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Lincoln Electric IDEALARC DC 1000 SVM123-A manual

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Table of contents for the manual

  • Page 1

    IDEALARC DC 1000 SER VICE MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors SVM123-A July, 1996 Safety Depends on You Lincoln arc welding and cutting equipmen[...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. Turn the engine off before trou- bleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or ve[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    SAFETY iv 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l[...]

  • Page 6

    v IDEALARC DC - 1000 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety .....................................................................................................................................................i - iv Installation .........................................................................................................[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 A-1 T ABLE OF CONTENTS -INST ALLA TION SECTION- INSTALLATION ..................................................................................Section A Technical Specifications .......................................................................[...]

  • Page 8

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Duty Cycle Amps Volts at Rated Amperes 100% 1000 44 60% 1140 44 55% 1250 44 Mode Current Range Maximum Open Auxiliary Constant Current 140 to 1250 Amps Circuit Voltage Power Cons[...]

  • Page 9

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-3 INST ALLA TION IDEALARC DC-1000 Read entire Installation Section before installing the IDEALARC DC-1000. SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • Only qualified person[...]

  • Page 10

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION IDEALARC DC-1000 A-4 FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Technical Specifications p[...]

  • Page 11

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 provid[...]

  • Page 12

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION IDEALARC DC-1000 A-6 CONNECTION FOR 380 VOLTS 1. Mount the movable reconnect panel to the stationary reconnect panel studs in the position shown, and secure firmly[...]

  • Page 13

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-7 INST ALLA TION IDEALARC DC-1000 All input power must be electrically disconnected before touching panel. ____________________________________________________ CONNECTION FOR 4[...]

  • Page 14

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION IDEALARC DC-1000 A-8 OUTPUT CONNECTIONS See Table A.1 for recommended IDEALARC DC-1000 cable sizes for combined length of electrode and work cables. TABLE A.1 Sugg[...]

  • Page 15

    A-9 INST ALLA TION IDEALARC DC-1000 A-9 CONNECTION FOR AIR/CARBON ARC CUTTING OPERA TION THE OUTPUT TERMINALS ARE ENERGIZED AT ALL TIMES WHEN THE IDEALARC DC-1000 IS CONNECTED FOR AIR/CARBON ARC CUTTING. ____________________________________________________ 1. Set ON/OFF PUSH BUTTON to OFF. 2. Locate and open the access door on the Front Case Assemb[...]

  • Page 16

    A-10 NOTES IDEALARC DC-1000 A-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 17

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 B-1 T ABLE OF CONTENTS -OPERA TION SECTION- OPERATION ...................................................................................................................................Section B Safety Precautions ...................................[...]

  • Page 18

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-2 IDEALARC DC-1000 Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS Only qualified personnel should operate this equip- men[...]

  • Page 19

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-3 OPERA TION 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: • [...]

  • Page 20

    B-4 OPERA TION B-4 • Three circuit solid state control system provides 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. • Easily removed case side, even when stacked. • Enclos[...]

  • Page 21

    B-5 OPERA TION B-5 1. ON/OFF PUSH BUTTON: This push button turns 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 u[...]

  • Page 22

    B-6 OPERA TION B-6 OPERA TING 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. Before operating the machine, make sure you have all materials needed to complete the job. Be sure you are familiar with, and [...]

  • Page 23

    B-7 OPERA TION B-7 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. 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 wi[...]

  • Page 24

    B-8 OPERA TION B-8 c. Set NA-3 Start Board current and voltage as close to the welding procedure current and voltage as possible. NOTE: The Start Board current and volt- age should be as close as possible to the welding procedure current and voltage, while still getting satisfactory starts. d. Set the start time to as low a time as possi- ble while[...]

  • Page 25

    C-1 ACCESSORIES C-1 IDEALARC DC-1000 T ABLE OF CONTENTS -ACCESSORIES SECTION- ACCESSORIES ........................................................................................................................Section C Options/Accessories ..............................................................................................................[...]

