39.2K

R17

20R1471.00M R

5

1815V

C12

68.1K

R35

15R114

J24

475

R21

1.00K

R60

5W700

R3

475

R85

4A400V

SCR1

35V1.0C22

332

R70

1.820V

C3

1N4004D9

+55V+16V

+16V

"M"-10V"N"

B

229

20R23

J113

600V.02C14

475K

R48

15W200

R1

2.67K

R8

POWER SUPPLY

+16V

+55V

-6.2V

1N4004

D5LED1

1N4007D2

120V. AC

255

150K

R146

150V45J

TP1

150K

R2

1.50K

R65

332

R46

1.00K

R107

1.3K

R50

J13

6.81K

R89

1N4004D6

68.1K

R92

500mW8.2VDZ5

100V.22C27

22.1K

R110

100V.047C24

lm224

X28

9

10

10K

R80

10K

R94

68.1K

R91

1N4004D36

230

10K

R98

100K

R79

2N4857Q2

J21

"L"

"H"

-10V

-10V

"P""H"

"K"

V F.B.

"J"

"M"

-10V

"P"

CVI

SW.4266

H

(FOR V.V. TAIL-OUT)

"LOW" WITH OUTPUTVOLTAGE BELOW 10V.

CVS

CURRENT. ("P" DELAYED

STARTING CIRCUITS.)

100

R108

LOW WITH NO OUTPUT

FOR FAST RESPONSE

1N4004D19

500mW25V

DZ14

2.775V

C10

5015V

C26

1.00M

R103

1.00M

R115

2N4857Q7

1N4004D34

lm224

X2

5

7

6

15.0K

R88

221K

R90

1W15V

DZ12

1N4007D3

J111

24.3K

R145

1815V

C8

20KCWR39

15.0K

R29

100V.047C7

1N4004D33

50V.022C1

J26

1.00K

R87 4.75K

R774.75K

R30

2N4857Q5

100K

R78

V.V. MIN.LM224

X2

4

11

600V.02C19

15W200

R113J1

14

47.5R136

47.5

R111

1N4004D27

-10V -10V

+16VV REF.

-6.2V

-10V

"N"

"H"

NO

TES

:

256

74

OUTPUT TRIM ANDREFERENCE CIRCUIT

TRIM

1N4004D29

100V.047C30

5W10VDZ2

301

R13

1N4007D4

J3

1

J3

2

4.75K

R62

1N4004D16

1N4004D31

600V.02C23

1N4004

D15

1N4004

D14

100V.047

C13

22.1K

R52

267K

R1168.1K

R53

1N4004D10

47.5

R66

1N4004D11

221K

R9

CW

50K

R10

5W16V

DZ1

4.75K

R71

100V.047C25

1N4004D17

J112

475

R61

47160V

C2

1.00K

R105

600mA40V

Q3

1N4007D1

lm224

X1

12

14

13

+

-10V

+16V

-6.2V

215 210

-

TO 50mV @ 1300 AMP SHUNT

CURRENT FEEDBACK

C

OVER-CURRENT AND FAULT PROTECTION

+

CR2

235

VOLTS TRIMMAX CONTROL

TO FIRING BOARDCONTROL SIGNAL

68.1K

R12

LED5100K

R100 267

R41

4.75K

R32

1W12VDZ15

68.1K

R93

D

221K

R96

lm224

X214

13

12

4.75K

R28

ERROR AMPLIFIER

2N4857Q6

1N4004D25

100K

CW

R34

1.00M

R15600V.02

C9

lm224

X1 8

10

9

(FOR O.C.V. BOOST)

47.5K

R14

40V600mA

Q11W10VDZ4

4.75K

R31

1N4004D30

82.5K

R104

"J"

"K"

+16V

V REF.

V F.B.

+16V

K

"LOW" WITHOUTPUT CURRENT

1.50K

R40

L

500MW25VDZ8

J12

CC

1N4004D13

82.5K

R55

LED21/2W15

R102

500mW5.1VDZ10

1.00K

R106

8556

1N4004D32

1W27K

R54 CVI

STARTING LOGIC

TRIMC.V.S. MAX.

CC33mH

L1

82.5KR56

"H"

1815V

C11

1N4004D20

OUTPUT STUDTO NEGATIVE

(FOR START-LOW CLAMP)VOLTAGE OR CURRENT.HIGH WITH NO OUTPUT

222

2N4857Q8

22.1K

R99

CVS

CANADAFRANCE AUSTRALIA

15.0K

R57

lm224

X2

3

1

2

J11

J2

5

500mW8.2VDZ11

.4750V

C15267

R97

J19

-10V

221

220

TO POS. OUTPUT STUD

231

215

CVS

CC

CVI

221K

R95

J1

5

100V.047C28

5W470

R4

2.67K

R7

lm224

X1 1

3

21.50K

R64

50K

CW

R63

2.21K

R58

5015V

C16

221K

R76

267

R47

1.00K

R86 50V

.022C20

.4W6.2VDZ3

DR.

