Page 2 - SAFETY; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines; WARNING
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINEpowered equipment. 1.a. T u r n t h e e n g i n e o f f b e f o r e t r o u - bleshooting and maintenance work unless the maintenancework requires it to be running. _________________________________________...
Page 3 - ii
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F U M E S A N D G A S E Scan be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing thesef u m e s a n d g a s e s . W h e n w e l d i n g , k e e pyour head out of the fume. Use ...
Page 4 - iii; Return to Master TOC
F O R E L E C T R I C A L LYp o w e r e d e q u i p m e n t . 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’srecommendations. 8.c...
Page 5 - PRÉCAUTIONS DE SÛRETÉ; iv
SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour Soudage A L’Ar...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; RETURN TO MAIN INDEX
v IDEALARC DC - 1000 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety .....................................................................................................................................................i - iv Installation ...........................................................
Page 7 - TABLE OF CONTENTS; INSTALLATION
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 A-1 TABLE OF CONTENTS -INSTALLATION SECTION- INSTALLATION..................................................................................Section A Technical Specifications ............................
Page 8 - TECHNICAL SPECIFICATIONS – IDEALARC DC - 1000; INPUT - THREE PHASE ONLY
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 C...
Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK CAN KILL.; SELECT PROPER LOCATION; STACKING; FA L L I N G E Q U I P M E N T; c a n; Two IDEALARC DC-1000 machines can be stacked.; TILTING; Machines; FIGURE A.2 - Input Power Supply Connection
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 INSTALLATION IDEALARC DC-1000 R e a d e n t i r e I n s t a l l a t i o n S e c t i o n b e f o r e i n s t a l l i n gthe I...
Page 10 - FUSE AND WIRE SIZES; Technical; GROUND CONNECTION; Follow all national and local electrical codes.; RECONNECT PROCEDURE
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 INSTALLATION IDEALARC DC-1000 A-4 FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses ordelay type circuit br...
Page 11 - CONNECTION FOR UNDER 300 VOLTS; CONNECTION FOR OVER 300 VOLTS
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 stationaryreconnect panel studs in the position shown...
Page 12 - CONNECTION FOR 380 VOLTS
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 INSTALLATION IDEALARC DC-1000 A-6 CONNECTION FOR 380 VOLTS 1. Mount the movable reconnect panel to the stationaryreconnect panel...
Page 13 - FIGURE A.3d - Input Supply Connection Diagram
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 INSTALLATION IDEALARC DC-1000 All input power must be electrically disconnected before touching panel. _____________________...
Page 14 - OUTPUT CONNECTIONS; AUXILIARY POWER; Semi-Automatic Wire Feeders
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 INSTALLATION IDEALARC DC-1000 A-8 OUTPUT CONNECTIONS See Table A.1 for recommended IDEALARC DC-1000cable sizes for combined leng...
Page 15 - Return to Section TOC
A-9 INSTALLATION IDEALARC DC-1000 A-9 CONNECTION FOR AIR/CARBON ARCCUTTING OPERATION THE OUTPUT TERMINALS ARE ENERGIZED ATA L L T I M E S W H E N T H E I D E A L A R C D C - 1 0 0 0 I SCONNECTED FOR AIR/CARBON ARC CUTTING. ____________________________________________________ 1. Set ON/OFF PUSH BUTTO...
Page 16 - NOTES
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 - OPERATION
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 B-1 TABLE OF CONTENTS -OPERATION SECTION- OPERATION...................................................................................................................................Section B Safety ...
Page 18 - SAFETY INSTRUCTIONS; • Keep your head out of fumes.; ELECTRIC SHOCK can kill.
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 OPERATION B-2 IDEALARC DC-1000 Read and understand this entire section beforeoperating your machine. SAFETY INSTRUCTIONS Only qu...
Page 19 - GENERAL DESCRIPTION
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 OPERATION GENERAL DESCRIPTION The IDEALARC DC-1000 is an SCR-controlled, threephase, welding and cutting power source. It us...
Page 20 - Low profile case provides maximum use of space.; WELDING CAPABILITY; The IDEALARC DC-1000 has the following duty cycle ratings.; Duty Cycle
B-4 OPERATION B-4 • Three circuit solid state control system providesmaximum performance and circuit protection. • Low profile case provides maximum use of space. • Convenient access to all controls. • Large output lead strain relief openings to preventterminal and cable damage. • Easily removed cas...
Page 21 - VOLTMETER: An optional voltmeter is available.; CONTROLS AND SETTINGS
B-5 OPERATION B-5 1. ON/OFF PUSH BUTTON: This push button turnsthe machine ON or OFF 2. OUTPUT CONTROL POTENTIOMETER: Thiscontrol provides tapered, continuous control of themachine output. The control can be rotated fromminimum to maximum while machine is underload to adjust the machine output. 3. W...
Page 22 - OPERATING STEPS; - Set toggle to “Electrode Negative” position if the; Accessories Section for wire feeder remote; NA-3 AUTOMATIC WIRE FEEDER
B-6 OPERATION B-6 OPERATING STEPS The following procedures are for using the IDEALARCDC-1000 in the local control mode of operation. Forr e m o t e c o n t r o l o f t h e m a c h i n e , s e e t h e R e m o t eControl of Machine Operation section. Before operating the machine, make sure you have al...