  • Page 26

    C-2 ACCESSORIES C-2 OPTIONS/ACCESSORIES • Remote Control Box Assembly (K775) • LN-7 • LN-8 } Semi-Automatic Wire Feeders • LN-9 • NA-3 • NA-5 } Automatic Wire Feeders • LT-7 and LT-56 Tractors METERS Optional factory-installed voltmeter and ammeter are available. REMOTE OUTPUT CONTROL - (OPTIONAL) The K775 Remote Output Control consis[...]

  • Page 27

    C-3 ACCESSORIES C-3 d. Tape the #21 lead to work cable for ease of use. 6. Connect the welding cables as shown in Figure C.1. NOTE: Welding cables must be of proper capacity for the current and duty cycle for immediate and future applications. NOTE: The connection diagram shown in Figure C.1 shows the electrode connected for positive polarity. To c[...]

  • Page 28

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-4 ACCESSORIES C-4 NOTE: The connection diagram shown in Figure C.2 shows the electrode connected for positive polarity. To change polarity: a . Set the IDEALARC DC-1000 ON/OFF [...]

  • Page 29

    C-5 ACCESSORIES C-5 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 termina[...]

  • Page 30

    C-6 ACCESSORIES C-6 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[...]

  • Page 31

    D-1 MAINTENANCE D-1 IDEALARC DC - 1000 T ABLE OF CONTENTS -MAINTENANCE SECTION- MAINTENANCE ...................................................................................................Section D Safety Precautions....................................................................................................D-2 Routine and Periodic Mainte[...]

  • Page 32

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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. Perform Periodically: Cl[...]

  • Page 33

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-3 MAINTENANCE D-3 IDEALARC DC-1000 FIGURE D.1 - Major Component Locations[...]

  • Page 34

    D-4 NOTES IDEALARC DC-1000 D-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 35

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-1 THEOR Y OF OPERA TION E-1 IDEALARC DC-1000 T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- THEORY OF OPERATION SECTION. ................................................................Section E General Description .............................................[...]

  • Page 36

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-2 THEOR Y OF OPERA TION E-2 INPUT LINE VOL T AGE, CONT AC- TOR, AND MAIN TRANSFORMER The desired three phase power is connected to the DC-1000 through an Input Contactor locate[...]

  • Page 37

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-3 OUTPUT RECTIFICA TION, CONTROL, AND FEEDBACK The neutrals of the Main Transformer secondary windings are connected together and the six starts are conne[...]

  • Page 38

    E-4 THEOR Y OF OPERA TION E-4 PROTECTION DEVICES AND CIRCUITS (CONT ACTOR 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[...]

  • Page 39

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-5 THEOR Y OF OPERA TION E-5 SCR OPERA TION A silicon controlled rectifier (SCR) is a three termi- nal device used to control rather large currents to a load. An SCR acts very m[...]

  • Page 40

    E-6 NOTES IDEALARC DC-1000 E-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 41

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 F-1 TROUBLESHOOTING & REP AIR F-1 T ABLE OF CONTENTS -TROUBLESHOOTING AND REP AIR SECTION- TROUBLESHOOTING AND REPAIR SECTION ...............................................................Section F How to Use Troubleshooting Guide .............[...]

  • Page 42

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 F-2 TROUBLESHOOTING & REP AIR F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three[...]

  • Page 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 F-3 TROUBLESHOOTING & REP AIR F-3 _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems c[...]

  • Page 44

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 troub[...]

  • Page 45

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-5 TROUBLESHOOTING & REP AIR IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or ar[...]

  • Page 46

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or ar[...]

  • Page 47

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-7 TROUBLESHOOTING & REP AIR IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or ar[...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-8 TROUBLESHOOTING & REP AIR F-8 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJU[...]

  • Page 49

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-9 TROUBLESHOOTING & REP AIR F-9 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures o[...]

  • Page 50

    F-10 TROUBLESHOOTING & REP AIR F-10 IDEALARC DC-1000 Observe all Safety Guidelines detailed througout 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 troubleshooting assistance before you proceed. Call 216-383[...]

