SVM123-A
TM
July, 1996
IDEALARC DC 1000
For use with Machine Code Numbers: 9919
9920
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK
can kill.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
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 bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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iii
iii
SAFETY
WELDING SPARKS can
CYLINDER may explode
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
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. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety .....................................................................................................................................................i - iv
Installation......................................................................................................................................Section A
Technical Specifications............................................................................................................................A-2
Safety Precautions ....................................................................................................................................A-3
Select Proper Location ..............................................................................................................................A-3
Electrical Input Connections......................................................................................................................A-3
Reconnect Procedures..............................................................................................................................A-4
Output Connections...................................................................................................................................A-8
Operation........................................................................................................................................Section B
Safety Precautions ...................................................................................................................................B-2
General Description...................................................................................................................................B-3
Recommended Processes and Equipment ...............................................................................................B-3
Operational Features and Controls ...........................................................................................................B-3
Design Features and Advantages .............................................................................................................B-3
Welding Capacity.......................................................................................................................................B-4
Controls and Settings ................................................................................................................................B-5
Operating Steps.........................................................................................................................................B-6
Remote Control of Machine Operation......................................................................................................B-6
Welding Proceure Recommendations.......................................................................................................B-6
Semi-Automatic and Automatic Wire Feeding with a DC-1000 and Wire Feeders............................B6 - B-8
Accessories....................................................................................................................................Section C
Options/Accessories..................................................................................................................................C-2
Meters .......................................................................................................................................................C-2
Remote Output Control (Optional).............................................................................................................C-2
Connections for Wire Feeder Control...............................................................................................C-2 - C-6
Maintenance...................................................................................................................................Section D
Safety Precautions ....................................................................................................................................D-2
Routine and Periodic Maintenance ...........................................................................................................D-2
Major Component Locations .....................................................................................................................D-3
Theory of Operation.......................................................................................................................Section E
General Description...................................................................................................................................E-2
Input Line voltage, Connector, and Main Transformer ..............................................................................E-2
Output, Rectification, Control, and Feedback............................................................................................E-3
Protection Devices and Circuits (Contactor Hold-In).................................................................................E-4
SCR Operation ..........................................................................................................................................E-5
Troubleshooting.............................................................................................................................Section F
How to Use Troubleshooting Guide...........................................................................................................F-2
PC Board Troubleshooting Procedures.....................................................................................................F-3
Troubleshooting Guide....................................................................................................................F-4 - F-12
Test Procedures............................................................................................................................F-13 - F-37
Oscilloscope Waveforms...............................................................................................................F-38 - F-44
Replacement Procedures ........................................................................................................................F-45
Retest After Repair ..................................................................................................................................F-63
Electrical Diagrams .......................................................................................................................Section G
Parts Manual..........................................................................................................................................P-146
IDEALARC DC - 1000
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A-1
A-1
INSTALLATION
TABLE OF CONTENTS
-INSTALLATION SECTION-
INSTALLATION..................................................................................Section A
Technical Specifications........................................................................A-2
Safety Precautions ................................................................................A-3
Select Proper Location ..........................................................................A-3
Stacking ..........................................................................................A-3
Tilting ..............................................................................................A-3
Electrical Input Connections..................................................................A-3
Fuses and Wire Sizes.....................................................................A-4
Ground Connection.........................................................................A-4
Input Power Supply Connections....................................................A-4
Reconnect Procedures..........................................................................A-4
Output Connections...............................................................................A-8
Electrode and Work Leads..............................................................A-8
Auxiliary Power ...............................................................................A-8
Connection for Wire Feeder Control ...............................................A-8
Connection for Air Carbon Arc........................................................A-9
IDEALARC DC-1000
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – IDEALARC DC - 1000
INPUT - THREE PHASE ONLY
Standard Voltage
Input Current at Rated Output
193/96.5/77
230/460/575
RATED OUTPUT
Duty Cycle
100%
Amps
1000
1140
Volts at Rated Amperes
44
44
60%
55%
1250
44
OUTPUT
Mode
Current Range
140 to 1250 Amps
140 to 1250 Amps
140 to 625 Amps
Maximum Open
Circuit Voltage
75 VDC
Auxiliary
Power
115 VAC, 8 Amps
Constant Current
Constant Voltage
Constant Voltage
(@500 Amp Stud)
RECOMMENDED INPUT WIRE AND FUSE SIZES
Type 75C Copper
Ground Wire in
Conduit AWG (IEC)
Sizes
Type 75C Copper
Wire in Conduit
AWG (IEC) Sizes
Input Ampere Rating on
Nameplate
Fuse (Super Lag)
or Breaker Size
Input
Voltage/Frequency
2
2
230/60
430/60
575/60
4 (25mm )
300
193
000 (85mm )
2
2
3 (26.7mm )
6 (16mm )
150
125
96.5
2
2
6 (16mm )
6 (16mm )
77
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
30.75 in
(781 mm)
22.25 in
(567 mm)
38.0 in
(965 mm)
821 Ibs
(372 kg)
IDEALARC DC-1000
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A-3
A-3
INSTALLATION
Read entire Installation Section before installing
the IDEALARC DC-1000.
STACKING HOLE
SAFETY PRECAUTIONS
WARNING
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 or
working on the equipment.
•
•
Do not touch electrically hot parts.
Always connect the IDEALARC DC-1000
grounding terminal to a good electrical
earth ground.
STACKING PIN
____________________________________________________
FIGURE A.1 - Stacking IDEALARC DC-1000
Machines
SELECT PROPER LOCATION
TILTING
Place the IDEALARC DC-1000 where clean, dry air
can freely circulate in through the front intake and out
through the rear louvers. Dirt, dust, or any foreign
material that can be drawn into the machine should be
kept at a minimum. Not following these precautions
can result in the nuisance shutdown of the machine
because of excessive operating temperatures.
The IDEALARC DC-1000 must be placed on a stable,
level surface so it will not topple over.
ELECTRICAL INPUT
CONNECTIONS
STACKING
Before installing the machine, check that the input
supply voltage, phase, and frequency are the same as
the machine’s voltage, phase, and frequency as spec-
ified on the machine’s rating plate on the Case Front
Assembly Control Panel. Connect input power supply
by removing the rear access panel and connecting to
the three line terminals on the input panel. See Figure
A.2 for the location of the machine’s input cable entry
opening and reconnect panel assembly for dual volt-
age machines.
WARNING
FALLING EQUIPMENT can
cause injury.
•
Do not lift this machine using lift bale if it
is equipped with a heavy accessory such
as trailer or gas cylinder.
Lift only with equipment of adequate lifting
capacity.
•
•
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 supporting
the total weight of two machines (1642
pounds/744 kilograms).
2. Set the bottom machine in place.
3. Stack the second machine on top of it by aligning
the two holes in the base rails of the second
machine with the two pins on top front of the bot-
tom machine.
NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
Figure A.1.
FIGURE A.2 - Input Power Supply Connection
IDEALARC DC-1000
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A-4
A-4
INSTALLATION
FUSE AND WIRE SIZES
RECONNECT PROCEDURE
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or ther-
mal/magnetic circuit breakers.
Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine’s rating
plate. Before installing the machine, check that the
Reconnect Panel in the Input Box Assembly is con-
nected for the proper voltage.
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in nui-
sance tripping caused by inrush current even when
machine is not being used for welding at high output
currents.
CAUTION
Failure to follow these instructions can cause immedi-
ate failure of components within the machine.
Use input and grounding wire sizes that meet local
electrical codes, or see the Technical Specifications
page in this manual.
____________________________________________________
To reconnect a multiple voltage machine to a different
voltage, remove input power and follow the Input
Connection Diagram located on the inside of Case
Back Input Access Door. These connection diagrams
are listed below:
GROUND CONNECTION
Ground the frame of the machine. A ground terminal
marked with the symbol
is located inside the Case
1. For 460 single voltage, 230/460 Dual Voltage,
220/440 Dual Voltage, 415 Single Voltage or 575
Single Voltage, refer to Figure A.3a.
Back of the machine. Access to the rear input panel is
at the upper rear of the machine. See your local and
national electrical codes for proper grounding meth-
ods.
2. For 380 Single Voltage Machines, refer to Figure
A.3b.
INPUT POWER SUPPLY CONNECTIONS
3. For 380/500 Dual Voltage Machines, refer to
Figure A.3c.
A qualified electrician should connect the input power
supply leads.
4. For 220/380/440 Triple Voltage Machines, refer to
Figure A.3d
1. Follow all national and local electrical codes.
2. Follow Input Supply Connection Diagram located
on the inside of the machine.
3. Use a three-phase line.
4. Remove Input Access Door at upper rear of
machine.
5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input terminals on the recon-
nect panel. See Figure A.2
IDEALARC DC-1000
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A-5
A-5
INSTALLATION
WARNING
All input power must be electrically disconnected before touching panel.
____________________________________________________
CONNECTION FOR UNDER 300 VOLTS
1. Mount the movable reconnect panel to the stationary
reconnect panel studs in the position shown, and
secure firmly with the nine hex nuts provided.
2. Conect L1, L2, and L3 input supply lines and H1 and
H2 control transformer leads to the input side of the
reconnect panel.
3. Insulate unused H3 lead terminal with adequate tape
to provide at least 600 volt insulation.
4. Connect terminal marked
Electrical Code.
to ground per National
CONNECTION FOR OVER 300 VOLTS
1. 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 nuts
provided. Secure the three remaining hex nuts over
the remaining three studs for future use.
2. Conect L1, L2, and L3 input supply lines and H1 and
H3 control transformer leads to the input side of the
reconnect panel.
3. Insulate unused H2 lead terminal with adequate tape
to provide at least 600 volt insulation.
4. Connect terminal marked
Electrical Code.
to ground per National
FIGURE A.3a - Input Connection Diagram
WARNING
All input power must be electrically disconnected before touching panel.
____________________________________________________
CONNECTION FOR 380 VOLTS
1. Conect L1, L2, and L3 input supply lines and H1 and
H3 Control Transformer Leads to the Input
Terminals as shown.
2. Connect terminal marked
Electrical Code.
to ground per National
FIGURE A.3b - Input Connection Diagram
IDEALARC DC-1000
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A-6
A-6
INSTALLATION
WARNING
All input power must be electrically disconnected before touching panel.
____________________________________________________
CONNECTION FOR 380 VOLTS
1. Mount the movable reconnect panel to the stationary
reconnect panel studs in the position shown, and
secure firmly with the nine hex nuts provided.
2. Connect L1, L2, and L3 input supply lines and H1
and H2 control transformer leads to the input side of
the reconnect panel.
3. Insulate unused H3 and H4 lead terminal with ade-
quate tape to provide at least 600 volt insulation.
4. Connect terminal marked
Electrical Code.
to ground per National
CONNECTION FOR 500 VOLTS
1. 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 nuts
provided. Secure the three remaining hex nuts over
the remaining three studs for future use.
2. Connect L1, L2, and L3 input supply lines and H1
and H4 control transformer leads to the input side of
the reconnect panel as shown
3. Insulate unused H2 and H3 lead terminal with ade-
quate tape to provide at least 600 volt insulation.
4. Connect terminal marked
Electrical Code.
to ground per National
FIGURE A.3c -Input Connection Diagram
IDEALARC DC-1000
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A-7
A-7
INSTALLATION
WARNING
All input power must be electrically disconnected before touching panel.
____________________________________________________
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 hex
bolt, push the link completely forward, and securely
tighten all hex bolts. Do not remove hex bolts at any
time.
2. Connect L1, L2, and L3 input supply lines and H1
and H4 control transformer leads to input terminals
as shown.
3. Insulate unused H2 and H3 lead terminal with ade-
quate tape to provide at least 600 volt insulation.
4. Connect terminal marked
Electrical Code.
to ground per National
CONNECTION FOR 380 VOLTS 50 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 hex
bolt, push the link completely forward, and securely
tighten all hex bolts. Do not remove hex bolts at any
time.
2. Connect L1, L2, and L3 input supply lines and H1
and H3 control transformer leads to input terminals
as shown.
3. Insulate unused H2 and H4 lead terminal with ade-
quate tape to provide at least 600 volt insulation.
4. Connect terminal marked
Electrical Code.
to ground per National
CONNECTION FOR 220 VOLTS 50 Hz. (230V 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 hex
bolt, push the link completely forward, and securely
tighten all hex bolts. Do not remove hex bolts at any
time.
2. Connect L1, L2, and L3 input supply lines and H1
and H2 control transformer leads to input terminals
as shown.
3. Insulate unused H3 and H4 lead terminal with ade-
quate tape to provide at least 600 volt insulation.
4. Connect terminal marked
Electrical Code.
to ground per National
FIGURE A.3d - Input Supply Connection Diagram
IDEALARC DC-1000
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A-8
A-8
INSTALLATION
3. Connect electrode lead to the desired terminal
(positive or negative) and tighten the output ter-
minal nut with a wrench.
OUTPUT CONNECTIONS
See Table A.1 for recommended IDEALARC DC-1000
cable sizes for combined length of electrode and work
cables.
4. Connect the second work lead to the other out-
put terminal (positive if negative is attached and
vice versa) following steps 2 and 3.
TABLE A.1
Suggested Copper Cable Sizes - 100% Duty Cycle
Combined Lengths of Electrodes and Work Cables
AUXILIARY POWER
This machine supplies the 115 volt, AC power need-
ed for operating wire feeding equipment. The power
is available from terminals #31 and #32 on the termi-
nal strip. An 8 amp slow blow fuse on the machine
control panel protects the auxiliary power from
excessive overloads. The circuit has a 1000 volt-
ampere rating.
Amperes
Length
Cable Size
1000
0 - 250 ft.
(76.2m)
3-3/0
2
(3 x 85.0 mm )
CONNECT ELECTRODE AND WORK
LEADS TO OUTPUT TERMINALS
CONNECTION FOR SEMI-AUTOMATIC
OR AUTOMATIC WIRE FEEDER
CONTROL
The output terminals are located on the lower case
front and labeled “+” and “-”. See Figure A.4. There
are 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 to
minimize the possibility of accidental contact by an
object or a person.
With the DC-1000 turned off, the control cable from
the semi-automatic or automatic wire feeding equip-
ment is connected to the terminal strip. A strain relief
box connector is provided for access into the termi-
nal strip section. A chassis grounding screw is also
provided below the terminal strip marked with the
The 1000 amp output connections provide the full
rated output range of the machine.
symbol
for connecting the wire feeding equip-
The 500 amp output connections provide enhanced
lower current arc characteristics, especially for sub-
merged arc and GMAW procedures below 450 amps.
ment grounding wire. See the appropriate connec-
tion diagram for the exact instructions for the wire
feeder being used. A spare plugged hole is provided
in case an additional box connector is required.
1. Set the ON/OFF PUSH BUTTON to OFF.
2. Insert the electrode lead through the oval opening
in the lower shelf of the front case, closest to the
desired polarity (positive or negative). Pull through
enough cable to reach the output terminals.
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
Tractors
}
LT-56
FIGURE A-4 - Output Terminals
IDEALARC DC-1000
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A-9
A-9
INSTALLATION
3. If necessary, disconnect all wire feeder control
cable connections from the DC-1000 terminal
strip.
CONNECTION FOR AIR/CARBON ARC
CUTTING OPERATION
WARNING
4. Remove the leads from the unit by pulling them
through and out of the strain relief box connector
(s).
THE OUTPUT TERMINALS ARE ENERGIZED AT
ALL TIMES WHEN THE IDEALARC DC-1000 IS
CONNECTED FOR AIR/CARBON ARC CUTTING.
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) position
for air/carbon arc cutting.
1. Set ON/OFF PUSH BUTTON to OFF.
2. Locate and open the access door on the Front
Case Assembly.
IDEALARC DC-1000
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A-10
A-10
NOTES
IDEALARC DC-1000
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B-1
B-1
OPERATION
TABLE OF CONTENTS
-OPERATION SECTION-
OPERATION...................................................................................................................................Section B
Safety Precautions..............................................................................................................................B-2
General Description............................................................................................................................B-3
Recommended Processes and Equipment............................................................................B-3
Operational Features and Controls........................................................................................B-3
Design Features and Advantages..........................................................................................B-3
Welding Capacity...................................................................................................................B-4
Controls and Settings .........................................................................................................................B-5
Operating Steps..................................................................................................................................B-6
Remote Control of Machine Operation ...............................................................................................B-6
Welding Procedure Recommendations ..............................................................................................B-6
Semi-Automatic and Automatic Wire Feeding with a DC-1000 and Wire Feeders.............................B-6
NA-3 Automatic Wire Feeder.................................................................................................B-6
Good Arc Striking Guidelines....................................................................................B-7
Arc Striking with IDEALARC DC-1000 and the NA-3 Start Board ............................B-7
NA-5 Automatic Wire Feeder.................................................................................................B-8
LN-8 Semi-Automatic Wire Feeder........................................................................................B-8
LN-7 and LN-9 Semi-Automatic Wire Feeders ......................................................................B-8
IDEALARC DC-1000
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B-2
B-2
OPERATION
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts such as
output terminals or internal wiring.