148

UN

LESS

OTH

ERW

ISE

SPEC

IFIE

D)

UN

LESS

OTH

ERW

ISE

SPEC

IFIE

D)

EQUI

P.

(UN

LESS

OTH

ERW

ISE

SPEC

IFIE

D)

ELEC

TRIC

AL S

YMB

OLS

PER

E15

37

SC

ALE

THE

LIN

CO

LN E

LEC

TRIC

CO

.

03-1

3-90

CLEV

ELAN

D, O

HIO

U.S

.A.

CHK.

JLV

TYP

E

SU

BJE

CT

.022

/50V

DA

TE

NO

NE

1A, 4

00V

CAP

ACIT

OR

S =

(M

FDRE

SIST

ORS

= O

hms

(D

IOD

ES =

1/4W

Ch'g

e.Sht

.No.

GEN

ERAL

INFO

RM

ATIO

NLA

BEL

S

D-

C-

30

R-LAST

NO

. USE

D

36TE

ST P

OIN

T

EAR

TH G

RO

UN

D C

ON

NEC

TIO

N

PO

WER

SU

PP

LY S

OU

RC

E P

OIN

T

SU

PP

LYVO

LTA

GE

NET

CO

MM

ON

CO

NN

ECTI

ON

FRA

ME

CO

NN

ECTI

ON

NO.

SUP'

S'D'

G.L

SHT.

8556

LM224

X1

4

11

WIT

HO

UT

AFFE

CTI

NG

TH

E IN

TER

CH

ANG

EAB

ILIT

Y O

F A

CO

MPL

ETE

BO

ARD

, TH

IS D

IAG

RAM

MAY

N.A

. S

INC

E C

OM

PON

ENTS

OR

CIR

CU

ITR

Y O

N A

PR

INTE

D C

IRC

UIT

BO

ARD

MAY

CH

ANG

E

NO

T S

HO

W T

HE

EXA

CT

CO

MP

ON

ENTS

OR

CIR

CU

ITR

Y O

F C

ON

TRO

LS H

AVI

NG

A C

OM

MO

N C

OD

E

WIT

H P

UB

LISH

ED S

TAN

DAR

DS

A

UN

LESS

OTH

ERW

ISE

SPEC

IFIE

D T

OLE

RAN

CE

MAT

ERIA

L TO

LERA

NC

E ("

t") T

O A

GRE

E

NU

MB

ER.

ON

2 P

LAC

E D

ECIM

ALS

IS +

.O2

ON

ALL

AN

GLE

S IS

+ .5

OF

A D

EGR

EE

ON

HO

LES

SIZE

S PE

R E

-205

6

ON

3 P

LAC

E D

ECIM

ALS

IS +

.OO

2C

ON

TRO

L B

OAR

D S

CH

EMAT

ICD

C-1

000

CR3CURRENT

ACTIVATEDREED SWITCH

SW4

SW4

SW.4A

J.J

.

266

2-1

9-93

G



IDEALARC DC1000

Firing PC Board (G1486-5 and above) Schematic



IDEALARC DC1000

Output Snubber (M14312) Schematic

600V.05C7

600V.05C8

160J320VTP7

160J320VTP8

NEG1

POS1

WELDER

HAVING A COMMON CODE.

19699

NONE

A.N.S.I. ELECTRICAL SYMBOLS PER E1537

DIAGRAM, MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS

S

OUTPUT

STUDS

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

MFD/VOLTS=CAPICITORS

(+)

(-)

MCW 4-10-90 19699

CA

NA

DA

SCALE

SUP'S'D'G.DATEDR. NO.

ON HOLES SIZES PER E-2056

SHT.

ON 3 PLACE DECIMALS IS + .OO2

AUST

RAL

IA

ON ALL ANGLES IS + .5 OF A DEGREEMATERIAL TOLERANCE ("t") TO AGREE

UNLESS OTHERWISE SPECIFIED TOLERANCE

CHK.

ON 2 PLACE DECIMALS IS + .O2

Ch'ge.Sht.No.

WITH PUBLISHED STANDARDS

FRA

NC

E

SUBJECTCLEVELAND, OHIO U.S.A.

S

THE LINCOLN ELECTRIC CO. TYPEEQUIP.

1

TO FRAME

OUTPUT SNUBBER SCHEMATIC

DC-1000

J.J.

2-19-93G

C7

TP7

C8

TP8

OU

TPU

T SN

UB

BER

GND

NEG

POS

M14312-1


SVM123-A IDEALARC DC 1000 - Red-D-Arc.com

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