  • Page 51

    F-11 TROUBLESHOOTING & REP AIR F-11 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-38[...]

  • Page 52

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 TROUBLESHOOTING & REP AIR F-12 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures[...]

  • Page 53

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 F-13 TROUBLESHOOTING & REP AIR F-13 TEST DESCRIPTION This test will determine if the correct voltage is being: a. applied to the primary of the control trans[...]

  • Page 54

    F-14 TROUBLESHOOTING & REP AIR F-14 TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Remove the Top and Case Sides. 3. Locate the Control Transformer (T2) on the left side of the Input Box (fac- ing the back of the machine). See Figure F.1. 4 . Locate the Control Transformer primary leads (H1, H2, H3, etc.). See wiring diagra[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-15 TROUBLESHOOTING & REP AIR F-15 5. Locate Control Transformer leads X1 and X2 at in line connectors. See Figure F.2. 6. Apply power and test for 115 VAC between leads X1 [...]

  • Page 56

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 technici[...]

  • Page 57

    F-17 TROUBLESHOOTING & REP AIR F-17 TEST DESCRIPTION 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. 3. Apply input power, push start button, and make sure the Input Contactor (1CR) energizes. 4. Test wi[...]

  • Page 58

    F-18 TROUBLESHOOTING & REP AIR F-18 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. NOTE: A long wire with clip or a long probe may be required to reach the lower middle lead. 7 . Test for 115 VAC between leads #31 to #32 on the termina[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 TROUBLESHOOTING & REP AIR F-19 MAIN TRANSFORMER (T1) VOL T AGE TEST IDEALARC DC-1000 From To Expected VAC Plug Pin Lead Plug Pin Lead J5 2 #203 J5 4 #204 75 VAC J5 7 #20[...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-20 TROUBLESHOOTING & REP AIR F-20 FIRING BOARD TEST IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized[...]

  • Page 61

    F-21 TROUBLESHOOTING & REP AIR F-21 TEST PROCEDURE FOR NORMAL FIRING BOARD OPERA TION 1. Disconnect main AC input power to the machine. 2. Remove screws, loosen and lower the front panel to access the Firing Board on the left side of Control Box facing the machine. 3 . Visually inspect the Firing Board for loose or faulty connections. 4 . Recon[...]

  • Page 62

    F-22 TROUBLESHOOTING & REP AIR F-22 1 0. 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. a . If the LEDs glow and change in brightness equal- ly as the potentiometer is turned and the problem conti[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-23 TROUBLESHOOTING & REP AIR F-23 15. Test the Output Pilot Relay (4CR) for operation by removing and replacing the jumper wire repeat- edly from terminal #2. See Figure F.[...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-24 TROUBLESHOOTING & REP AIR F-24 FIRING BOARD TEST IDEALARC DC-1000 T ABLE F .1 - LED 7, 8 and 9 Check List IF LED 7 is ON LED 7 is OFF or is DIM- MER than other LEDs LED [...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-25 TROUBLESHOOTING & REP AIR F-25 IDEALARC DC-1000 CONTROL BOARD TEST Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorize[...]

  • Page 66

    F-26 TROUBLESHOOTING & REP AIR F-26 TEST PROCEDURE FOR NORMAL CONTROL BOARD OPERA TION 1. Remove main supply power to the DC-1000. 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. 3. Apply the correct three-phase input power to the DC-1000. Turn on[...]

  • Page 67

    F-27 TROUBLESHOOTING & REP AIR F-27 POSSIBLE PROBLEMS PERT AINING 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 a. 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[...]

  • Page 68

    F-28 TROUBLESHOOTING & REP AIR F-28 IF LED 2 does not light when #2 and #4 are jumpered together. 1. Check for the presence of open cir- cuit voltage at the weld output ter- minals (27 to 75 VDC in constant voltage mode, 75 VDC in constant current mode). a . If open circuit voltage IS present at the output termi- nals, then check for open circu[...]