•Insulate yourself from the work and ground.
•
Always wear dry insulating gloves.
____________________________________________________
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
____________________________________________________
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
•
Do not weld, cut or gouge on containers that
have held combustibles.
____________________________________________________
ARC RAYS
can burn.
• Wear eye, ear and body protection.
____________________________________________________
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.
IDEALARC DC-1000
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B-3
B-3
OPERATION
OPERATIONAL FEATURES AND
CONTROLS
GENERAL DESCRIPTION
The IDEALARC DC-1000 is an SCR-controlled, three
phase, welding and cutting power source. It uses a
single range potentiometer to control:
The IDEALARC DC-1000 comes with the following
standard controls:
•
DOUBLE ON/OFF PUSH BUTTON (Main Power
and 115V Auxiliary)
OUTPUT CONTROL POTENTIOMETER
OUTPUT CONTROL SWITCH (Remote or
Machine Control)
•
Submerged Arc Semi-Automatic or Automatic
Welding
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.
•
•
•
•
•
•
•
•
•
WELDING MODE SWITCH
•
CONTROL CIRCUIT POLARITY SWITCH
POWER SOURCE PILOT LIGHT
DC AMMETER (OPTIONAL)
DC VOLTMETER (OPTIONAL)
The IDEALARC DC-1000 has a three-position
Welding Mode Switch to enable the user to operate in
one of three modes:
DESIGN FEATURES AND
ADVANTAGES
The following list of design features will help you
understand the machine’s total capabilities and how
you can take advantage of them to get maximum use
of your machine.
•
•
•
Constant Voltage (CV) Innershield®
Constant Voltage (CV) Submerged Arc
Variable Voltage (VV) - Constant Current (CC)
Submerged Arc
•
Excellent arc characteristics for optimum constant
voltage submerged arc and Innershield® welding
performance.
The IDEALARC DC-1000 can be easily connected to
wire feeding equipment, including:
•
•
•
•
•
•
A control circuit designed to provide good starting
for a large variety of processes and procedures.
Output Control Potentiometer that provides easy
single range continuous control.
Output Control Switch that provides simple switch-
ing from local to remote control.
•
Semi-automatic wire feeders LN-7, LN-8, and
LN-9
Automatic wire feeders NA-3 and NA-5
Tractors LT-56 and LT-7
•
•
Red neon pilot light to confirm that the Input
Contactor is energized.
RECOMMENDED PROCESSES AND
EQUIPMENT
Auxiliary power source to provide 115-volt AC
power (1000 VA) to wire feeding equipment.
Multi-functional terminal strip for easy connection
of wire feeding control cables and switching
between CV Innershield® and CV Submerged Arc
welding when using the Dual Process or Dual
Procedure Kits.
Recessed output terminals to help prevent any
person or object from accidentally coming into
contact with the output current. These terminals
are prominently labeled positive and negative for
easy identification.
The IDEALARC DC-1000 is recommended for the fol-
lowing welding or cutting processes within its output
capacity of 140 amps to 1250 amps (625 amps at 500
amp output stud) in the Constant Voltage mode, and
140 amps to 1250 amps in the Variable Voltage
(Constant Current) mode:
•
•
Submerged Arc Semi-Automatic or Automatic
Welding
Open Arc Semi-Automatic or Automatic Welding
Air/Carbon Arc Cutting (Carbon Rod Sizes up to
5/8” [15.9 mm] Diameter)
•
•
•
•
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 repetitive
welding applications.
IDEALARC DC-1000
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B-4
B-4
OPERATION
•
Three circuit solid state control system provides
•
Enclosure designed with air intake louvers that
maximum 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.
keep dripping water from entering the unit, allow-
ing outdoor operation. Transformer, SCR bridge,
and choke have special corrosion resistant paint
for added protection.
•
•
•
•
Easily removed case side, even when stacked.
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 keeping
the input contactor open until the machine cools to normal operating temperature. The machine can then be
restarted by pushing the ON/OFF push button.
Duty Cycle
55% (Based on 10 min.)
60% (Based on 10 min.)
100%
Amps
1250
1140
1000
Volts
44
Hertz
50/60
50/60
50/60
44
44
IDEALARC DC-1000
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B-5
B-5
OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the Case Front Assembly of the IDEALARC DC-1000. See
Figure B.1 for the location of each control.
FIGURE B.1 - Control Panel Keys
1. ON/OFF PUSH BUTTON: This push button turns
5. CONTROL CIRCUIT POLARITY SWITCH: This
toggle switch is used to set power source voltage
sensing polarity to match the polarity to which the
electrode is connected to the machine. This pro-
vides the correct polarity at the terminal strip for
correct operation of the automatic wire feeding
equipment powered by the auxiliary power from
the power source.
the machine ON or OFF
2. OUTPUT CONTROL POTENTIOMETER: This
control provides tapered, continuous control of the
machine output. The control can be rotated from
minimum to maximum while machine is under
load to adjust the machine output.
3. WELDING MODE SWITCH: This toggle switch is
used to select the proper welder performance
characteristics for the process being used. There
are three modes: CV (Constant Voltage)
Innershield®, CV (Constant Voltage) Submerged
Arc, and VV (Variable Voltage) CC (Constant
Current) Submerged Arc.
6. POWER SOURCE PILOT LIGHT: The red neon
light glows when the power source input contactor
is energized.
7. VOLTMETER: An optional voltmeter is available.
8. AMMETER: An optional ammeter is available.
4. OUTPUT CONTROL SWITCH: This toggle switch
is used to switch between “Output Control at DC-
1000” for local control of machine output and
“Output Control Remote” for remote control of
machine output.
IDEALARC - DC 1000
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B-6
B-6
OPERATION
WELDING PROCEDURE
RECOMMENDATIONS
Select Welding Mode Switch position based on type of
welding to be done.
OPERATING STEPS
The following procedures are for using the IDEALARC
DC-1000 in the local control mode of operation. For
remote control of the machine, see the Remote
Control of Machine Operation section.
1
Innershield® Welding/Other Open Arc Processes:
Use the CV Innershield® mode.
Before operating the machine, make sure you have all
materials needed to complete the job. Be sure you are
familiar with, and have taken all possible safety pre-
cautions before starting work. It is important that you
follow these operating steps each time you use the
machine.
2. Submerged Arc Welding: Use the CV Submerged
Arc mode. If performing high speed welding,
switch between the CV Submerged Arc and the
CV Innershield® mode and use the mode that
produces the best welding results. High Current,
Large Puddle Submerged Arc Welding: Use the
VV (CC) mode.
1. Turn on the main AC power supply to the
machine.
2. Set the CONTROL CIRCUIT POLARITY SWITCH
to the appropriate position.
3. When the IDEALARC DC-1000 is used for
Air/Carbon Arc cutting, use the CV (I) mode and
initially set the OUTPUT CONTROL POTEN-
TIOMETER to “9”. Based on the size of the car-
bon being used, turn the potentiometer to a lower
setting as required to obtain the best results. You
can use carbon rods up to 5/8” (15.9 mm) in diam-
eter. The welder protection circuit protects the
machine from extremely high short circuiting puls-
es.
- Set toggle to “Electrode Negative” position if the
electrode is connected to the negative (-) output
terminal.
- Set toggle to “Electrode Positive” position if the
electrode is connected to the positive (+) output
terminal.
3. Set the WELDING MODE SWITCH to welding
process being used.
SEMI-AUTOMATIC AND
AUTOMATIC WIRE FEEDING WITH
IDEALARC DC-1000 AND WIRE
FEEDERS
- CV Innershield®
- CV Submerged Arc
- VV (CC)
4. Push the ON/OFF PUSH BUTTON to the ON
position.
NA-3 AUTOMATIC WIRE FEEDER
1. Set the DC-1000 Output Control Switch to
Remote.
- The red neon light glows.
- The fan starts.
NOTE: Later model NA-3 automatic wire feeders are
capable of cold starts when the NA-3 Mode switch is
in the CV or VV (CC) mode position. Some earlier
models are capable of cold starting only in the VV
(CC) mode position. Cold starting enables you to
inch the wire down to the work, automatically stop,
and automatically energize the flux hopper valve.
5. Set Output Control Potentiometer to desired volt-
age or current.
6. Make the weld (NOTE: Terminal #2 and #4 must
be connected together to energize the machine
output).
REMOTE CONTROL OF MACHINE
OPERATION
2. Set the DC-1000 welding mode switch for the
desired process: CV Submerged Arc, CV
Innershield® mode or VV (CC) mode.
The toggle switch on the control panel labeled “Output
Control at DC-1000” - “Output Control Remote” gives
the operator the option of controlling the machine out-
put from a remote location. If in the Remote position, a
wire feeder with remote control capabilities or a
remote 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 remote
information.
3. Set the NA-3 mode Switch Position to either CV or
VV (CC) to match the DC-1000 mode selected in
step 2.
4. Refer to the NA-3 operators manual for instruc-
tions on how to use the NA-3 in conjunction with
the DC-1000.
5. Follow the following guidelines for good arc strik-
ing detailed below for each welding mode.
IDEALARC DC-1000
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B-7
B-7
OPERATION
ARC STRIKING WITH IDEALARC DC-1000 AND
THE NA-3 START BOARD
GOOD ARC STRIKING GUIDELINES FOR THE
NA-3 WITH THE IDEALARC DC-1000 IN THE CV
INNERSHIELD®, CV SUBMERGED ARC OR VV
(CC) WELDING MODES.
When electrical strikeouts exceed 1 3/4” (44.4 mm) an
NA-3 Start Board may be required to improve arc
striking. When the NA-3 Start Board is used to
improve arc striking, use the following procedures:
Following are some basic arc striking techniques that
apply 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. Set start time at 0.
2. Set NA-3 start current and start voltage at mid
range.
1. Cut the electrode to a sharp point.
3. Set the NA-3 output current and voltage to the
proper settings for the welding procedure to be
used.
2. Set the NA-3 Open Circuit Voltage Control to the
same dial setting as the Arc Voltage Control. If
this is a new welding procedure, a good starting
point is to set the Open Circuit Voltage Control to
#6.
4. Turn the Start Board Timer to maximum.
5. Set Start Board current and voltage control.
NOTE: The open circuit voltage of the IDEALARC
DC-1000 varies from approximately 25 volts to 75
volts in the CV Innershield or CV Submerged Arc
modes. The open circuit voltage is constant in the
VV (CC) mode.
a.
b.
Set the Start Board current control to 1-
1/2 dial numbers below that set on the
NA-3 current control.
Set the Start Board voltage control equal
with the NA-3 voltage control setting
3. Run a test weld. Set proper current, voltage, and
travel speed.
NOTE: These Start Board current and voltage set-
tings result in a start-up current that is lower than
the NA-3 current setting and approximately equal
with the NA-3 voltage setting for the desired weld-
ing procedure.
a.
For the best starting performance, the
NA-3 Open Circuit Voltage Control and
Voltage Control setting should be the
same. Set the Inch Speed Control for the
slowest inch speed possible.
6. Establish the correct arc striking procedure with
the NA-3 Start Board timer set at maximum.
b.
To adjust the Open Circuit Voltage Control
to get the best starting performance, make
repeated starts observing the NA-3 volt-
meter.
a.
For the best starting performance, the
NA-3 Open Circuit Voltage Control and
Voltage Control setting should be the
same. Set the Inch Speed Control for the
slowest inch speed possible.
When the voltmeter pointer swings smoothly up to the
desired arc voltage, without undershooting or over-
shooting the desired arc voltage, the Open Circuit
Voltage Control is set properly.
b.
To adjust the Open Circuit Voltage Control
to get the best starting performance, make
repeated starts observing the NA-3 volt-
meter.
If the voltmeter pointer overshoots the desired voltage
and then returns back to the desired voltage, the
Open Circuit Voltage Control is set too high. This can
result in a bad start where the wire tends to “Blast off.”
When the voltmeter pointer swings smoothly up to the
desired arc voltage, without undershooting or over-
shooting the desired arc voltage, the Open Circuit
Voltage Control is set properly.
If the voltmeter pointer hesitates before coming up to
the desired voltage, the Open Circuit Voltage Control
is set too low. This can cause the electrode to stub.
If the voltmeter pointer overshoots the desired voltage
and then returns back to the desired voltage, the
Open Circuit Voltage Control is set too high. This can
result in a bad start where the wire tends to “Blast off.”
4. Start and make the weld.
a.
Cold starts. For cold starts, be sure the
work piece is clean and the electrode
makes positive contact with the work
piece.
If the voltmeter pointer hesitates before coming up to
the desired voltage, the Open Circuit Voltage Control
is set too low. This can cause the electrode to stub.
b.
Hot “On the Fly” starts. For hot starts, trav-
el should begin before the wire contacts
the work piece.
IDEALARC DC-1000
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B-8
B-8
OPERATION
c.
Set NA-3 Start Board current and voltage
as close to the welding procedure current
and voltage as possible.
LN-8 SEMI-AUTOMATIC WIRE FEEDER
To use the LN-8 Semi-Automatic Wire Feeder with
IDEALARC DC-1000
NOTE: The Start Board current and volt-
age should be as close as possible to the
welding procedure current and voltage,
while still getting satisfactory starts.
1. Set the IDEALARC DC-1000 WELDING MODE
SWITCH to either CV Innershield® mode or CV
Submerged Arc mode depending on the welding
process being used.
d.
Set the start time to as low a time as possi-
ble while still getting satisfactory starts.
2. Set the IDEALARC DC-1000 OUTPUT CONTROL
SWITCH to the REMOTE position.
7. Start and make the weld.
3. Set the LN-8 Welding Mode Switch to the CV
position. The LN-8 Welding Mode Switch is locat-
ed on the variable voltage VV (CC) board.
IDEALARC DC-1000 POWER SOURCE
SETTING WHEN CONNECTED TO NA-5
AUTOMATIC WIRE FEEDER
4. Refer to the LN-8 Operator’s Manual for instruc-
tions on how to use the LN-8.
When using the IDEALARC DC-1000 with the NA-5
automatic wire feeder, set the controls on the IDE-
ALARC DC-1000 as follows for the best performance:
LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
FEEDERS OR OTHER CONSTANT WIRE
FEEDERS
1. Turn OFF main AC input power supply to the IDE-
ALARC DC-1000.
To use the LN-7, LN-9, or other constant wire feed
speed semi-automatic wire feeders with IDEALARC
DC-1000
2. Connect the electrode cables to terminal
polarity to be used.
3. Set the CONTROL CIRCUIT POLARITY SWITCH
to the same polarity as the electrode cable con-
nection.
1. Set the IDEALARC DC-1000 WELDING MODE
SWITCH to either CV Innershield® mode or CV
Submerged Arc mode depending on the welding
process being used.
4. Set the OUTPUT CONTROL SWITCH to
REMOTE.
NOTE: These semi-automatic wire feeders cannot be
used in the VV (CC) mode.
5. Set the IDEALARC DC-1000 WELDING MODE
SWITCH to the position that matches the welding
process being used.
2. Set the IDEALARC DC-1000 OUTPUT CONTROL
SWITCH.
a.
For submerged arc welding, set WELDING
MODE SWITCH TO CV SUBMERGED
ARC position.
a.
b.
LN-7: Use either an optional K775 Remote
Control Box Assembly or set the IDE-
ALARC DC-1000 OUTPUT CONTROL
SWITCH in the Local position.
b.
For all open arc welding processes set
WELDING MODE SWITCH TO CV
INNERSHIELD® position.
LN-9: Refer to the LN-9 Operator’s Manual
for instructions on how to use the LN-9.
6. Set the Open Voltage Control four volts higher
than the welding voltage, and the inch speed at
1/2 the welding wire feed speed for the initial test
weld.
7. Refer to NA-5 Operator’s Manual for instructions
on how to use the NA-5.
