Lincoln Electric IDEALARC DC-1000 Operator's Manual

Subarc welder lincoln electric idealarc dc-1000

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Service manual (110 pages)

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Page 1 RETURN TO MAIN MENU IM420-C ® IDEALARC DC- 1 000 October, 2006 For use with machines Code 9919 - 9925, 10293, 11305, 11330, 11331, 11332, 11333 & 11334 Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind.
Page 2: California Proposition 65 Warnings
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
Page 6: Introductory Information
The code number is especially important when identifying the correct replacement parts. On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
Page 7: Table Of Contents
TABLE OF CONTENTS Page Safety Precautions ......................2-5 Introductory Information .......................6 Technical Specifications ......................8 Product Description......................9 Installation .........................9-12 Safety Precautions ......................9 Location .........................9 Stacking.........................9 Input Wiring ........................9 Reconnect Procedures ....................10-11 Output Connections......................12 Operating Instructions ......................13-14 Safety Precautions .......................13 To Set Polarity ......................13 Set-Up For Various Procedures ...................14 Maintenance ........................15 General Maintenance ....................15...
Page 8: Technical Specifications
TECHNICAL SPECIFICATIONS – DC-1000 INPUT - THREE PHASE ONLY Standard Input Current at Rated Output Voltage 50% Duty Cycle 100% Duty Cycle 60% Duty Cycle 230/460/60 193/96.5 215/108 230/115 575/60 77.2 220/380/440/50/60 193/112/96.5 215/124/108 230/133/115 380/500/50/60 112/85 124/94 133/101 415/50/60 RATED OUTPUT Duty Cycle Amps...
Page 9: Safety Precautions
PRODUCT DESCRIPTION The total enclosure, designed to permit outdoor operation, resists dust, salt, rain, humidity, and high and low temperature extremes. The DC-1000 is an SCR-controlled three phase DC power source. It is designed with a single range The machine uses a 38” (965mm) long base. The low profile potentiometer control for submerged arc or open arc case facilitates installation of the machine under a workbench automatic and semiautomatic welding.
Page 10: Reconnect Procedure
RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different voltage, remove input power and change the position of the reconnect board on the Reconnect Panel. Multiple voltage machines are shipped connected to Follow The Input Connection Diagram located on the the highest input voltage listed on the machine’s rating inside of Case Back Input Access Door.
Page 11 FIGURE 2 FIGURE 3 – –...
Page 12: Output Connections
OUTPUT CONNECTIONS Control Cable Connection Output Studs Terminal strips with screw connections are located behind the hinged door on the front of the power The output leads are connected to the output termi- source to make all the control cable connections for nals.
Page 13: Operating Instructions
OPERATING INSTRUCTIONS Starting the Machine - The push button power “on” switch at the extreme right side of the control panel energizes and closes the three phase input contactor WARNING from a 115 volt auxiliary transformer. This in turn ener- gizes the main power transformer.
Page 14: Set-Up For Various Procedures
Set-Up for Various Procedures Run a test weld, setting the proper current, voltage and travel speed. Once the proper welding procedure 1. Selection of mode switch position - There are is established and if the start is poor - wire blast off, several general rules to follow in the selection of stub, etc.
Page 15: Maintenance
MAINTENANCE 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 electrically hot parts. --------------------------------------------------------------------- GENERAL MAINTENANCE 1. The fan motors have sealed bearings which require no service.
Page 16: Troubleshooting
TROUBLESHOOTING 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 electrically hot parts. --------------------------------------------------------------------- Trouble Cause What To Do a.
Page 17 Trouble Cause What To Do Machine has maximum output but a. Output control switch (SW3) in a. Check position of switch. wrong position. not control. b. Output control switch faulty. b. Check switch and replace if faulty. c. Open in feedback circuitry. c.
Page 18 Trouble Cause What To Do Output control not functioning on a. Output control switch in wrong a. Place switch in “Output Control remote control. Remote”. position. b. Faulty output control switch. b. Check and replace if found faulty. c. Faulty remote control potentiome- c.
Page 19: P.c. Board Troubleshooting Guide
Trouble Cause What To Do Poor arc characteristics on all a. Defective control board. a. Check and replace if defective. processes. See P.C. board troubleshooting guide. b. Defective firing board. b. Check and replace if defective. See P.C. board troubleshooting guide.
Page 20 1. Lights 7, 8, and 9 indicate AC power being sup- PROCEDURE FOR REPLACING P.C. BOARDS plied to the P.C. boards from T1 auxiliary winding. If a light is not lit, turn the machine off and unplug When P.C. board is to be replaced, the following pro- P5 from J5 on the firing P.C.
Page 21: Outline For Dc-1000 Troubleshooting Guide
OUTLINE FOR DC-1000 TROUBLESHOOTING GUIDE If troubleshooting guide indicates a possible P.C. board problem, the following guide can be used to locate the problem. NO WELDER OUTPUT (INPUT CONTACTOR “ON”. 2 AND 4 CLOSED) CHECK CONTROL BOARD LED5 IF ON IF OFF CHECK FIRING BOARD CHECK LED1...
Page 22: Connection Diagrams
CONNECTION OF DC-1000 WITH NL OPTION KIT TO LAF-3 (Obsolete) N.C. POWER SOURCE N.B. 82 21 2 31 32 NL OPTION 67 21 2 31 32 75 76 CONNECT THE RED LEAD TO TERMINAL 22 N.A. NEGATIVE POSITIVE N.D. 35 VOLT CONTROL K775 REMOTE CONTROL EXCITER MOUNTED AT LAF-3...
Page 23 CONNECTION OF DC-1000 to NA-5 N.A. Welding cables must be of proper capacity for the cur- rent and duty cycle of immediate and future applica- tions. T O N A - 5 I N P U T N.B. Extend lead 21 using #14 or larger insulated wire phys- C A B L E P L U G N .
Page 24 CONNECTION OF DC-1000 WITH NL OPTION KIT TO LT-3 or LT-34 (Obsolete) N.C. POWER SOURCE N.B. 82 21 4 31 32 73 74 75 76 77 NL OPTION 67 21 4 2 31 32 75 76 77 CONNECT THE RED LEAD TO TERMINAL 22 NEGATIVE POSITIVE...
Page 25 CONNECTION OF DC-1000 TO LN-7 T O L N - 7 I N P U T C A B L E P L U G N.A. Welding cables must be of proper capacity for the current and P O W E R S O U R C E duty cycle of immediate and future applications.
Page 26: Wiring Diagram
– –...
Page 27 NOTES...
Page 28 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
Page 29 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
Page 30 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

Lincoln Electric IDEALARC DC-1000 Operator's Manual

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