  • Page 69

    F-29 TROUBLESHOOTING & REP AIR F-29 I F LED 3 does not light when the Start Button is depressed (but LED 1 does light). 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 4 lights, 1 [...]

  • Page 70

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-30 TROUBLESHOOTING & REP AIR F-30 IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed[...]

  • Page 71

    F-31 TROUBLESHOOTING & REP AIR F-31 TEST PROCEDURE 1. Remove main supply power to the DC-1000. 2 . Remove all Molex plugs from the firing board and control board. See Figure F.12. ST A TIC SCR TEST IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC R[...]

  • Page 72

    F-32 TROUBLESHOOTING & REP AIR F-32 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) a. If a low resistance is [...]

  • Page 73

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-33 TROUBLESHOOTING & REP AIR F-33 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 Ac[...]

  • Page 74

    F-34 TROUBLESHOOTING & REP AIR F-34 IDEALARC DC-1000 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[...]

  • Page 75

    F-35 TROUBLESHOOTING & REP AIR F-35 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. ACTIVE SCR TEST IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master T[...]

  • Page 76

    F-36 TROUBLESHOOTING & REP AIR F-36 3 . Remove the red insulating paint from heat sink test points. See Figure F.16. 4. Perform test procedure as follows. Refer to Figure F.17. Repeat test for all six SCRs. NOTE: Do not disassemble the heat sinks. ACTIVE SCR TEST IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC[...]

  • Page 77

    F-37 TROUBLESHOOTING & REP AIR F-37 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. BA TTERY TEST Check the battery by shorting leads (A) and (C) and then close switch SW1. Replace battery if voltag[...]

  • Page 78

    TROUBLESHOOTING & REP AIR F-38 NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM CONST ANT CURRENT MODE - NO LOAD IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 50 V/Div. Horizontal Sweep . . . . . 2 ms/Div. Coupling . . . . . . . . . . . . . . . . . DC Trigger . . . . . . . . . . . . . . . Internal SCOPE SETTINGS F-38 This is the typical DC open [...]

  • Page 79

    F-39 TROUBLESHOOTING & REP AIR F-39 NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM CONST ANT VOL T AGE INNERSHIELD - MAXIMUM OUTPUT SETTING - NO LOAD IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 50 V/Div. Horizontal Sweep . . . . . 2 ms/Div. Coupling . . . . . . . . . . . . . . . . . DC Trigger . . . . . . . . . . . . . . . Internal SCOPE SET[...]

  • Page 80

    F-40 TROUBLESHOOTING & REP AIR F-40 NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM CONST ANT VOL T AGE INNERSHIELD MINIMUM OUTPUT SETTING - NO LOAD IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 50 V/Div. Horizontal Sweep . . . . . 2 ms/Div. Coupling . . . . . . . . . . . . . . . . . DC Trigger . . . . . . . . . . . . . . . Internal SCOPE SETTI[...]

  • Page 81

    F-41 TROUBLESHOOTING & REP AIR TYPICAL OUTPUT VOL T AGE W A VEFORM -MACHINE LOADED CONST ANT VOL T AGE INNERSHIELD MODE IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 20 V/Div. Horizontal Sweep . . . . . 2 ms/Div. Coupling . . . . . . . . . . . . . . . . . DC Trigger . . . . . . . . . . . . . . . Internal SCOPE SETTINGS F-41 This is the t[...]

  • Page 82

    F-42 TROUBLESHOOTING & REP AIR F-42 TYPICAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED - 500 AMP OUTPUT TERMINAL CONST ANT VOL T AGE INNERSHIELD MODE IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 20 V/Div. Horizontal Sweep . . . . . 2 ms/Div. Coupling . . . . . . . . . . . . . . . . . DC Trigger . . . . . . . . . . . . . . . Internal S[...]