IDEALARC DC-1000
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C-1
C-1
ACCESSORIES
TABLE OF CONTENTS
-ACCESSORIES SECTION-
ACCESSORIES........................................................................................................................Section C
Options/Accessories....................................................................................................................C-2
Meters..........................................................................................................................................C-2
Remote Output Control................................................................................................................C-2
Connections for Wire Feeder Control..........................................................................................C-2
NA-3, or LT-7 ..................................................................................................................C-2
NA-5................................................................................................................................C-3
LN-8 ................................................................................................................................C-4
LN-9 ................................................................................................................................C-5
LN-7 ................................................................................................................................C-6
IDEALARC DC-1000
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C-2
C-2
ACCESSORIES
CONNECTING THE NA-3 OR LT-7 TO
IDEALARC DC-1000
OPTIONS/ACCESSORIES
•
•
•
•
•
•
•
Remote Control Box Assembly (K775)
LN-7
1. Disconnect main AC input power to the IDE-
ALARC DC-1000.
LN-8 Semi-Automatic Wire Feeders
}
}
LN-9
NA-3
NA-5
2. Set IDEALARC DC-1000 ON/OFF PUSH BUT-
TON to OFF.
Automatic Wire Feeders
LT-7 and LT-56 Tractors
3. Connect the wire feeder control cable leads to the
IDEALARC DC-1000 terminal strip as shown in
Figure C.1.
METERS
Optional factory-installed voltmeter and ammeter are
available.
REMOTE OUTPUT CONTROL -
(OPTIONAL)
The K775 Remote Output Control consists of a control
box 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 made
available by opening the terminal access cover on the
case front. This control will give the same control as
the output control on the machine.
CONNECTIONS FOR SEMI-AUTO-
MATIC OR AUTOMATIC WIRE
FEEDER CONTROL
1. Set the ON/OFF PUSH BUTTON to OFF.
2. Locate and open the hinged access door on the
Front Case Assembly.
FIGURE C.1 - NA-3 or LT-7 Wire Feeder
Connection to the IDEALARC DC-1000
3. Insert control cable through the strain relief box
connector and pull enough cable through to reach
the terminal strip.
4. Connect the wire feeder control cable ground lead
to the frame terminal marked
.
4. Connect the automatic wire feeder control cable to
the terminal strip. See corresponding connection
diagram in this section of the manual, or the
instructions included with the wire feeder.
CAUTION
The IDEALARC DC-1000 must be properly grounded.
____________________________________________________
5. Connect the wire feeder grounding wire to the
5. Extend wire feeder control cable lead #21 so it
can be connected directly to the work piece.
chassis ground screw marked with the symbol
.
NOTE: The IDEALARC DC-1000 Auxiliary Power
Circuit (at #31 and #32 on the terminal strip) supplies
115-volt AC power to the wire feeding equipment. The
circuit has a 1000 volt ampere rating. An 8-amp slow
blow fuse on the machine’s control panel protects the
auxiliary power supply from excessive overloads or
short circuits.
a.
Make a bolted connection using AWG #14
or larger insulated wire.
b.
Tape the bolted connection with insulating
tape.
NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.
c.
Keep the #21 lead electrically separate
from the work cable circuit and connection.
IDEALARC DC-1000
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C-3
C-3
ACCESSORIES
d.
Tape the #21 lead to work cable for ease
of use.
5. Extend wire feeder control cable lead #21 so it
can be connected directly to the work piece.
6. Connect the welding cables as shown in Figure
C.1.
a.
Make a bolted connection using AWG #14
or larger insulated wire.
NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.
b.
Tape the bolted connection with insulating
tape.
NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.
NOTE: The connection diagram shown in Figure C.1
shows the electrode connected for positive polarity.
To change polarity:
c.
Keep the #21 lead electrically separate
from the work cable circuit and connection.
a.
b.
c.
d.
Set the IDEALARC DC-1000 ON/OFF
PUSH BUTTON to OFF.
d.
Tape the #21 lead to work cable for ease
of use.
Move the electrode cable to the Negative
(-) output terminal.
6. Connect NA-5 wire feeder control jumpers on the
Voltage Control Board. See NA-5 Operator’s
Manual.
Move the work cable to the Positive (+)
output terminal.
a.
Connect red jumper on Voltage Control
Board to pin “S.”
Set the IDEALARC DC-1000 CONTROL
CIRCUIT POLARITY SWITCH to NEGA-
TIVE.
b.
Connect white jumper on Voltage Control
Board to pin “B.”
e.
Reverse the leads at the back of the
ammeter and voltmeter on the wire feeder
automatic control box.
7. Connect the welding cables as shown in Figure
C.2.
NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.
CONNECTING THE NA-5 TO THE
IDEALARC DC-1000
NOTE: For optimum performance, use the NA-5 with
IDEALARC DC-1000 codes 8288 and above.
1. Disconnect main AC input power to the IDE-
ALARC DC-1000.
2. Set the IDEALARC DC-1000 ON/OFF PUSH
BUTTON to OFF.
3. Connect the wire feeder control cable leads to the
IDEALARC DC-1000 terminal strip as shown in
Figure 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 #73
on the terminal strip.
4. Connect the wire feeder control cable ground lead
to the frame terminal marked
.
CAUTION
The IDEALARC DC-1000 must be properly grounded.
____________________________________________________
FIGURE C.2 - NA-5 Wire Feeder Connection to
the IDEALARC DC-1000
IDEALARC DC-1000
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C-4
C-4
ACCESSORIES
NOTE: The connection diagram shown in Figure C.2
shows the electrode connected for positive polarity.
To change polarity:
a.
b.
c.
d.
Set the IDEALARC DC-1000 ON/OFF
PUSH BUTTON to OFF.
Move the electrode cable to the Negative
(-) output terminal.
Move the work cable to the Positive (+)
output terminal.
Set the IDEALARC DC-1000 CONTROL
CIRCUIT POLARITY SWITCH to NEGA-
TIVE.
e.
Refer to NA-5 operator’s manual for proper
control box polarity connections.
NOTE: For proper NA-5 operation, the electrode
cables must be secured under the clamp bar on the
left side of the NA-5 Control Box.
FIGURE C.3 - LN-8 Wire Feeder Connection
CONNECTING THE LN-8 TO THE
IDEALARC DC-1000
to 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.
1. Set the ON/OFF PUSH BUTTON to the OFF pos-
tion.
2. Disconnect AC input power to the IDEALARC DC-
1000.
9. Connect the welding cables as shown in Figure
C.3.
3. Connect the wire feeder control cable leads to the
DC-1000 terminal strip. See Figure C.3.
NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.
4. Connect the wire feeder control cable ground lead
to the frame terminal marked
.
10. Set the DC-1000 output control switch to the
”Output Control Remote” position.
CAUTION
NOTE: The connection diagram shown in figure C-3
The IDEALARC DC-1000 must be properly grounded.
shows electrode connected positive. To change polari-
ty:
____________________________________________________
a.
b.
c.
d.
Set the IDEALARC DC-1000 ON/OFF
PUSH BUTTON to OFF.
5. Extend the wire feeder control cable #21 lead so it
can be connected directly to the work piece.
Move the electrode cable to the Negative
(-) output terminal.
a.
Make a bolted connection using AWG #14
or larger insulated wire.
Move the work cable to the Positive (+)
output terminal.
b.
Tape the bolted connection with insulating
tape.
Set the IDEALARC DC-1000 CONTROL
CIRCUIT POLARITY SWITCH to NEGA-
TIVE.
NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.
c.
Keep the #21 lead electrically separate
from the work cable circuit and connection.
e.
Refer to LN-8 operator’s manual for proper
control box polarity connections.
d.
Tape the #21 lead to the work cable for
ease of use.
IDEALARC DC-1000
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C-5
C-5
ACCESSORIES
CONNECTING THE LN-9 WIRE FEEDER
TO 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 the
DC-1000 terminal strip. See Figure C.4.
4. Connect the wire feeder control cable ground lead
to the frame terminal marked
.
CAUTION
The IDEALARC DC-1000 must be properly grounded.
____________________________________________________
5. Extend the wire feeder control cable #21 lead so it
can be connected directly to the work piece.
FIGURE C.4 - LN-9 Wire Feeder Connection
a.
Make a bolted connection using AWG #14
or larger insulated wire.
to the IDEALARC DC-1000
11. Set the DC-1000 output control switch to the
”Output Control Remote” position.
b.
Tape the bolted connection with insulating
tape.
NOTE: The connection diagram shown in figure C-4
shows electrode connected for positive polarity. To
change polarity:
NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.
c.
Keep the #21 lead elecrically separate
from the work cable circuit and connection.
a.
b.
c.
d.
Set the IDEALARC DC-1000 ON/OFF
PUSH BUTTON to OFF.
d.
Tape the #21 lead to the work cable for
ease of use.
Move the electrode cable to the Negative
(-) output terminal.
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.
Move the work cable to the Positive (+)
output terminal.
Position the positive-negative switch on
the power source to correspond to the
polarity of the electrode cable connection.
9. Connect the welding cables as shown in Figure
C.4.
e.
Refer to LN-9 operating manual for
required polarity connections.
Note: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.
10. Connect LN-9 wire feeder jumpers on voltage
board as follows: See LN-9 operator’s manual.
a.
b.
White jumper on voltage board to pin “S”
Blue jumper on voltage board (later mod-
els) or on start board (earlier models) to
pin “B”.
IDEALARC DC-1000
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C-6
C-6
ACCESSORIES
CONNECTING THE LN-7 WIRE FEEDER TO
THE IDEALARC DC-1000
1. Set the IDEALARC DC-1000 ON/OFF PUSH
BUTTON to OFF.
2. Disconnect main AC input power to the IDE-
ALARC DC-1000.
3
Connect the wire feeder control cable leads to the
IDEALARC DC-1000 terminal strip as shown in
Figure C.5.
4. Connect the wire feeder control cable ground lead
to the frame terminal marked
.
CAUTION
The IDEALARC DC-1000 must be properly grounded.
____________________________________________________
5. PERFORM THIS STEP ONLY IF THE LN-7 IS
EQUIPPED WITH A METER KIT.
Extend wire feeder control cable lead #21 so it can be
connected directly to the work piece.
FIGURE C.5 - LN-7 Wire Feeder Connection to
the IDEALARC DC-1000
NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.
a.
Make a bolted connection using AWG #14
or larger insulated wire.
b.
Tape the bolted connection with insulating
tape.
NOTE: The connection diagram shown in Figure C.5
shows the electrode connected for positive polarity.
To change polarity:
NOTE: If the work cable length is less than 25 feet
and 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.
a.
b.
c.
d.
Set the IDEALARC DC-1000 ON/OFF
PUSH BUTTON to OFF.
Move the electrode cable to the Negative
(-) output terminal.
NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.
Move the work cable to the Positive (+)
output terminal.
b.
Keep the #21 lead electrically separate
from the work cable circuit and connection.
Set the IDEALARC DC-1000 CONTROL
POLARITY SWITCH to NEGATIVE.
c.
Tape the #21 lead to work cable for ease
of use.
6. Connect the welding cables as shown in Figure
C.5.
IDEALARC DC-1000
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D-1
D-1
MAINTENANCE
TABLE OF CONTENTS
-MAINTENANCE SECTION-
MAINTENANCE...................................................................................................Section D
Safety Precautions....................................................................................................D-2
Routine and Periodic Maintenance...........................................................................D-2
Major Component Locations.....................................................................................D-3
IDEALARC DC - 1000
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D-2
D-2
MAINTENANCE
3. Inspect the electrode cables for any slits or punc-
tures in the cable jacket, or any condition that
would affect the proper operation of the machine.
SAFETY PRECAUTIONS
WARNING
Perform Periodically:
ELECTRIC SHOCK
CAN KILL
Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure
D.1.
Only qualified personnel should
perform this maintenance.
•
•
•
•
•
•
Main transformer and choke
Electrode and work cable connections.
SCR rectifier bridge and heat sink fins.
Control board.
Turn the input power OFF at the disconnect switch or
fuse box before working on this equiptment.
Do not touch electrically hot parts.
____________________________________________________
ROUTINE AND PERIODIC
MAINTENANCE
Firing board.
Fan Assembly.
.....................................................................................
NOTE: The fan motor has sealed bearings which
require no maintenance.
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1
Perform the following daily:
1. Check that no combustible materials are in the
welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.
IDEALARC DC - 1000
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D-3
D-3
MAINTENANCE
FIGURE D.1 - Major Component Locations
IDEALARC DC-1000
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D-4
D-4
NOTES
IDEALARC DC-1000
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E-1
E-1
THEORY OF OPERATION
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
THEORY OF OPERATION SECTION. ................................................................Section E
General Description............................................................................................E-2
Input Line Voltage, Contactor, and Main Transformer .......................................E-2
Output Rectification, Control, and Feedback......................................................E-3
Protection Devices and Circuits (Contactor Hold-In)..........................................E-4
SCR Operation...................................................................................................E-5
FIGURE E.1 Block Logic Diagram
IDEALARC DC-1000
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E-2
E-2
THEORY OF OPERATION
GENERAL DESCRIPTION
range potentiometer ouptut control. It can be used
for submerged arc or open arc automatic and semi-
automatic welding.
The DC 1000 is an SCR - controlled DC power
source. It is designed to be controlled with a single
FIGURE E.2 - Input Line Voltage, Contactor and Main Transformer
INPUT LINE VOLTAGE, CONTAC-
TOR, AND MAIN TRANSFORMER
The desired three phase power is connected to the
DC-1000 through an Input Contactor located in the
input box at the rear of the machine. Two phases of the
input lines are also connected to the Control
Transformer which supplies power to the Contactor
Hold-In Circuit. The Contactor Hold-In Circuit will dis-
able the Input Contactor if the DC-1000 is overloaded
or overheated.
age, low current input power to a low voltage, high
current output. The finishes or “neutrals” of the
main secondary coils are connected together and
the six starts of the secondary windings are con-
nected to the rectifier assembly. In addition, the
main transformer also has an isolated 115 VAC
auxiliary winding that supplies 115 VAC to operate
the cooling fan and offers 8 amps of auxiliary power
to operate wire feeding equipment. The three 75
VAC phase angle windings are also housed in the
Main Transformer assembly. These windings pro-
vide power and “timing” to the Firing Board.
A Reconnect Panel allows the user to configure the
machine for the desired input voltage. This AC input
voltage is applied to the primary of the Main
Transformer. The transformer changes the high volt-
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
IDEALARC DC-1000
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3- Output, Rectification, Control and Feedback
OUTPUT RECTIFICATION,
CONTROL, AND FEEDBACK
proper amount of energy to the gates of the power
SCRs. 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 output
of the machine. See SCR Operation.
The neutrals of the Main Transformer secondary
windings are connected together and the six starts
are connected to the six SCR assemblies to form a
six phase output. This six phase AC output from the
Main Transformer secondary is rectified and con-
trolled through the SCR bridge. Output current is
sensed at the shunt, and output voltage is moni-
tored at the welding output terminals. This feedback
information is processed in the control board. The
control board compares the commands of the Mode
switch and the Output Control Potentiometer (or
Remote Control) with the feedback information and
sends the appropriate signal to the Firing Board.
The Pilot Relay signals the Firing Board circuit to
supply gate pulses to the SCR Bridge. Closing of
the Pilot Relay (a “dry” closure of leads #2 and #4)
also brings the Latching Resistor into the machine
output circuit. The Latching Resistor provides a
pre-load for the SCR Bridge.
In later models (above code 9500) a Choke and
separate 500 amp output terminal is provided to
enhance lower current arc characteristics, espe-
cially for submerged arc and GMAW procedures
below 450 amps.
The Firing Board is a three phase circuit. Each
phase provides two firing pulses, one for each of
the two Silicon Controlled Rectifiers (SCR) con-
trolled by that phase. The firing circuit supplies the
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
IDEALARC DC-1000
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 - Protection Devices and Circuits (Contactor Hold-In)
PROTECTION DEVICES AND
CIRCUITS (CONTACTOR HOLD-IN)
Two thermostats protect the DC-1000 from exces-
sive operating temperatures. Excessive operating
temperatures may be caused by a lack of cooling air
or operating the machine beyond the duty cycle and
output rating. If excessive operating temperature
should occur, the thermostat(s) will deactivate the
input contactor, turning the machine off. The input
contactor will remain open until the machine cools.
The machine can then be restarted by operating the
start push button.
The DC-1000 is also protected against high current
overloads. This electronic protection circuit senses
an overload on the power source and opens the
input contactor should the overload remain for a
predetermined time. If the overload is great the
machine will shut down immediately. The input con-
tactor will remain open until the start push button is
operated.
The Remote Control circuit is also protected from
“grounds” or voltage intrusions. If the #73, #74, #75,
#76 or #77 leads come in contact with either of the
machine’s output cables, the DC-1000 will only
operate at a minimum output or the input contactor
will open.
Upon restart, if the fan does not turn or the air intake
louvers are obstructed, then the input power must
be removed and the fan problem or air obstruction
be corrected.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
IDEALARC DC-1000
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 - SCR Operation
SCR OPERATION
An SCR is fired by a short burst of current into the
gate. This gate pulse must be more positive than
the cathode voltage. Since there is a standard PN
junction between gate and cathode, the voltage
between these terminals must be slightly greater
than 0.6 V. Once the SCR has fired it is not neces-
sary to continue the flow of gate current. As long as
current continues to flow from anode to cathode the
SCR will remain on. When the anode to cathode
current drops below a minimum value, called hold-
ing current, the SCR will shut off. This normally
occurs as the AC supply voltage passes through
zero into the negative portion of the sine wave. If
the SCR is turned on early in the positive half cycle,
the conduction time is longer resulting in greater
SCR output. If the gate firing occurs later in the
cycle the conduction time is less resulting in lower
SCR output.
A silicon controlled rectifier (SCR) is a three termi-
nal device used to control rather large currents to a
load. An SCR acts very much like a switch. When a
gate signal is applied to the SCR it is turned ON and
there is current flow from anode to cathode. In the
ON state the SCR acts like a closed switch. When
the SCR is turned OFF there is no current flow from
anode to cathode thus the device acts like an open
switch. As the name suggests, the SCR is a rectifi-
er, so it passes current only during positive half
cycles of the AC supply. The positive half cycle is
the portion of the sine wave in which the anode of
the 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 cycle
time in the on state and the remainder of the time in
the off state. The amount of time spent in the ON
state is controlled by the Gate.
IDEALARC DC-1000
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E-6
E-6
NOTES
IDEALARC DC-1000
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F-1
F-1
TROUBLESHOOTING & REPAIR
TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTION-
TROUBLESHOOTING AND REPAIR SECTION...............................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
Safety Precautions.................................................................................................................F-3
PC Board Troubleshooting Procedures.................................................................................F-3
Troubleshooting Guide ..........................................................................................................F-4
Output Problems .............................................................................................................F-4
Function Problems ..........................................................................................................F-9
Welding Problems.........................................................................................................F-11
Test Procedures
Control Transformer (T2) Voltage Test .........................................................................F-13
Main Transformer (T1) Voltage Test.............................................................................F-16
Firing Board Test...........................................................................................................F-20
Control Board Test........................................................................................................F-25
Static SCR Test.............................................................................................................F-30
Active SCR Test............................................................................................................F-34
Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform Constant Current Mode ..................................F-38
No Load
Normal Open Circuit Voltage Waveform Constant Voltage............................................F-39
Innershield - Maximum Output Setting - No Load
Normal Open Circuit Voltage Waveform Constant Voltage............................................F-40
Innershield - Minimum Output Setting - No Load
Typical Output Voltage Waveform - Machine Loaded Constant Voltage........................F-41
Innershield Mode
Typical Output Voltage Waveform - Machine Loaded ....................................................F-42
500 Amp Output Terminal Constant Voltage Innershield Mode
Typical SCR Gate Voltage Waveform Constant Voltage................................................F-43
Innershield Maximum Output Setting - No Load
Abnormal Open Circuit Voltage Waveform Constant Voltage ........................................F-44
Innershield One Output SCR Not Functioning Maximum Output Setting
Replacement Procedures
Input Contactor Cleaning and or Replacement.............................................................F-45
SCR Output Bridge Replacement .................................................................................F-49
SCR Output Bridge Removal..................................................................................F-50
Removal of Individual SCR Heat Sink Assemblies.................................................F-52
SCR Heat Sink Installation .....................................................................................F-53
SCR Output Bridge Installation...............................................................................F-53
Removal and Reassembly of Lift Bail ...........................................................................F-55
Removal of Lift Bail.................................................................................................F-56
Reassembly of Lift Bail ...........................................................................................F-57
Main Transformer Removal and Installation .................................................................F-58
Main Transformer Disassembly and Assembly ......................................................F-59
Main Transformer Disassembly..............................................................................F-60
Coil Removal and Replacement .............................................................................F-60
Transformer Reassembly .......................................................................................F-61
Retest After Repair ..............................................................................................................F-63
IDEALARC DC-1000
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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 and
machine 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.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
STEP 3. RECOMMENDED
COURSE OF ACTION
procedure listed below.
The last column labeled “Recommended
Course of Action” lists the most likely com-
STEP 1 LOCATE PROBLEM
ponents that may have failed in your
(SYMPTOM).
machine. It also specifies the appropriate
test procedure to verify that the subject
Look under the column labeled “PROBLEM
component is either good or bad. If there
(SYMPTOMS)”. This column describes
are a number of possible components,
possible symptoms that the machine may
check the components in the order listed to
exhibit. Find the listing that best describes
eliminate one possibility at a time until you
the symptom that the machine is exhibiting.
locate the cause of your problem.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, and welding problems.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chap-
ter. Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
STEP 2 PERFORM EXTERNAL
TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/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.
_____________________________________________________________
IDEALARC DC-1000
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the P.C. Board from the static-shielding
bag and place it directly into the equipment. Don’t
set the P.C. Board on or near paper, plastic or
cloth which could have a static charge. If the P.C.
Board can’t be installed immediately, put it back in
the static-shielding bag.
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and
service this equipment. Turn
the input power OFF at the
fuse box before working on
equipment. Do not touch elec-
trically hot parts.
- If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation is
complete.
_______________________________
- If you return a P.C. Board to The Lincoln Electric
Company for credit, it must be in the static-shield-
ing bag. This will prevent further damage and
allow proper failure analysis.
CAUTION: Sometimes machine failures appear to
be due to PC board failures. These problems can
sometimes be traced to poor electrical connections.
To avoid problems when troubleshooting and
replacing PC boards, please use the following pro-
cedure:
4. Test the machine to determine if the failure
symptom has been corrected by the replace-
ment PC board.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: It is desirable to have a spare (known
good) PC board available for PC board trou-
bleshooting.
2. Check for loose connections at the PC board to
assure that the PC board is properly connect-
ed.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
5. Remove the replacement PC board and sub-
stitute it with the original PC board to recreate
the original problem.
a.
b.
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.
P.C. Board can be damaged by static electricity.
- Remove your body’s static
charge before opening the
static-shielding bag. Wear an
anti-static wrist strap. For
safety, use a 1 Meg ohm
resistive cord connected to a
grounded part of the equip-
If the original problem is recreated by
the substitution of the original board,
then the PC board was the problem.
Reinstall the replacement PC board
and test the machine.
ATTENTION
Static-Sensitive
ment frame.
Devices
Handle only at
Static-Safe
- If you don’t have a wrist
strap, touch an unpainted,
grounded, part of the equip-
ment frame. Keep touching
the frame to prevent static
build-up. Be sure not to touch
any electrically live parts at
the same time.
6. Always indicate that this procedure was fol-
lowed when warranty reports are to be submit-
ted.
Workstations
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
Reusable
Container
Do Not Destroy
- Tools which come in contact with the P.C. Board
must be either conductive, anti-static or static-dissi-
pative.
IDEALARC DC-1000
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical
Damage is Evident.
Contact the Lincoln Electric
Service Dept. (216) 383-2531
or 1-800-833-9353 (WELD)
The Machine is dead - The Input
contactor does not operate.
1. Check for blown or missing
fuses in input lines.
1. The.Start/Stop button (S1)
may be faulty- Check for prop-
er operation. See wiring dia-
gram.
2. Check the three-phase input
line voltage at the machine.
The input voltage must match
the rating plate and reconnect
panel.
2. The Control Transformer (T2)
may be faulty. Perform the
Control Transformer Test.
3. The primary or secondary
thermostats may be open.
Check or replace. Also check
the associated wiring. See
wiring diagram.
4. The pilot relay (2CR) may be
faulty. Check or replace. See
wiring diagram.
5. The input contactor coil may
be open. See wiring diagram.
6. The Control board may be
faulty - Replace.
Input contactor (1CR) chatters.
1. The input line voltage may be
low. Check all three phases.
1. The pilot relay (2CR) may
have bad contacts. Check or
replace relay.
2. Make sure input line voltage
matches machine rating and
reconnect panel.
2. Check for loose or faulty
wiring between pilot relay
(2CR) and input contactor
(1CR) coil connections.
3. The input contactor (1CR)
may be faulty - Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-5
F-5
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Input contactor pulls in when start
button is pressed but immediately
drops out when start button is
released.
1. Make sure input voltages
match machine rating and
reconnect panel.
1. The 1CR interlock may be
faulty. Replace if necessary.
2. The Start/Stop button may be
faulty. Check or replace.
2. Remove all external wires
attached to terminal strip (2, 4,
31, 32, 73, 74, 75, 76, 77). If
contactor (1CR) functions cor-
rectly, there may be a ground
or negative intrusion on the
remote control leads (73, 74,
75, 76, or 77). There may also
be a short at the welder output
terminals.
3. Check internal remote control
circuit (leads 73, 74, 75, 76
and 77) and switch SW3 for
grounds or shorts.
4. The control board may be
faulty - Replace.
3. If the problem persists after
performing steps #1 and #2,
the problem is in the DC-
1000.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-6
F-6
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine input contactor operates
but machine has no weld output.
Fan runs and pilot light glows.
1. Install a jumper from #2 to #4
on machine terminal strip. If
machine weld output is
restored, the problem is in the
wire feeder or control cable.
1. Check operation of output
pilot relay (4CR). There
should be 115 VAC present
on leads #31 and #4 at (4CR)
when #2 and #4 are jumpered
together at the terminal strip.
2. If remote control is not being
used, make certain the output
control switch (SW3) is in the
“OUTPUT CONTROL AT DC
1000” position.
a. If the correct voltage is pre-
sent and the relay does not
activate, the relay may be
faulty - Replace.
3. Check 8 AMP fuse in the front
panel. Replace if blown.
b. If the 115 VAC is missing,
check the associated wiring
for loose or faulty connec-
tions. See wiring diagram.
4. Check for loose or faulty weld
cable connections.
2. Check the output control
potentiometer (R1) and asso-
ciated circuitry for loose or
faulty connections. See wiring
diagram.
3. Perform Main Transformer
Test
4. Perform Firing Board Test.
5. Perform Control Board Test.
6. Perform SCR Output Bridge
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-7
F-7
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine has maximum weld out-
put and no control.
1. If remote control is being
used, put output control switch
(SW3) in “OUTPUT CON-
TROL AT DC-1000” position
and control weld output with
the 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. Check output control switch
(SW3) and associated wiring.
2. Check feedback leads #222
(negative output terminal) and
#215, #210(output shunt) for
loose or faulty connections.
See wiring diagram.
3. Check the #75 lead for conti-
nuity (zero ohms) from the
output control potentiometer
(R1) to the control board plug
10J1. See wiring diagram.
4. Perform Firing Board Test.
5. Perform Control Board Test.
6. Perform SCR Output Bridge
Test.
Machine has minimum output
and no control.
1. If a remote control unit is NOT
connected to the terminal strip
#73, #74,#75, #76, and/or #77
terminals, the output control
switch must be in the “OUT-
PUT CONTROL AT DC-1000”
position.
1. Check the output control
potentiometer (R1) and asso-
ciated wiring.
2. Check the output control
switch (SW3) the welding
mode switch (SW4) and asso-
ciated wiring.
2. If a remote control cable is
connected to terminals #73,
#74, #75, #76, and/or #77, the
leads may be shorted to the
positive weld output.
3. Perform the Control Board
Test.
4. Perform the Firing Board
Test.
3. Make certain the three phase
input voltage is correct and
matches the machine rating
and the reconnect panel.
5. Perform the SCR Output
Bridge Test..
6. Perform Main Transformer
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-8
F-8
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The machine does not have max-
imum weld output.
1. Check all three-phase input
lines at the DC-1000. Make
sure input voltages match
machine rating and reconnect
panel.
1. Check the output control
potentiometer (R1) and asso-
ciated circuitry for loose or
faulty connections. See wiring
diagram.
2. Put output control switch
(SW3) in “OUTPUT CON-
TROL AT DC-1000” position.
If problem is solved, then
check remote control unit or
wire feeder.
2. Perform Control Board Test.
3. Perform Firing Board test.
4. Perform Main Transformer
Test.
5. Perform SCR Output Bridge
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-9
F-9
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Machine shuts off (input contac-
tor drops out) when the welder
output terminals are electrically
energized. (#2 to #4 closure at
terminal strip.)
1. Remove all welding cables
and control cables from the
DC-1000. Jumper #2 to #4 at
the terminal strip. If the
machine does NOT shut off
and normal open circuit volt-
age is present at the welder
output terminals, the problem
is external to the DC-1000.
Either the remote leads #73,
#74, #75, #76 or #77 are
grounded to the negative out-
put cable, or there is a short
on the welding output termi-
nals.
1. Check for grounds and or
shorts in the #73, #74, #75,
#76, #77 circuit. See wiring
diagram.
2. Check for grounds and shorts
in the welder output terminals
and associated leads. See
wiring diagram.
3. Check the output shunt and
associated leads. See wiring
diagram.
4. Perform the Control Board
Test.
2. If the machine still shuts off
when all control and welding
cables are removed, then the
problem is internal to the DC-
1000.
The DC-1000 will NOT shut off
when the Stop button is pushed.
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. The input contactor (1CR)
contacts may be stuck closed.
Check and replace if neces-
sary.
2. The Interlock contacts (part of
1CR) may be faulty. Replace
if necessary.
3. The Start/Stop button may be
faulty. Check or replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-10
F-10
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed througout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The weld output terminals are
always electrically “hot”.
1. Remove any external leads
hooked to #2 and #4 on the
terminal strip. If the problem
disappears, the fault is in the
control cable or wire feeder.
1. Check for an internal short
between leads #2 and #4. See
wiring diagram.
2. The Pilot Relay (4CR) may be
stuck closed. Check or
replace.
2. If some open circuit voltage is
present (over 3 VDC.) after
performing Step #1, then the
problem is within the DC-
1000.
3. Perform Firing Board Test.
4. Perform Control Board Test.
5. Perform the SCR Output
Bridge Test.
6. The SCR Snubber(s) may be
“leaky”. Check or replace. See
wiring diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-11
F-11
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Poor arc starting when the DC-
1000 is in the CV Sub-Arc or CV
Innershield Modes.
1. Make sure the proper welding
procedures are being used
(wire feed speed, arc voltage
and wire size).
1. Check the 3CR reed switch.
The voltage from lead #215 to
lead #220 should be 8 VDC
when the DC-1000 is in an
idle condition (on but not
welding). When the machine
is producing welding current,
the reed switch (3CR) should
close and the voltage from
#215 to #220 should drop to
zero.
2. Check weld cables for loose
or faulty connections.
2. Perform the Firing Board
Test.
3 Perform the SCR Output
Bridge Test.
4. The control board may be
faulty - Replace.
Poor arc characteristics in all
processes.
1. Check for the correct input
voltages on the three phase
input lines at the DC-1000.
1. Check the Mode Switch
(SW4) and the associated
wiring for loose or faulty con-
nections. See wiring diagram.
2. Make sure the proper welding
procedures are being used
(wire feed speed, arc voltage
and wire size).
2. Check the 3CR reed switch.
The voltage from lead #215 to
lead #220 should be 8 VDC
when the DC-1000 is in an
idle condition. When the
machine is producing welding
current, the reed switch (3CR)
should close and the voltage
from #215 to #220 should
drop to zero.
3. Check the welding cables for
loose or faulty connections.
3. Perform the Firing Board
Test.
4. Perform the SCR Output
Bridge Test.
5. The control board may be
faulty - Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-12
F-12
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Poor performance (including arc
outages) while welding at low
current (less than 450 amps)
when connected to 1000 amp (+)
output terminals.
1. Change the welding cable(s)
to the 500 amp terminal (later
models only).
The machine frequently shuts off
while using the 500 amp (+) out-
put terminal (later models only).
1.The output current demand
may 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 be
faulty - Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
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F-13
F-13
TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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 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).
IDEALARC DC-1000
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F-14
F-14
TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
FIGURE F.1 - Control Transformer Lead Location
TEST PROCEDURE
1. Disconnect main AC input power to
the machine.
4. Locate the Control Transformer
primary leads (H1, H2, H3, etc.).