  • Page 83

    F-43 TROUBLESHOOTING & REP AIR F-43 TYPICAL SCR GA TE VOL T AGE W A VEFORM CONST ANT VOL T AGE INNERSHIELD MAXIMUM OUTPUT SETTING - NO LOAD IDEALARC DC-1000 SCOPE SETTINGS Volts/Div . . . . . . . . . . . . . . 1 V/Div. Horizontal Sweep . . . . . .5 ms/Div. Coupling . . . . . . . . . . . . . . . . . DC Trigger . . . . . . . . . . . . . . . Inter[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-44 TROUBLESHOOTING & REP AIR F-44 ABNORMAL OPEN CIRCUIT VOL T AGE W A VEFORM CONST ANT VOL T AGE INNERSHIELD ONE OUTPUT SCR NOT FUNCTIONING MAXIMUM OUTPUT SETTING IDEALARC [...]

  • Page 85

    F-45 TROUBLESHOOTING & REP AIR F-45 IDEALARC DC-1000 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[...]

  • Page 86

    F-46 TROUBLESHOOTING & REP AIR F-46 CLEANING PROCEDURE 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 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.[...]

  • Page 87

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-47 TROUBLESHOOTING & REP AIR F-47 DO NOT APPLY INPUT POWER TO THE DC-1000 WITH THE CONTACTOR COVER PLATE REMOVED. POWER APPLIED WITHOUT COVER PLATE IN POSITION MAY CAUSE SE[...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 INSTALLATION 1. Install input contactor using a 7/16” socket wrench. Attach the four mounting bolts, nuts, and associat- ed washers (or tight[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on t[...]

  • Page 90

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-50 TROUBLESHOOTING & REP AIR SCR OUTPUT BRIDGE REMOV AL 1 . Remove input power to machine. 2. Using a 5/16 (8mm) nut driver or flat head screw driver, remove 20 screws (ten[...]

  • Page 91

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 1 0 . Cut any necessary cable ties to allow for the SCR bridge assembly removal. 11. Using a 1/2” socket wrench, remove the four screws (2 on[...]

  • Page 92

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-52 TROUBLESHOOTING & REP AIR REMOV AL OF INDIVIDUAL SCR HEA T SINK ASSEMBLIES 1. Using a 9/16” wrench, remove two nuts, flat washers, and lock wash- ers from the SCR asse[...]

  • Page 93

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 SCR HEA T SINK INST ALLA TION NOTE: Upon reassembly, apply a thin layer of Lincoln E1868 (Dow Corning #340) heat sink compound to all bolted el[...]

  • Page 94

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-54 TROUBLESHOOTING & REP AIR 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 Figur[...]

  • Page 95

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-55 IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on t[...]

  • Page 96

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-56 TROUBLESHOOTING & REP AIR REMOV AL OF LIFT BAIL 1 . Remove input power to machine. 2. Using a 5/16 (8mm) nut driver or flat head screw driver, remove 20 screws (ten per [...]

  • Page 97

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-57 REASSEMBL Y OF LIFT BAIL 1 . Place the lift bail onto the IDE- ALARC DC-1000 from the top, low- ering straight onto the unit. 2. Using a 9/16?[...]

  • Page 98

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-58 TROUBLESHOOTING & REP AIR IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on t[...]

  • Page 99

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-59 MAIN TRANSFORMER DISASSEMBL Y AND ASSEMBL Y IDEALARC DC-1000 FIGURE F .26 - Main T ransformer Disassembly F-59[...]

  • Page 100

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-60 TROUBLESHOOTING & REP AIR MAIN TRANSFORMER DISASSEMBL Y 1 . Perform Lift Bail Removal Procedure . 2. Remove lead #271 from resistor R3 (located near the input contactor)[...]

  • Page 101

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-61 TRANSFORMER REASSEMBL Y 1. Using a hoist, carefully lift the top iron onto the assembly. Lightly tap on the top of the iron. 2 . Position the t[...]

  • Page 102

    NOTES IDEALARC DC-1000 F-62 F-62 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 103

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-63 TROUBLESHOOTING & REP AIR OPEN CIRCUIT VOL T AGES Mode Input Hertz Open Circuit Volts Variable Voltage 60 74/76 DC Auxiliary Output (#31-#32) 60 122/124 AC RETEST AFTER [...]