See wiring diagram.
2. Remove the Top and Case Sides.
NOTE: Unused leads should be
taped. Check for loose or faulty
connections.
3. Locate the Control Transformer (T2)
on the left side of the Input Box (fac-
ing the back of the machine). See
Figure F.1.
IDEALARC DC-1000
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F-15
F-15
TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
FIGURE F.2 - Control Transformer X1 and X2 Test Points
5. Locate Control Transformer leads
X1 and X2 at in line connectors.
See Figure F.2.
7. If 115 VAC is not present between
leads X1 and X2, test for correct
main AC input power to the Control
Transformer primary windings (H1,
H2, H3, etc.) See wiring diagram.
6. Apply power and test for 115 VAC
between leads X1 to X2.
If the correct main AC input power to
the Control Transformer is present, and
the secondary voltage is not correct,
the Control Transformer may be faulty.
Replace.
IDEALARC DC-1000
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F-16
F-16
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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).
_____________________________________________________________
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).
IDEALARC DC-1000
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F-17
F-17
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST
FIGURE F.3 - Input Contactor, Reconnect Panel, and Primary Leads to
Main Transformer Locations
TEST DESCRIPTION
5. Test with an AC voltmeter for
proper main AC input voltage from
the output side of the Input
Contactor. (1CR). See wiring dia-
gram.
1. Disconnect main AC input power to
the machine.
2. Inspect the Input Contactor,
Reconnect Panel, and primary leads
to the Main Transformer for loose or
faulty connections. See Figure F.3.
T1 to T2.
T2 to T3.
T1 to T3.
3. Apply input power, push start button,
and make sure the Input Contactor
(1CR) energizes.
a.
If correct voltage is pre-
sent, the Contactor is
working properly.
4. Test with an AC voltmeter for proper
main AC input voltage to the line
side of the Input Contactor (1CR).
See wiring diagram.
b.
If the correct voltage is not
present for any or all of the
three phases, the contac-
tor may be faulty.
L1 to L2.
L2 to L3.
L1 to L3.
6. Test with an AC voltmeter for
approximately 60 VAC from each
of the six main transformer sec-
ondary leads to the common buss
connected to the negative output
terminal. See Figure F.4.
a.
If proper voltage is not pre-
sent in any or all of the three
phases, check input fuses
and leads.
IDEALARC DC-1000
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F-18
F-18
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST
FIGURE F.4 - Main Secondary Lead Test Points
b.
If the wiring is good, then the
Main Transformer may be
faulty.
a.
If one or more of the above
voltage tests are incorrect,
check for loose or faulty
wiring. If the wiring is good,
then the Main Transformer
may be faulty.
8. Remove the screws from the control
box cover. It does not have to be
completely removed to perform this
test.
NOTE: A long wire with clip or a
long probe may be required to
reach the lower middle lead.
9. Test with an AC voltmeter for 75
VAC for each phase angle winding
as shown. See Figure F.5.
7. Test for 115 VAC between leads
#31 to #32 on the terminal strip.
These can be accessed through
the front panel assembly door.
NOTE: If the main supply voltage
varies, the Main Transformer volt-
ages will vary proportionately. See
Figure F.5.
a.
If the 115 VAC is not pre-
sent, check for loose or
faulty wiring or blown fuse.
If necessary, untape and
track the continuity of leads
#31 and #32 through the
entire harness.
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F-19
F-19
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST
From
To
Pin
4
Expected VAC
Plug
J5
Pin
2
Lead
#203
#205
#207
Plug
J5
Lead
#204
#206
#208
75 VAC
75 VAC
75 VAC
J5
7
J5
3
J5
9
J5
8
FIGURE F.5 - Phase Angle Windings Test Points and Firing Board Pin
Location
IDEALARC DC-1000
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F-20
F-20
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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 determines whether or not the Firing Board is receiving the correct voltages and
gate signals. The LED’s (Light Emitting Diodes) will help you determine if the Firing Board is
generating gate signals to the main SCR’s.
MATERIALS NEEDED
Volt/Ohm Meter (Multimeter)
IDEALARC DC-1000 Wiring Diagram and Firing Board Schematic Diagram (See Electrical
Diagram Section of Manual).
IDEALARC DC-1000
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F-21
F-21
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
FIGURE F.6 - Firing Board LED and Molex Plug Locations
TEST PROCEDURE FOR
NORMAL FIRING
BOARD OPERATION
1. Disconnect main AC input power to
WARNING
the machine.
JUMPERING LEADS 2 AND 4 ELEC-
TRICALLY ENERGIZES MACHINE’S
OUTPUT TERMINALS. DO NOT
TOUCH ELECTRICALLY HOT COM-
2. Remove screws, loosen and lower
the front panel to access the Firing
Board on the left side of Control
Box facing the machine.
PONENTS.
3. Visually inspect the Firing Board
for loose or faulty connections.
______________________________________
7. Locate LEDs 1 thru 6. Each LED
should glow with equal brightness.
4. Reconnect the input power and
turn the DC-1000 on.
NOTE: LEDs 1 through 6 indicate that
the gate firing signals are being gener-
ated to send to each of the output
SCRs.
5. Locate LEDs 7, 8, and 9 on the
Firing Board. See Figure F.6. Each
LED should be ON and equally
bright. Use Table F.1 to check LED
operation.
8. Set the output control switch (SW3)
in the “Output Control at DC-1000”
position.
6. Connect a jumper wire from termi-
nal #2 to terminal #4 on the termi-
nal strip. These can be accessed
through the Front Panel Assembly
door. See Figure F.7.
9. Set the welding mode switch
(SW4) in either of the “CV” posi-
tions.
IDEALARC DC-1000
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F-22
F-22
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
FIGURE F.7 - Terminal Strip Jumper Wire Connections
10. Rotate the output control poten-
tiometer (R1). As the potentiometer
is turned clockwise, the LEDs
should glow brighter. As the poten-
tiometer is turned counter-clock-
wise, the LEDs should dim.
11. Locate and test for 6 to 15 VDC
between leads #231 and #215 on
the Firing Board in the CV mode.
When the output control poten-
tiometer (R1) is rotated, the DC
voltage between leads #231 and
#215 should vary from 6 to 15 VDC.
a.
If the LEDs glow and
change in brightness equal-
ly as the potentiometer is
turned and the problem
continues, then the SCR
bridge may be faulty.
Perform the SCR Bridge
Test.
12. If an LED continues to be lit and
should not be, a circuit may be
faulty on the Firing Board between
a Molex plug and LED. Replace
Firing Board.
13. If the DC voltage does NOT vary,
as potentiometer (R1) is rotated,
the Control Board may be faulty.
b.
c.
If any or all of LEDs 1
through 6 do not glow, or
do not change in brightness
equally as the potentiome-
ter is turned, continue to
next step.
14. Locate and test for approximately
5.8 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 #231
and #215 should NOT vary and
should remain at a constant approx-
imate 5.8 VDC.
If one or two LEDs stay
bright or dim while the oth-
ers change, this could indi-
cate either an open or
shorted gate or a faulty
snubber on the related SCR
assembly. Perform SCR
Bridge Test.
NOTE: The DC voltage may vary
slightly at the lower portion of the
range.
IDEALARC DC-1000
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F-23
F-23
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
and closing. If the Output Pilot
15. Test the Output Pilot Relay (4CR)
for operation by removing and
replacing the jumper wire repeat-
edly from terminal #2. See Figure
F.7. This should cause the relay
contacts to open and close. The
contacts can be seen closing and
opening through the clear plastic
relay case or can be heard opening
Relay (4CR) does not close when
energized, check for loose or faulty
wiring. See Wiring Diagram and
Figure F-8.
16. Replace the Firing Board if the
above voltage and control relay
tests are passed. It may be faulty.
FIGURE F.8 - Output Pilot Relay 4CR Location
IDEALARC DC-1000
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F-24
F-24
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
TABLE F.1 - LED 7, 8 and 9 Check List
IF
THEN
LED 7 is ON
AC power is being supplied to the Firing Board from
leads #203 and #204 connected to the phase angle wind-
ing in the Main Transformer.
LED 7 is OFF or is DIM-
MER than other LEDs
The proper AC voltage may not be reaching Firing Board.
Check for loose or faulty connections. Perform Main
Transformer Test.
LED 8 is ON
AC power is being supplied to the Firing Board from
leads #205 and #206 connected to the phase angle wind-
ing in the Main Transformer.
LED 8 is OFF or is DIM-
MER than other LEDs
The proper AC voltage may not be reaching Firing Board.
Check for loose or faulty connections. Perform Main
Transformer Test.
LED 9 is ON
AC power is being supplied to the Firing Board from
leads #207 and #208 connected to the phase angle wind-
ing in the Main Transformer.
LED 9 is OFF or is DIM-
MER than other LEDs
The proper AC voltage may not be reaching Firing Board.
Check for loose or faulty connections. Perform Main
Transformer Test.
IDEALARC DC-1000
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F-25
F-25
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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 feedback
signals.
MATERIALS NEEDED
Volt/Ohm Meter (Multimeter)
IDEALARC DC-1000 Wiring Diagram and Control Board Schematic (See Electrical Diagram
Section of Manual).
IDEALARC DC-1000
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F-26
F-26
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
FIGURE F.9 Control Board LED and Pin Locations.
TEST PROCEDURE FOR
NORMAL CONTROL BOARD
OPERATION
1. Remove main supply power to the
DC-1000.
7. LED 4 should NOT be lit. LED 4
should light only if there is a “fault”
condition.
2. Remove screws, loosen and lower
the Front Panel to access and
inspect the Control Board located
in the right front control box. See
Figure F.9.
8. LED 2 should be lit indicating output
voltage feedback is being supplied
to the Control Board. With the
Output Control Switch (SW3) in the
“Output Control At DC-1000”
(Panel) position and the Welding
Mode Switch (SW4) in a CV posi-
tion, LED 2 should change in bright-
ness as the Output Control
Potentiometer is rotated. As the
open circuit voltage is increased,
LED 2 should get brighter and vice
versa.
3. Apply the correct three-phase input
power to the DC-1000. Turn on the
machine.
4. Connect a jumper wire from termi-
nal #2 to terminal #4 on the termi-
nal strip. These can be accessed
through the front panel assembly
door. See Figure F.7.
9. LED 5 indicates a control signal
(lead #231) is being supplied to the
firing circuit. As the output is varied,
LED 5 should change in brilliancy
from bright (at low output) to dim (at
high output). When the Weld Mode
Switch (SW4) is in the CC (Stick)
position, the open circuit voltage is
at maximum, and LED 5 will be very
dim or not lit.
WARNING
JUMPERING LEADS 2 AND 4 ELEC-
TRICALLY ENERGIZES MACHINE’S
OUTPUT TERMINALS. DO NOT
TOUCH ELECTRICALLY HOT COM-
PONENTS.
______________________________________
5. LED 1 should be lit indicating the
presence of 115 VAC at leads
#255 to #256 Plug J1.
6. LED 3 should be lit indicating
power is being applied to the fault
protection relay (2CR).
IDEALARC DC-1000
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F-27
F-27
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
POSSIBLE PROBLEMS
PERTAINING TO THE
CONTROL BOARD
IF LED 1 does not light, when the
start switch is ON.
1. Check for 115 VAC at leads #255
to #256 plug J1
c.
d.
Test for continuity (zero
ohms) from lead #256 plug
J1 at the Control Board to
the pilot light. See wiring dia-
gram.
a.
b.
If the correct voltage is not
present, check leads #255
and #256 and associated
wiring for loose or faulty
connections. See wiring dia-
gram and Figure F.10.
If the 115 VAC is present at
leads #255 to #256 at plug
J1 and LED 1 does not light,
the Control Board may be
faulty. Replace.
Remove main supply power
to the DC-1000. Test for
continuity (zero ohms) from
lead #255 plug J1 at the
Control Board to lead #212
at the Start/Stop Button.
FIGURE F.10 - LED 1 Test Points
IDEALARC DC-1000
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F-28
F-28
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
IF LED 2 does not light when #2 and
#4 are jumpered together.
See wiring diagram and Figure
F.11.
1. Check for the presence of open cir-
cuit voltage at the weld output ter-
minals (27 to 75 VDC in constant
voltage mode, 75 VDC in constant
current mode).
3. Test for continuity (zero ohms) from
the negative output terminal to lead
#222 at plug J1 on the Control
Board. See wiring diagram.
4. If the previous tests do not reveal
the problem then the Control Board
may be faulty. Replace.
a.
If open circuit voltage IS
present at the output termi-
nals, then check for open
circuit voltage from lead
#222 (-) plug J1 to lead
#215 (+) plug J2 on the
Control Board See Figure
F.11.
5. If open circuit voltage is NOT mea-
sured at the weld output terminals,
then check the Output Choke and
associated heavy current carrying
leads for loose or faulty connec-
tions.
b.
If open circuit voltage is
NOT present at the Control
Board, then check leads
#222 and #215 and associ-
ated wiring for loose or
faulty connections. See
wiring diagram. Remove
main supply power to the
DC-1000.
•
Perform the Main Transformer
Test.
•
•
Perform the Firing Board Test.
Perform the SCR Output Bridge
Test.
If the previous tests do not reveal the
problem then the Control Board may be
faulty. Replace.
2. Test for continuity (zero ohms)
from the output shunt to lead #215
at plug J2 on the Control Board.
FIGURE F.11 - LED 2 Open Circuit Voltage Test Points
IDEALARC DC-1000
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F-29
F-29
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
IF LED 3 does not light when the
Start Button is depressed (but LED 1
does light).
2. If the above procedures do not
reveal the problem, then the
Control board may be faulty-
Replace.
The Fault Protection Relay (2CR) is not
receiving supply voltage (24 VDC) and
the Input Contactor (1CR) will not stay
closed. Check to see if LED 4 lights or
“flickers” when the Start Button is held
in.
IF LED 5 does not light and varies in
brightness when #2 and #4 are
jumpered together, while the Output
Control Potentiometer is rotated .
The Control Board may be faulty-
Replace.
If LED 4 lights,
1. There may be a “short” at the
welder output terminals or the
remote control circuit (leads #73,
#74, # 75, #76 and #77) may be
shorted to the negative welding
voltage. Check the weld output ter-
minals and associated leads and
also the remote control circuitry.
See wiring diagram.
NOTE: The Weld Mode Switch (SW4)
must be in the CV position and the
Output Control Switch (SW3) in the
“Output Control at DC-1000” position.
Also check the Output Control
Potentiometer and associated circuitry.
IDEALARC DC-1000
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F-30
F-30
TROUBLESHOOTING & REPAIR
STATIC SCR TEST
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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
The Static SCR Test is a quick check to determine if an SCR is shorted or “leaky”. See
machine 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).
IDEALARC DC-1000
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F-31
F-31
TROUBLESHOOTING & REPAIR
STATIC SCR TEST
TEST PROCEDURE
2. Remove all Molex plugs from the
1. Remove main supply power to the
DC-1000.
firing board and control board. See
Figure F.12.
FIRING BOARD
CONTROL BOARD
FIGURE F.12 - Firing and Control Board Molex Plug Locations.
IDEALARC DC-1000
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F-32
F-32
TROUBLESHOOTING & REPAIR
STATIC SCR TEST
FIGURE F.13 - SCR Heat Sink Assembly Test Points.
a.
If a low resistance is indicat-
ed in either direction, dis-
connect the snubber circuit
(See wiring diagram) and
retest SCR 1. If a low resis-
tance is still indicated, SCR
1 is faulty - Replace. If a
very high or infinite resis-
tance is indicated without
the snubber circuit, then
replace the snubber circuit,
See Figure F.14.
3. Remove the red insulating paint
from heat sink test points. See
Figure 13.
NOTE: DO NOT DISASSEMBLE THE
HEAT SINKS.
4. Using an analog ohmmeter, test the
resistance from anode to cathode of
SCR 1. Reverse the meter leads
and check from cathode to anode of
SCR 1. (R x 1000 SCALE)
IDEALARC DC-1000
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F-33
F-33
TROUBLESHOOTING & REPAIR
STATIC SCR TEST
FIGURE F.14 - Snubber Location and Circuit
5. Repeat Step 4 testing SCR 2, SCR
3, SCR 4, SCR 5, and SCR 6.
To further check the SCRs’ functions
use an SCR tester and proceed to
Active SCR Test.
IDEALARC DC-1000
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F-34
F-34
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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
The Active SCR Test will determine if the device is able to be gated “ON” and conduct current
from anode to cathode.
MATERIALS NEEDED
An SCR tester as outlined in this procedure.
DC-1000 Wiring Diagram (See Electrical Diagrams Section of this manual).
IDEALARC DC-1000
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F-35
F-35
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
1. Remove main supply power to the
DC-1000.
2. Remove all Molex plugs from the
Firing Board and Control Board.
See Figure F.15.
FIRING BOARD
CONTROL BOARD
FIGURE F.15 - Firing Board and Control Board Molex Plug Locations
IDEALARC DC-1000
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F-36
F-36
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
FIGURE F.16 - Heat Sink Assembly Test Points
3. Remove the red insulating paint
from heat sink test points. See
Figure F.16.
NOTE: Do not disassemble the heat
sinks.
4. Perform test procedure as follows.
Refer to Figure F.17. Repeat test
for all six SCRs.
IDEALARC DC-1000
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F-37
F-37
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
FIGURE F.17- Silicon Controlled Rectifier (SCR) Test Setup
5. To test SCRs, construct the circuit
outlined in Figure F.17. Use one 6V
lantern battery. Resistor values are
in ohms ±10%. The voltmeter scale
should be low, approximately 0-5 or
0-10 volts.
NOTE: Do not disassemble the heat
sinks.
6. With switch SW1 closed, close
switch SW2 for two seconds and
release. The voltmeter should read
3 to 6 volts before and after switch
SW2 is released. If the voltmeter
does not read, or reads only while
SW2 is depressed, the SCR or bat-
tery is defective (repeat Battery
Test Procedure).
BATTERY TEST
Check the battery by shorting leads (A)
and (C) and then close switch SW1.
Replace battery if voltage is less than
4.5 volts.
7. Open switch SW1, disconnect the
gate lead (G) and reverse the (A)
and (C) leads on the SCR. Close
switch SW2. The voltmeter should
read zero. If the voltage is higher
than zero, the SCR is shorted.
A. Connect SCR into the test circuit as
shown (A) lead to anode (C) lead to
cathode and (G) lead to the gate.
B. Close switch SW1 (switch SW2
should open), voltmeter should read
zero. If the voltmeter reads higher
than zero the SCR is shorted.
8. Replace any SCR assembly that
does not pass test in Step 4.
IDEALARC DC-1000
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F-38
F-38
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT CURRENT MODE - NO LOAD
This is the typical DC open circuit volt-
age waveform generated from a proper-
ly operating machine. Note that each
SCOPE SETTINGS
vertical division represents 50 volts and
Volts/Div. . . . . . . . . . . . . 50 V/Div.
that each horizontal division represents
Horizontal Sweep . . . . . 2 ms/Div.
2 milliseconds in time.
Coupling . . . . . . . . . . . . . . . . . DC
Note: Scope probes connected at
machine output terminals: (+) probe to
positive 1000 Amp terminal, (-) probe to
negative terminal.
Trigger . . . . . . . . . . . . . . . Internal
IDEALARC DC-1000
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F-39
F-39
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD - MAXIMUM
OUTPUT SETTING - NO LOAD
This is the typical DC open circuit volt-
age waveform generated from a proper-
ly operating machine. Note that each
SCOPE SETTINGS
vertical division represents 50 volts and
Volts/Div. . . . . . . . . . . . . 50 V/Div.
that each horizontal division represents
Horizontal Sweep . . . . . 2 ms/Div.
2 milliseconds in time.
Coupling . . . . . . . . . . . . . . . . . DC
Trigger . . . . . . . . . . . . . . . Internal
Note: Scope probes connected at
machine output terminals: (+) probe to
positive 1000 Amp terminal, (-) probe to
negative terminal.
IDEALARC DC-1000
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F-40
F-40
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
MINIMUM OUTPUT SETTING - NO LOAD
This is the typical DC open circuit volt-
age waveform generated from a proper-
ly operating machine. Note that each
vertical division represents 50 volts and
that each horizontal division represents
2 milliseconds in time.
SCOPE SETTINGS
Volts/Div. . . . . . . . . . . . . 50 V/Div.
Horizontal Sweep . . . . . 2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . DC
Trigger . . . . . . . . . . . . . . . Internal
Note: Scope probes connected at
machine output terminals: (+) probe to
positive 1000 Amp terminal, (-) probe to
negative terminal
IDEALARC DC-1000
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F-41
F-41
TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM -MACHINE
LOADED CONSTANT VOLTAGE INNERSHIELD MODE
This is the typical DC open circuit volt-
age waveform generated from a proper-
SCOPE SETTINGS
ly operating machine. Note that each
vertical division represents 20 volts and
that each horizontal division represents
2 milliseconds in time. The machine
was loaded with a resistance grid bank.
The grid bank meters read 600 amps at
44 VDC.
Volts/Div. . . . . . . . . . . . . 20 V/Div.
Horizontal Sweep . . . . . 2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . DC
Trigger . . . . . . . . . . . . . . . Internal
Note: Scope probes connected at
machine ouput terminals: (+) probe to
positive 1000 Amp terminal, (-) probe to
negative terminal.
IDEALARC DC-1000
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F-42
F-42
TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE
LOADED - 500 AMP OUTPUT TERMINAL
CONSTANT VOLTAGE INNERSHIELD MODE
This is the typical DC open circuit volt-
age waveform generated from a proper-
ly operating machine. Note that each
vertical division represents 20 volts and
that each horizontal division represents
2 milliseconds in time. The machine
was loaded with a resistance grid bank.
The grid bank meters read 400 amps at
36 VDC.
SCOPE SETTINGS
Volts/Div. . . . . . . . . . . . . 20 V/Div.
Horizontal Sweep . . . . . 2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . DC
Trigger . . . . . . . . . . . . . . . Internal
Note: Scope probes connected at
machine ouput terminals: (+) probe to
positive 500 amp terminal, (-) probe to
negative terminal.
IDEALARC DC-1000
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F-43
F-43
TROUBLESHOOTING & REPAIR
TYPICAL SCR GATE VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
MAXIMUM OUTPUT SETTING - NO LOAD
This is the typical SCR gate pulse volt-
age waveform. The machine was in an
open circuit condition (no load) and
operating properly. Note that each verti-
SCOPE SETTINGS
cal division represents 1 volt and that
each horizontal division represents 5
Horizontal Sweep . . . . . .5 ms/Div.
milliseconds in time.
Volts/Div. . . . . . . . . . . . . . 1 V/Div.
Coupling . . . . . . . . . . . . . . . . . DC
Trigger . . . . . . . . . . . . . . . Internal
Note: Scope probes connected at SCR
gate and cathode: (+) probe to gate, (-)
probe to cathode.
IDEALARC DC-1000
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F-44
F-44
TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT VOLTAGE INNERSHIELD
ONE OUTPUT SCR NOT FUNCTIONING
MAXIMUM OUTPUT SETTING
This is NOT the typical DC output volt-
age waveform. One output SCR is not
functioning. Note the “gap” in the wave-
form. One SCR gate is disconnected to
simulate an open or nonfunctioning out-
put SCR. Each vertical division repre-
sents 50 volts and each horizontal divi-
sion represents 2 milliseconds in time.
SCOPE SETTINGS
Volts/Div. . . . . . . . . . . . . 50 V/Div.
Horizontal Sweep . . . . . 2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . DC
Trigger . . . . . . . . . . . . . . . Internal
Note: Scope probes connected at
machine ouput terminals: (+) probe to
positive 1000 amp terminal, (-) probe to
negative terminal.
IDEALARC DC-1000
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F-45
F-45
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR (1CR) CLEANING AND/OR REPLACEMENT
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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).
_____________________________________________________________
MATERIALS NEEDED
7/16” socket wrench
1/2” open end wrench
11/16” socket wrench
Phillips head screwdriver
Flat head screwdriver
Low pressure air source
IDEALARC DC-1000
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F-46
F-46
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR (1CR) CLEANING AND/OR REPLACEMENT
CLEANING PROCEDURE
from the input contactor. Mark,
label, and remove leads as neces-
sary to access the two nuts and
washers on the studs. See Figures
F.18 and F.19.
1. Remove main input supply power to
the DC-1000 and remove case top
and sides.
2. Locate the input contactor. Using a
1/2” wrench, remove the cover plate
FIGURE F.18 - Input Contactor Cover Removal
FIGURE F.19 - Input Contactor Removal
IDEALARC DC-1000
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F-47
F-47
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR (1CR) CLEANING AND/OR REPLACEMENT
WARNING
CONTACTOR REPLACEMENT
DO NOT APPLY INPUT POWER TO
THE DC-1000 WITH
REMOVAL
THE
COVER
REMOVED. POWER
APPLIED WITHOUT
COVER PLATE IN
CONTACTOR
PLATE
1. Using a 11/16” wrench, remove
leads L1, L2, L3 and output power
leads from 1CR contactor. Mark
and label all leads for proper recon-
nection. See Figure F.19.
POSITION MAY CAUSE SEVERE
ARCING RESULTING IN BODILY
2. Remove lead #257 at secondary
thermostat. See Figure F.20 and
refer to Wiring Diagram. Remove
any cable ties and/or harness
looms as necessary.
INJURY.
________________________________________
3. Blow out any dirt or dust from in
and around contacts.
3. Remove the contactor interlock
leads from quick disconnects (leads
211 and 212) and from resistor R3.
See Figure F-21 and refer to Wiring
Diagram.
4. Examine contacts for signs of wear.
5. If contacts are stuck together or
overheated, parts of the contactor,
or the entire assembly, should be
replaced.
4. Remove input contactor using a
7/16” socket wrench. Remove the
four mounting bolts, nuts, and asso-
ciated washers (or loosen the two
bottom bolts and nuts, and remove
the top two).
FIGURE F.20 - Lead #257 at
Secondary Thermostat
FIGURE F.21 - Lead #211 and #212
Quick Disconnects
IDEALARC DC-1000
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F-48
F-48
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR (1CR) CLEANING AND/OR REPLACEMENT
INSTALLATION
3. Attach leads from contactor coil.
Attach any cable ties and/or har-
ness looms cut at removal. Attach
lead #257 at secondary thermostat.
See Figure F.20.
1. Install input contactor using a 7/16”
socket wrench. Attach the four
mounting bolts, nuts, and associat-
ed washers (or tighten the two bot-
tom bolts and nuts, and attach the
top two).
4. Using a 11/16” wrench, attach
leads L1, L2, L3 and output power
leads to 1CR contactor. See Figure
F.19.
2. Attach leads to contactor interlock.
Connect quick connects on leads
#211 and #212. See Figure F.21.
NOTE: Ensure all leads are connected
correctly. See Wiring Diagram.
IDEALARC DC-1000
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F-49
F-49
TROUBLESHOOTING & REPAIR
SCR OUTPUT BRIDGE REPLACEMENT
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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).
_____________________________________________________________
MATERIALS NEEDED
9/16” socket wrench
9/16” open end wrench
1/2” long-handled flat rachet wrench
1/2” socket wrench
1/2” open end wrench
3/8” socket wrench
5/16” socket wrench
Lincoln E1868 (Dow Corning #340) heat sink compound
IDEALARC DC-1000
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F-50
F-50
TROUBLESHOOTING & REPAIR
SCR OUTPUT BRIDGE REPLACEMENT
SCR OUTPUT BRIDGE
REMOVAL
6. Using a 5/16” socket remove the
screw and small reed switch lead
(#210) from the left, top rear SCR
heat sink.
1. Remove input power to machine.
2. Using a 5/16 (8mm) nut driver or flat
head screw driver, remove 20
screws (ten per side) to remove
case sides and 2 screws to remove
top.
NOTE: It may be necessary to move or
remove the output choke to gain access
to the bottom anode leads. For access
to the bottom middle screw, nut, and
associated washers, a long handled flat
ratchet is recommended.
3. Using a 5/16 (8mm) nut driver or flat
head screw driver, remove 6
screws, then lower the front control
panel.
7. Identify and label the six trans-
former secondary (heavy alu-
minum) leads that connect to the
anodes of the SCR heat sink
assemblies. Using a 1/2” socket
and open-end wrench, remove the
secondary leads (see Figure F.22).
4. Remove the J4 gate lead Molex
plug from firing board, and feed the
plug down through the hole in bot-
tom of the PC board compartment.
5. Using a 9/16” socket and open-end
wrench, remove the two bolts and
nuts holding the shunt assembly to
the two positive buss leads con-
nected to the SCR bridge. See
Figure F.22.
8. Support the SCR bridge assembly
with a lift hook or rope.
9. Using a 3/8” socket wrench,
remove the two screws (one on
each side) holding the SCR assem-
bly rails to the front panel assem-
bly.
FIGURE F.22 - Preparation For SCR Output Bridge Removal
IDEALARC DC-1000
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F-51
F-51
TROUBLESHOOTING & REPAIR
SCR OUTPUT BRIDGE REPLACEMENT
FIGURE F.23 - SCR Output Bridge Removal
10. Cut any necessary cable ties to
allow for the SCR bridge assembly
removal.
NOTE: Upon reassembly, apply a thin
layer of Lincoln E1868 (Dow Corning
340) heat sink compound to all bolted
electrical connections on the aluminum
heat sinks.
11. Using a 1/2” socket wrench, remove
the four screws (2 on each side)
holding the transformer side panels
and SCR assembly rails to the main
transformer. See Figure F.23.
CAUTION
UPON REASSEMBLY, THE SCR
BRIDGE ASSEMBLY MUST BE ELEC-
12. Remove leads #217 and #222 from
resistor R2 located on the lift bail
assembly. Remove resistor R2
using a 7/16” wrench.
TRICALLY
GROUND.
ISOLATED
FROM
_______________________________________
15. Place insulators between SCR
bridge assembly and the output
rectifier mounting bracket (see
Figure F.23). Check for electrical
isolation with an analog ohmmeter.
13. With the 5/16” socket wrench,
remove the bottom six screws hold-
ing the front panel assembly to the
base. Carefully pull the front panel
forward to allow room to remove the
SCR bridge assembly.
CAUTION
14. Clear all leads and carefully remove
the SCR bridge assembly.
MINIMUM ACCEPTABLE RESIS-
TANCE TO GROUND IS 500,000
OHMS.
_______________________________________
IDEALARC DC-1000
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F-52
F-52
TROUBLESHOOTING & REPAIR
SCR OUTPUT BRIDGE REPLACEMENT
FIGURE F.24 - Individual SCR Assembly Heat Sink Removal
REMOVAL OF INDIVIDUAL
SCR HEAT SINK ASSEMBLIES
1. Using a 9/16” wrench, remove two
CAUTION
nuts, flat washers, and lock wash-
ers from the SCR assembly mount-
DO NOT DISASSEMBLE THE SCR
ing studs. See Figure F.24.
FROM THE HEAT SINK. MACHINE
DAMAGE MAY RESULT. REPLACE
THE SCR ONLY AS AN ASSEMBLY.
_______________________________________
2. Using a 5/16 (8mm) nut driver or
flat head screw driver, remove
snubber ground wire attachment.
The snubber assembly can now be
removed. Replace if necessary.
3. Carefully remove the positive buss
bar from the heat sink in question.
It may be necessary to remove the
buss bar completely.
4. Carefully slide the SCR assembly
from the mounting studs.
Replacement will be made with a
new SCR assembly.
IDEALARC DC-1000
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F-53
F-53
TROUBLESHOOTING & REPAIR
SCR OUTPUT BRIDGE REPLACEMENT
SCR HEAT SINK
INSTALLATION
SCR OUTPUT BRIDGE
INSTALLATION
NOTE: Upon reassembly, apply a thin
layer of Lincoln E1868 (Dow Corning
#340) heat sink compound to all bolted
electrical connections on the aluminum
heat sinks, including positive buss bar.
NOTE: Upon reassembly, apply a thin
layer of Lincoln E1868 (Dow Corning
#340) heat sink compound to all bolted
electrical connections on the aluminum
heat sinks.
1. Slide a new SCR assembly onto the
mounting studs.
1. Support the SCR bridge assembly
with a lift hook or rope.
2. Carefully attach the positive buss
bar onto the heat sink which had
been removed. If it had been nec-
essary to remove the buss bar,
replace it at this time.
2. Clear all leads and carefully posi-
tion the SCR bridge assembly in
place.
3. Place insulators between SCR
bridge assembly and the output
rectifier mounting bracket. See
Figure F.23. Check for electrical
isolation with an analog ohmmeter.
Minimum acceptable resistance to
ground is 500,000 ohms.
3. Align snubber assembly in position
on SCR output bridge assembly.