  • Page 104

    F-64 NOTES IDEALARC DC-1000 F-64 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 105

    G-1 ELECTRICAL DIAGRAMS G-1 IDEALARC DC-1000 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- DIAGRAMS ........................................................................................Section G Wiring Diagram (Codes 9919, 9920) ...........................................................G-2 Operating Schematic ................................[...]

  • Page 106

    NOTES IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 107

    G-2 ELECTRICAL DIAGRAMS IDEALARC DC1000 Wiring Diagram (Codes 9919, 9920) 9008 Ch'ge. Sht. No. 2-19-93G 3-19-93D 11-19-93C t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (" ") TO AGREE TH[...]

  • Page 108

    G-3 ELECTRICAL DIAGRAMS IDEALARC DC1000 Operating Schematic TS 2 21 4 2 31 32 TS 3 R1 S4-A S4-C CVI CVI CVS CVS S3 2CR L1 L2 L3 1CR START STOP R 1CR 2CR SECONDARY PRIMARY SHUNT 215 215 210 210 226 238 75 3CR 220 215 CURRENT REED SW. CLOSED WITH OUTPUT CURRENT 235 236 236 235 210 215 222 222 231 204 203 206 205 208 207 G1 G2 G3 G4 G5 G6 215 215 X Y [...]

  • Page 109

    G-4 ELECTRICAL DIAGRAMS IDEALARC DC1000 Control PC Board (G1585) Layout IDENTIFICATION PART No. REQ'D. ITEM C3 C15 D1,D2,D3,D4 1N4004 DZ2 DZ3 DZ4 DZ7 R1,R113 R13 R34 R39 R48 20K 1/2W R80,R94,R98 R84 D36 3 1 4 1 4 1 2 1 2 4 1 9 S16668-5 S13490-48 T11577-38 S13490-35 S13490-67 T11577-28 T12199-2 S13490-27 S13490-63 .047/100 50/16 .22/100 T12199-[...]

  • Page 110

    G-5 ELECTRICAL DIAGRAMS IDEALARC DC1000 Firing PC Board (G1486-5 and above) Layout 1/4W 150 1/2W 5.1 1/4W 475 FIRING BOARD G1486-5 R1 R2 R3 R4 R5 R6 R46 R47 R48 R64 R65 R66 R54 R53 R52 R42 R45 R41 R44 R43 R40 R21 R27 R39 R33 R19 R25 R37 R31 R16 R22 R34 R28 R20 R26 R38 R32 R55 R56 R57 R17 R23 R35 R30 R24 R36 R29 R18 C25 C26 C16 C22 C13 C19 C17 C23 C[...]

  • Page 111

    G-6 ELECTRICAL DIAGRAMS IDEALARC DC1000 Control PC Board (G1585) Schematic 1.00K R22 J1 10 100V .047 C6 162 R133 75.0 R142 100V .047 C29 10K J1 8 15.0K R25 1N4004 D35 J2 8 1N4004 D24 LED3 J2 7 1N4004 D26 50V .022 C18 1N4004 D18 2.21K R27 1K CW R38 77 74 75 SW.3 226 1N4004 D12 332 R74 18 15V C4 2N6027 QU2 224 "N" R1 73 233 75 C.V.I. MIN. T[...]

  • Page 112

    G-7 ELECTRICAL DIAGRAMS IDEALARC DC1000 Firing PC Board (G1486-5 and above) Schematic G-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board l[...]

  • Page 113

    G-8 ELECTRICAL DIAGRAMS IDEALARC DC1000 Output Snubber (M14312) Schematic 600V .05 C7 600V .05 C8 160J 320V TP7 160J 320V TP8 NEG 1 POS 1 WELDER HAVING A COMMON CODE. 19699 NONE A.N.S.I. ELECTRICAL SYMBOLS PER E1537 DIAGRAM, MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS[...]