4. Using a 9/16” wrench, secure the
SCR output bridge and snubber
assemblies with two nuts, flat wash-
ers, and lock washers.
4. With the 5/16” socket wrench,
attach bottom six screws securing
the front panel assembly to the
base. Carefully push the front panel
rearward into position.
5. Using a 5/16 (8mm) nut driver or flat
head screw driver, attach snubber
assembly ground wire with screws
previously removed.
5. Attach resistor R2 to the unit using
a 7/16” wrench Secure leads #217
and #222 to resistor R2.
6. Using a 1/2” socket wrench, attach
the four screws (2 on each side)
holding the transformer side panels
and SCR assembly rails to the main
transformer.
IDEALARC DC-1000
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F-54
F-54
TROUBLESHOOTING & REPAIR
SCR OUTPUT BRIDGE REPLACEMENT
7. Using a 3/8” socket wrench, attach
the two screws (one on each side)
holding the SCR assembly rails to
the front panel assembly. See
Figure F-23.
10. Using a 9/16” socket and open-end
wrench, attach the two bolts and
nuts holding the shunt assembly to
the two positive buss leads con-
nected to the SCR bridge.
NOTE: It may have been necessary to
move or remove the output choke to
gain access to the bottom anode leads.
For access to the bottom middle screw,
nut, and associated washers, a long
handled flat ratchet is recommended.
11. Feed the J4 gate lead Molex plug
up through the hole in bottom of the
PC board compartment. Attach the
plug onto the firing board.
12. Secure any cable ties removed pre-
viously to allow for the SCR bridge
assembly removal.
8. Using a 1/2” socket and open-end
wrench, attach the secondary leads
that connect the anodes of the SCR
heat sink assemblies to the six
transformer secondary (heavy alu-
minum) leads as labeled during dis-
assembly.
13. Using a 5/16 (8mm) nut driver or
flat head screw driver, attach 20
screws (ten per side) to attach the
case sides. Attach the top using 2
similar screws.
14. Raise the front control panel into
position, and, using a 5/16 (8mm)
nut driver or flat head screw driver,
secure in position using 6 screws.
9. Using a 5/16” socket attach the
small reed switch lead (#210) to the
left, top rear SCR heat sink using
the screw previously removed.
IDEALARC DC-1000
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F-55
F-55
TROUBLESHOOTING & REPAIR
REMOVAL AND REASSEMBLY OF LIFT BAIL
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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).
_____________________________________________________________
MATERIALS NEEDED
3/8” socket wrench
9/16” socket wrench
IDEALARC DC-1000
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F-56
F-56
TROUBLESHOOTING & REPAIR
REMOVAL AND REASSEMBLY OF LIFT BAIL
FIGURE F.25 - Lift Bail Removal
REMOVAL OF LIFT BAIL
1. Remove input power to machine.
6. Using a 9/16” socket wrench,
remove the four bolts and associat-
ed washers mounting the lift bail to
the base assembly. See Figure
F.25.
2. Using a 5/16 (8mm) nut driver or flat
head screw driver, remove 20
screws (ten per side) to remove
case sides and 2 screws to remove
top.
7. Loosen or remove any cable or wire
ties necessary for lift bail removal.
3. Remove two leads, #217 and #222
from resistor R2.
8. Carefully remove the lift bail by lift-
ing straight up and clear.
4. Using a 3/8” socket wrench, remove
the two screws holding the input
contactor bracket to the lift bail.
5. Using a 9/16” socket wrench,
remove the four bolts mounting the
lift bail to the main transformer
assembly.
IDEALARC DC-1000
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F-57
F-57
TROUBLESHOOTING & REPAIR
REMOVAL AND REASSEMBLY OF LIFT BAIL
REASSEMBLY OF LIFT
BAIL
1. Place the lift bail onto the IDE-
ALARC DC-1000 from the top, low-
ering straight onto the unit.
4. Using a 3/8” socket wrench, attach
the two screws holding the input
contactor bracket to the lift bail.
2. Using a 9/16” socket wrench, attach
the four bolts and associated wash-
ers mounting the lift bail to the base
assembly.
5. Reattach leads #217 and #222 to
resistor R2.
6. Reattach or reconnect any cables
or wire ties previously removed.
3. Using a 9/16” socket wrench, attach
the four bolts mounting the lift bail
to the main transformer assembly.
7. Using a 5/16 (8mm) nut driver or
flat head screw driver, attach 20
screws (ten per side) to secure
case sides, and 2 screws to secure
top.
IDEALARC DC-1000
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F-58
F-58
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND INSTALLATION
WARNING
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 or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/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).
_____________________________________________________________
MATERIALS NEEDED
3/8” socket wrench
1/2” socket wrench
3/4” socket wrench
IDEALARC DC-1000
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F-59
F-59
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER DISASSEMBLY AND ASSEMBLY
FIGURE F.26 - Main Transformer Disassembly
IDEALARC DC-1000
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F-60
F-60
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER DISASSEMBLY
COIL REMOVAL AND
REPLACEMENT
MAIN TRANSFORMER
DISASSEMBLY
1
Label and disconnect leads to the
coils that are being removed or
replaced (see Wiring Diagram).
1. Perform Lift Bail Removal
Procedure.
2. Remove lead #271 from resistor R3
(located near the input contactor).
2
Refer to Figure F.26 for proper coil
locations (top, bottom, left, right,
and center) of primary and sec-
ondary coils. If secondary coils are
to be replaced, it will be necessary
to cut the leads and TIG weld upon
reassembly.
3. Separate the in-line connectors
from leads #211 and #212. See
Figure F.21.
4. Remove lead #256 from the choke
thermostat.
3. Remove the coils:
5. Remove lead #220 from the reed
switch (3CR).
a. Some prying and jolting may be
necessary to free the coils from
the iron.
6. Cut any necessary cable ties or
restraints and clear the leads nec-
essary for the removal of the top
transformer iron.
b. Note placement of insulation
and wedges for reassembly
(especially primary coil to lami-
nation insulation and secondary
to primary insulation).
7. Using a 3/8” socket wrench, remove
two screws mounting the input con-
tactor bracket to the case back
assembly. With leads attached,
carefully pull assembly up and out
of the way. Set assembly aside.
4. Replace the coils:
a. Be sure to replace all insulation
and wedges that were removed
(lamination to coils, and primary
to secondary coils).
8. Using a 1/2” socket wrench, move
16 screws (8 on each side) from the
transformer side brackets. Taking
note of placement, remove the four
brackets and two bottom spacers.
See Figure F.26.
b. Using a high temperature
industrial epoxy, such as
Lincoln E1603, glue the coils in
place by applying the epoxy to
the coil sides along the lamina-
tion, cell insulation, and
wedges.
9. Using a 3/4” wrench, remove the six
nuts and lock washers from the
transformer threaded rods. It may
be necessary to hold the threaded
rods to keep them from turning.
c. Glue the secondary coils in
place from the iron to the coil
sides.
10. Using a hoist, carefully lift the top
iron from the assembly. Note the
placement of shims and insulators.
5. Re-TIG weld the secondary coil
leads (if previously cut).
NOTE: Some prying and jolting may be
necessary to free the iron from the coils.
Replace any coils that may be faulty. If
any heavy aluminum secondary coils
are to be replaced, identify and label all
leads to the transformer. The leads will
have to be cut and then TIG welded
upon reassembly.
6. When reconnecting any aluminum
leads, apply a thin layer of Dow
Corning 340 Heat Sink Compound
to mating surfaces.
IDEALARC DC-1000
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F-61
F-61
TROUBLESHOOTING & REPAIR
TRANSFORMER INSTALLATION
TRANSFORMER
REASSEMBLY
1. Using a hoist, carefully lift the top
iron onto the assembly. Lightly tap
on the top of the iron.
5. With leads still attached, carefully
reposition the input contactor brack-
et onto the case back assembly.
Using a 3/8” socket wrench, secure
in position using two screws
removed previously.
2. Position the transformer threaded
rods securing the transformer.
Using a 3/4” wrench, secure the six
nuts and lock washers. It may be
necessary to hold the threaded rods
to keep them from turning. Tighten
nuts to 39 - 41 Ft.-Lbs.
6. Attach lead #220 onto the reed
switch (3CR).
7. Attach lead #256 onto the choke
thermostat.
3. The primary coils should be ground
tested at 2700 VAC for one second.
The secondary coils should be
ground tested at 1500 VAC for one
second. The primary to secondary
insulation should be tested at 2700
VAC for one second.
8. Reconnect lead #211 and #212 to
the in-line connectors.
9. Attach lead #271 onto resistor R3.
10. Perform Lift Bail Installation
Procedure.
11. Replace any cable ties or restraints
which were cut to remove the top
transformer iron.
4. Install the four brackets and two
bottom spacers in the position
noted at disassembly. Using a 1/2”
socket wrench, secure in position
with 16 screws (8 on each side)
onto the transformer side brackets.
IDEALARC DC-1000
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F-62
F-62
NOTES
IDEALARC DC-1000
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F-63
F-63
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Testing is required after the removal of any mechanical part that could affect the machine’s
electrical characteristics, or if any electrical components are repaired or replaced.
INPUT IDLE AMPS AND WATTS
Input Volts/Phase/Hertz
230/3/60
Maximum Idle Amps
Maximum Idle KW
14.0
7.0
2.0
2.0
2.0
460/3/60
575/3/60
5.6
OPEN CIRCUIT VOLTAGES
Mode
Input Hertz
Open Circuit Volts
74/76 DC
Variable Voltage
60
60
Auxiliary Output (#31-#32)
122/124 AC
MAXIMUM ACCEPTABLE OUTPUT VOLTAGE - AT MINIMUM OUTPUT
SETTINGS
Mode
Input Hertz
Load
Constant Voltage Innershield
60
140 Amps @ 14/18 VDC
MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT
SETTINGS
Mode
Input Hertz
Load
Variable Voltage
60
60
60
1250 Amps @ 47/52 VDC
1250 Amps @ 47/52 VDC
625 Amps @ 53/58 VDC
Constant Voltage Submerged Arc
Constant Voltage Submerged Arc
at 500 Amp Terminal
IDEALARC DC-1000
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F-64
F-64
NOTES
IDEALARC DC-1000
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
DIAGRAMS........................................................................................Section G
Wiring Diagram (Codes 9919, 9920)...........................................................G-2
Operating Schematic...................................................................................G-3
Control PC Board (G1585) Layout ..............................................................G-4
Firing PC Board (G1486-5 and above) Layout............................................G-5
Control PC Board (G1585) Schematic ........................................................G-6
Firing PC Board (G1486-5 and above) Schematic......................................G-7
Output Snubber (M14312) Schematic.........................................................G-8
IDEALARC DC-1000
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NOTES
IDEALARC DC-1000
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G-2
G-2
ELECTRICAL DIAGRAMS
Wiring Diagram (Codes 9919, 9920)
OUTPUT CONTROL
CENTER TERMINAL
ON FUSE HOLDER
METER KIT
(OPTIONAL)
TO GROUND PER
NATIONAL ELECTRICAL
CODE
R1
75
236
238
237
N.C.
X1
CC
CVI
CVS
SW4
32A
31
216
T2
NEG
211
H1
H2
VM
H1
H2
+
-
211
4
5
222
226
TO
3 PHASE
POWER
SUPPLY
1CR
L1
L2
L3
216
1
2
3
7
8
9
226
STOP
START
TO
PRIMARY
COILS
SW3
222
POS
SW2
H3
H4
AM
215
+
-
21
266
229
230
6
221
SW1
224
76
255
32
77
2
212
210
215
X2
SINGLE OR DUAL VOLTAGE INPUT PANEL
T.S.2
T.S.3
5
7
SHOWN CONNECTED FOR LOW VOLTAGE
255
235
271
271
2CR
B
A
PILOT
LIGHT
R
TO T2
TO GROUND PER
31
NATIONAL ELECTRICAL
CODE
233
TO
1
2
3
4
5
6
7
8
221
1
2
266
S
256
1
2
3
222
230
1CR
S
32A
3
S
S
S
S
256
4
229
215
224
73
J2
S
T1
220
257
5
257A
203
205
207
6
H1
H3
233
7
6
4
31
6
15
4
5
CHOKE
12
10
SECONDARY
J1
8
74
231
75
238
13
14
THERMOSTAT
TO
3 PHASE
POWER
SUPPLY
THERMOSTAT
9
L1
L2
L3
1
2
7
10
11
12
13
14
S
S
N.A.
FAN
MOTOR
1
2
210
215
226
235
255
256
S
J3
8
206
5
6
204
208
7
32A
31
11
8
9
215
CONTROL
P.C. BOARD
3
9
214
6
9
4
7
5
S
11
S
S
B
TO PRIMARY COILS
4CR
10
12
380 VOLTS OR TRIPLE VOLTAGE INPUT PANEL
A
8
SHOWN CONNECTED FOR 380 VOLTS
N.B.
4
215
G3
G6
G1
1
SEC
SEC
214
1
217
R2
222
2
2
203
206
204
215
215
205
208
207
TO T2
TO GROUND PER
NATIONAL ELECTRICAL
CODE
3
4
5
6
3
4
222
222
J4
J5
TO
G4
G5
G2
1CR
5
-
6
210
7
3CR
220
1
2
3
4
5
6
7
8
A
B
8
9
OUTPUT
10
11
12
231
SNUBBER
H1
H2
B'
J7
J6
P.C. BOARD
C
TO
3 PHASE
POWER
SUPPLY
L1
L2
L3
7
8
9
4
5
6
C'
13
14
500 AMP
OUTPUT
1
2
3
4
Y
X
G1
G3
G5
TO
GATE LEADS
A'
TO FIRING CIRCUIT
P.C. BOARD
PRIMARY
COILS
Z
216
FIRING
CIRCUIT
15
P.C. BOARD
L1
SCR SNUBBERS
SCR
3
SCR
1
S5CR
380/ 500 VOLTS OR 460/ 575 VOLTS
INPUT PANEL
OUTPUT SHUNT
50 MV
NOTES:
SHOWN CONNECTED FOR LOW VOLTAGE
N.A. 13, 14, AND 15 CONNECTIONS PRESENT
210
-
215
+
ON 380/500 AND 460/575 MACHINES
ONLY.
LEGEND
1000 AMP
OUTPUT
SW1 INPUT POWER
N.B. 10,11, AND 12 CONNECTIONS NOT
PRESENT ON 380V. OR TRIPLE
VOLTAGE MACHINES.
SW2 ELECTRODE POLARITY
SW3 OUTPUT CONTROL
SW4 WELDING MODE
SCR
2
SCR
4
S6CR
F1
8 AMP SLOW BLOW FUSE
10K OHM POTENTIOMETER
N.C. CONNECTIONS TO H2, H3, OR H4
DEPENDS ON INPUT VOLTAGE. SEE
INPUT SUPPLY CONNECTION
R1
R2 30 OHM, 300 W
R3 10 OHM, 50 W (20W ON EARLIER MODELS)
G6
G4
G2
GATE LEADS
INSTRUCTIONS. H4 CONNECTION
APPEARS ON 380V AND TRIPLE
VOLTAGE MACHINES ONLY.
T1
MAIN POWER TRANSFORMER
TO FIRING CIRCUIT
T2 CONTROL TRANSFORMER
P.C. BOARD
L1
LOW CURRENT WELDING CHOKE
1CR INPUT CONTACTOR
2CR FAULT PROTECTION RELAY
3CR CURRENT ACTIVATED REED SWITCH
4CR OUTPUT PILOT RELAY
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
J4
J3
J2, J7
J6
J1
J5
ELECTRICAL SYMBOLS PER E1537
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
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G-3
G-3
ELECTRICAL DIAGRAMS
Operating Schematic
2 1 4 G 7
L3
L2
L1
255
START
1CR
STOP
271
257
211
212
2CR
H3
R3
120VAC
1CR
R
H2
H1
256
SECONDARY
T2
PRIMARY
222
216
S2
31
32A
1CR
1CR
1CR
21
2
1
3
203
204
205
206
4
2
TO GROUND
TI
4
7
6
9
5
8
207
4CR
222
31
OUTPUT STUD
10
11
12
208
"-"
31
32
FAN MOTOR
120VAC
500 AMP OUTPUT
F1
8A
32A
TS 2
R2
216
4CR
OUTPUT
SNUBBER
PCB
214
4CR
4CR
SCR1
SCR3
SCR5
OUTPUT
SHUNT
215
OUTPUT STUD
"+"
5J11
1J1
210
220
221
215
210
50mV
SCR2
SCR4
SCR6
CC
CVI
CURRENT REED SW.
CLOSED WITH OUTPUT CURRENT
215
255
@
1300Amps
256
3CR
215
55V
+
STARTING LOGIC
16V
+
CVS
POWER SUPPLY
6.2V
10V
S4-B
-
215
-
CC
S4-A
SET POINT
229
1J5
214
215
215
FIRING BD. ENABLE
CVI
CVS
6J2
7J2
8J1
5J5
6J5
73
74
CONTROL PCB
SCR1
&
SCR2
4J5
2J5
10J1
11J1
2J6
X
204
203
GATE DRIVE
GATE DRIVE
75
3J4
FIRING CIRCUIT
G1
G2
73
75 VAC
1J7
A
6J4
A'
231
226
R1
8J7
74
75
FAULT DETECT.
8J2
3J5
7J5
238
SCR3
FIRING CIRCUIT
&
SCR4
206
205
1J6
76
77
75 VAC
231
Y
B
GATE DRIVE
GATE DRIVE
1J4
4J4
S3
G3
G4
2J7
5J7
CC
CVI
B'
3J1
1J2
230
266
TS 3
CONTROL AMP
CVS
9J1
10J5
FIRING SIGNAL
S4-C
231
3J6
VOLTAGE FEEDBACK
Z
231
8J5
9J5
CC
6J7
5J7
208
207
GATE DRIVE
GATE DRIVE
4J2
C
5J4
2J4
G5
G6
75 VAC
224
C'
CVI
SCR5
FIRING CIRCUIT
&
SCR6
CVS
222
235
S4-B
SHUTDOWN
12J1
7J1
235
OVERLOAD DETECT.
CURRENT FEEDBACK
2CR
236
FIRING PCB
210
215
236
1J3
2J3
2J11
UNLESS OTHERWISE SPECIFIED TOLERANCE
THIS SHEET CONTAINS PROPRIETARY INFORMATION
EQUIP.
ON HOLE SIZES PER E2056
TRANSFORMER WELDERS
OPERATING SCHEMATIC
THE LINCOLN ELECTRIC CO.
TYPE
4-27-90
OWNED BY
AND IS
THE LINCOLN ELECTRIC CO.
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
.02
2-19-93L
CLEVELAND, OHIO U.S.A.
NOT TO BE REPRODUCED, DISCLOSED OR USED
ON
.002
SUBJECT
ON ALL ANGLES IS
.5 OF
A
DEGREE3-19-93D
WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
SCALE NONE
t
SHT.
NO.
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
3-1-90
SUP'S'D'G
C.S.
7-31-92
J.J.
REF.
2147
DR
DATE
CHK
G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
IDEALARC DC1000
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
Control PC Board (G1585) Layout
REQ'D.
PART No.
ITEM
IDENTIFICATION
S16668-5
S13490-48
S13490-19
S13490-39
C1,C18,C20
3
1
.022/50
47/160
1.8/20
18/15
C2
C3
1
4
C4,C8,C11,C12
C5,C6,C7,C13,C24,C25,
C28,C29,C30
9
S13490-102
.047/100
1
C10
S13490-27
2.7 MFD 75V
.47/50
C15
1
2
S13490-63
S13490-35
C16,C26
50/16
C17
1
2
1
4
4
S13490-67
T11577-28
S13490-42
T11577-38
T12199-2
2/50
.22/100
C21,C27
C22
1.0/35
.02/600
1N4007
C9,C14,C19,C23
D1,D2,D3,D4
X
X
X
X
X
D5,D6,D7,D8,D9,D10,D11,D12,D13,D14,D15,
X
X
X
D16,D17,D18,D19,D20,D23,D24,D25,D26,
D27,D28,D29,D30,D31,D32,D33,D34,D35,
D36
T12199-1
1N4004
30
X
X
X
X
X
X
R113
X
X
R1
X
X
R3
R4
X
X
1
1
1
1
2
4
1
DZ1
DZ2
DZ3
T12702-34
T12702-33
IN5353
1N5347B
X
X
R26
R38
X
X
X
X
T12702-18
T12702-27
1N821
1N4740
DZ4
DZ5,DZ11
1N5237B
1N4744A
1N5225B
1N5253B
1N5231B
1N4742A
T12702-31
DC1000 CONTROL
G1585-[ ]
DZ6,DZ9,DZ12,DZ13
T12702-29
T12702-30
DZ7
DZ8,DZ14
DZ10
2
T12702-12
T12702-15
T12702-19
R83
1
1
DZ15
TP1
C2
33 mH
L1
1
5
T12218-4
T13657-2
R70
C17
C29
LED1,LED2,LED3,LED4,LED5
RED LED
+
LED2
C10
2
6
1
2
Q1,Q3
T12704-68
T12704-36
T12704-69
T12707-4
2N4401
2N4857
2N4403
Q4
QU2
QU1
LED1
R46
Q2,Q5,Q6,Q7,Q8,Q9
R79
R50
D5
R2
R146
LED3
Q4
D18
R71
D17
QU1,QU2
R1,R113
R2,R146
R3
2N6027
200 15W
R55
D13
T12300-47
S19400-1503
T14648-15
2
150K 1/4W
700 5W
Q2
Q7
R54
1
1
5
9
SCR1
T14648-7
S19400-1004
470 5W
R4
L1
R5,R15,R24,R103,R115
R6,R22,R59,R60,R86,R87,
R105,R106,R107
R7,R8
1M 1/4W
LED4
S19400-1001
1K 1/4W
C23
C9
LED5
2
5
2.67K 1/4W
221K 1/4W
S19400-2671
Q6
C26
R9,R76,R90,R95,R96
S19400-2213
T10812-39
2
R10,R63
50K 1/2W
C19
R11
1
267K 1/4W
S19400-2673
S19400-6812
S19400-3010
S19400-4752
R40
R41
R12,R35,R53,R91,R92,R93
6
1
1
8
68.1K 1/4W
301 1/4W
R110
D34
R13
C27
X1
Q8
R14
47.5K 1/4W
4.75K 1/4W
39.2K 1/4W
15.0K 1/4W
100K 1/4W
475K 1/4W
R16,R28,R30,R31,R32,R62,R71,R77
S19400-4751
S19400-3922
S19400-1502
Q1
R34
R17,R20
2
5
C24
R18,R25,R29,R57,R88
R19,R78,R79,R100
R21,R61,R85
C20
C21
C16
4
3
2
S19400-1003
S19400-4750
S19400-20R0
X2
R23,R147
20.0 1/4W
Q5
T10812-68
1K 1/2W
2
4
1
1
3
3
4
1
3
3
1
3
3
R26,R38
R27,R37,R58,R81
R34
22.1K 1/4W
S19400-2211
T10812-67
100K 1/2W
20K 1/2W
1.5K 1/4W
R9
R39
T10812-77
R40,R64,R65
R41,R47,R97
S19400-1501
S19400-2670
S19400-3320
S19400-4753
R10
R63
R39
267 1/4W
332 1/4W
475K 1/4W
1.3K 1/4W
R7
R46,R70,R74,R148
R48
R65
Q9
Q3
R50,R83,R143
R52,R99,R110
R54
R64
R8
S19400-1301
S19400-2212
22.1K 1/4W
27K 1W
T12732-3
R114
R48
R55,R56,R104
R66,R111,R136
R73,R102,R114
R80,R94,R98
R82,R133
R84
82.5K 1/4W
S19400-8252
47.5 1/4W
15 .5W
S19400-47R5
T14231-3
3
3
2
1
1
1
2
1
10K 1/4W
1.3K 1/4W
1.3K 1/4W
S19400-1002
S19400-1620
S19400-6810
S19400-6811
R89
6.81K 1/4W
100 1/4W
S19400-1000
S19400-75R0
S19400-2432
R108
75.0 1/4W
24.3K 1/4W
R112,R142
R145
SCR1
TP1
1
1
2
S15161-17
T13640-11
S15128-4
45J
X1,X2
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 not
available 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 result
in danger to the Machine Operator or Technician. Improper PC board repairDsocwonuloladd rfreosmuWltwinw.Sdoammanaugaels.ctoomt.hAell MmaancuahlisnSee.arch And Download.
IDEALARC DC1000
G-5
G-5
ELECTRICAL DIAGRAMS
Firing PC Board (G1486-5 and above) Layout
R 5 7
R 5 6
R 5 5
R 1 3
R 1 5
R 1 4
C 1 6
R 1 9
R 2 5
R 3 7
C 1 7
R 2 0
R 2 6
R 3 8
C 1 8
R 2 1
R 2 7
R 3 9
D 3 8
R 1 0
R 1 1
R 1 2
C 1 3
R 1 6
R 2 2
R 3 4
C 1 4
R 1 7
R 2 3
R 3 5
C 1 5
R 1 8
R 2 4
R 3 6
1/4W 150
1/4W 1.5 K
1/4W 475
1/4W 2.67 K
1/4W 26.7 K
1/2W 5.1
1/4W 332K
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 not
available 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 result
in danger to the Machine Operator or Technician. Improper PC board repairDsocwonuloladd rfreosmuWltwinw.Sdoammanaugaels.ctoomt.hAell MmaancuahlisnSee.arch And Download.
IDEALARC DC1000
G-6
G-6
ELECTRICAL DIAGRAMS
Control PC Board (G1585) Schematic
J2
5
STARTING LOGIC
DZ5
C27
.22
100V
68.1K
6.81K
10K
8.2V
22.1K
TO POS. OUTPUT STUD
215
500mW
C24
.047
SW4
10
9
100V
6
CR3
CVS
8
X2
"K"
X2
"L"
7
CURRENT
ACTIVATED
D34
1N4004
12
13
5
220
J1
REED SWITCH
"LOW" WITH OUTPUT
VOLTAGE BELOW 10V.
(FOR V.V. TAIL-OUT)
CVI
CC
HIGH WITH NO OUTPUT
VOLTAGE OR CURRENT.
(FOR START-LOW CLAMP)
lm224
14
lm224
X2
"J"
68.1K
10K
5
221K
15.0K
J1
1
"LOW" WITH
221
OUTPUT CURRENT
(FOR O.C.V. BOOST)
lm224
68.1K
"P"
267
D6
-10V
DZ11
C28
C15
.47
50V
1N4004
D25
1N4004
8.2V
.047
-10V
D36
500mW
H
100V
"M"
1N4004
10K
LOW WITH NO OUTPUT
CURRENT. ("P" DELAYED
FOR FAST RESPONSE
STARTING CIRCUITS.)
+16V
C9
2
3
X2
"H"
R98
1
R14
332
1.3K
.02
600V
47.5K
R108
100
lm224
D19
1N4004
DZ4
10V
1W
R15
ERROR AMPLIFIER
Q2
2N4857
Q7
1.00M
Q1
600mA
40V
C26
50
15V
221K
221K
2N4857
9
V
F.B.
R28
100K
D
8
R103
1.00M
"J"
X1
"P"
4.75K
"H"
R115
R32
10
1.00M
lm224
4.75K
V
REF.
R31
J1
DZ15
12V
1W
231
V
F.B.
-10V
4.75K
9
C20
.022
50V
SW.4
-10V
266
1.00K
1.00K
Q6
+16V
CONTROL SIGNAL
TO FIRING BOARD
J2
DZ14
25V
CVS
1
K
267
J1
230
CW
500mW
DZ12
15V
2N4857
C10
2.7
CVI
266
3
82.5K
1.50K
C11
1W
75V
100K
CC
"K"
C16
50
15V
82.5K
D32
R102
R57
D30
1N4004
1.00K
15
1/2W
15.0K
18
15V
D13
MAX CONTROL
VOLTS TRIM
22.1K
R99
LED2
221K
2.21K
1N4004
267
SW4
Q8
2N4857
100K
1.00K
LED5
1N4004
D20
1N4004
CVS
DZ10
TO NEGATIVE
OUTPUT STUD
82.5K
5.1V
CVI
27K
1W
500mW
"H"
L1
J1
CC
222
2
C25
33mH
.047
TO 50mV
@
1300 AMP SHUNT
C13
100V
C21
.22
68.1K
R12
"N"
-10V
R52
68.1K
215
+
210
-
"M"
-6.2V
D31
100V
22.1K
100V
.047
CURRENT FEEDBACK
221K
1N4004
VOLTAGE FEEDBACK
229
R53
J2
2
1
4
R21
475
R11
68.1K
1.3K
+16V
J3
J3
267K
C22
1.0
35V
1.50K
R64
R7
2.67K
2
3
50K
1
X1
13
12
15
Q3
600mA
40V
D11
1N4004
C12
18
15V
D15
CW
X1
D14
D10
1N4004
C14
.02
14
1.3K
47.5
CW
600V
50K
lm224
lm224
1N4004
1.50K
R65
R81
R60
R59
1N4004
R8
2.67K
2.21K
1.00K
1.00K
+55V
+16V
DZ8
25V
500MW
+16V
R4
B
D16
1N4004
475K
470
5W
Q9
C
2N4857
C23
POWER SUPPLY
Q4
600mA
40V
DZ13
15V
1W
200
475
.02
4.75K
15W
R1
J1
600V
13
255
-6.2V
"L"
150K
150K
D1
1N4007
DZ1
-10V
A
16V
5W
+55V
120V. AC
DZ3
6.2V
.4W
+
C2
+16V
47
D5
1N4004
TP1
160V
LED1
R113
D2
150V
45J
1N4007
DZ6
OVER-CURRENT AND FAULT PROTECTION
J1
D9
1N4004
+16V
D28
681
700
5W
-6.2V
15V
1W
39.2K
4.75K
1.00K
D8
1N4004
1N4004
D4
1N4007
J1
14
256
DZ2
10V
5W
235
301
12
200
15W
D3
1N4007
475
100K
D17
1.00M
15.0K
R147
20
SCR1
1N4004
1.00M
332
-10V
4.75K
4A
QU1
-10V
LED4
39.2K
C3
400V
2N6027
D7
1N4004
1.8
CR2
20V
R23
20
C17
2
LED3
C4
18
15V
QU2
2N6027
100K
50V
1.00K
D18
C18
.022
50V
C7
1N4004
15.0K
1.00K
4.75K
4.75K
Q5
2N4857
.047
233
75
J1
7
100V
+16V
D29
1N4004
"N"
V
REF.
C8
18
15V
J1
SW.4A
CVS
-10V
10
DZ7
3V
500mW
15.0K
24.3K
C6
.047
100V
"N"
"H"
6
D26
1N4004
R39
CW
224
CVI
4
75
J2
4
10K
20K
1K
C1
.022
50V
DZ9
15V
1W
VV
C19
.02
600V
X2
R82
162
R133
162
X1
V.V. MIN.
TRIM
CW
76
2.21K
LM224
SW.3
226
LM224
J1
C5
D23
1N4004
11
C.V.I. MIN.
TRIM
.047
11
77
100V
11
D33
1N4004
C.V.S. MAX.
TRIM
D27
1N4004
1K
238
OUTPUT TRIM AND
REFERENCE CIRCUIT
J2
8
R73
R74
332
R148
332
CW
"N"
15
T.S.3
74
1/2W
47.5
47.5
D12
-10V
C30
-10V
1N4004
.047
D24
1N4004
C29
"N"
J1
100V
.047
R136
-6.2V
100V
2.21K
74
8
73
73
J2
7
R112
75.0
R142
75.0
OUTPUT TRIM CIRCUIT
D35
1N4004
-6.2V
-6.2V
F R A N C E
C A N A D A
A U S T R A L I A
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 not
available 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 result
IDEALARC DC1000
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
Firing PC Board (G1486-5 and above) Schematic
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 not
available 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 result
IDEALARC DC1000
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
Output Snubber (M14312) Schematic
1 9 6 S 9 9
NEG
1
(-)
M 1 4 3 1 2 - 1
C7
.05
TP7
G N D
320V
160J
600V
N E G
P O S
WELDER
OUTPUT
STUDS
1
TO FRAME
C8
TP8
320V
160J
.05
600V
(+)
POS
1
CAPICITORS
=
MFD/VOLTS
A.N.S.I. ELECTRICAL SYMBOLS PER E1537
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS
DIAGRAM, MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS
HAVING A COMMON CODE.
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
EQUIP.
TYPE
Ch'ge.Sht.No.
DC-1000
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
-9-3G
OUTPUT SNUBBER SCHEMATIC
SUBJECT
NONE
SCALE
SHT.
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 not
available 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 result
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
IDEALARC DC1000
Download from Www.Somanuals.com. All Manuals Search And Download.
|