Page 23 - Cut the electrode to a sharp point.
B-7 OPERATION B-7 G O O D A R C S T R I K I N G G U I D E L I N E S F O R T H ENA-3 WITH THE IDEALARC DC-1000 IN THE CVINNERSHIELD®, CV SUBMERGED ARC OR VV(CC) WELDING MODES. Following are some basic arc striking techniques thatapply to all wire feed processes. Using these proce-dures should provide...
Page 24 - Start and make the weld.
B-8 OPERATION B-8 c. Set NA-3 Start Board current and voltageas close to the welding procedure currentand voltage as possible. NOTE: The Start Board current and volt-age should be as close as possible to thewelding procedure current and voltage,w h i l e s t i l l g e t t i n g s a t i s f a c t o r...
Page 25 - ACCESSORIES
C-1 ACCESSORIES C-1 IDEALARC DC-1000 TABLE OF CONTENTS -ACCESSORIES SECTION- ACCESSORIES ........................................................................................................................Section C Options/Accessories ................................................................
Page 26 - METERS; Connection to the IDEALARC DC-1000; CAUTION; The IDEALARC DC-1000 must be properly grounded.
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 areavailable. REMOTE OUTPUT CONTROL -(OPTIONAL) The...
Page 28 - S e t t h e D C - 1 0 0 0 o u t p u t c o n t r o l s w i t c h t o t h e
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.2shows the electrode connected for positive polarity.To chang...
Page 29 - Connect LN-9 wire feeder jumpers on voltage
C-5 ACCESSORIES C-5 CONNECTING THE LN-9 WIRE FEEDERTO THE IDEALARC DC-1000 1. Set the ON/OFF PUSH BUTTON to the OFF pos-tion. 2. Disconnect AC input power to the IDEALARC DC-1000. 3. Connect the wire feeder control cable leads to theDC-1000 terminal strip. See Figure C.4. 4. Connect the wire feeder ...
Page 31 - MAINTENANCE
D-1 MAINTENANCE D-1 IDEALARC DC - 1000 TABLE OF CONTENTS -MAINTENANCE SECTION- MAINTENANCE ...................................................................................................Section D Safety Precautions.....................................................................................
Page 32 - Perform Periodically:; Main transformer and choke; Perform the following daily:; Do not touch electrically hot parts.
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 thatwould affect the proper op...
Page 35 - THEORY OF OPERATION; FIGURE E.1 Block Logic Diagram
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-1 THEORY OF OPERATION E-1 IDEALARC DC-1000 TABLE OF CONTENTS -THEORY OF OPERATION SECTION- THEORY OF OPERATION SECTION. ................................................................Section E General Description ...
Page 36 - FIGURE E.2 - Input Line Voltage, Contactor and Main Transformer
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 THEORY OF OPERATION E-2 I N P U T L I N E V O LTA G E , C O N TA C -T O R , A N D M A I N T R A N S F O R M E R The desired ...
Page 39 - SCR OPERATION
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 THEORY OF OPERATION E-5 SCR OPERATION A silicon controlled rectifier (SCR) is a three termi-nal device used to control rathe...
Page 41 - TROUBLESHOOTING & REPAIR
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDEALARC DC-1000 F-1 TROUBLESHOOTING & REPAIR F-1 TABLE OF CONTENTS -TROUBLESHOOTING AND REPAIR SECTION- TROUBLESHOOTING AND REPAIR SECTION ...............................................................Section F...
Page 42 - HOW TO USE TROUBLESHOOTING GUIDE
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 & REPAIR F-2 This Troubleshooting Guide is provided tohelp you locate and repair possib...
Page 43 - E L E C T R I C S H O C K c a n k i l l .; PC BOARD TROUBLESHOOTING PROCEDURES
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 & REPAIR F-3 _______________________________ CAUTION: Sometimes machine failures appear...
Page 44 - OUTPUT PROBLEMS
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 Linco...
Page 48 - Observe all Safety Guidelines detailed throughout this manual; P u t o u t p u t c o n t r o l s w i t c h
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 & REPAIR F-8 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBL...
Page 49 - FUNCTION PROBLEMS
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 & REPAIR F-9 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any r...
Page 50 - Observe all Safety Guidelines detailed througout this manual; R e m o v e a n y e x t e r n a l l e a d s; S C R O u t p u t
F-10 TROUBLESHOOTING & REPAIR 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 ElectricService Department for technical troubleshoo...
Page 51 - WELDING PROBLEMS
F-11 TROUBLESHOOTING & REPAIR 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 ElectricService Department for technical troublesho...
Page 52 - . T h e o u t p u t c u r r e n t d e m a n d
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 & REPAIR F-12 IDEALARC DC-1000 Observe all Safety Guidelines detailed throughout this manual If for any...
Page 53 - TEST DESCRIPTION; applied to the primary of the control transformer.; MATERIALS NEEDED
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 & REPAIR F-13 TEST DESCRIPTION This test will determine if the correct voltage is bein...
Page 54 - TEST PROCEDURE; Remove the Top and Case Sides.; FIGURE F.1 - Control Transformer Lead Location
F-14 TROUBLESHOOTING & REPAIR F-14 TEST PROCEDURE 1. Disconnect main AC input power tothe machine. 2. Remove the Top and Case Sides. 3. Locate the Control Transformer (T2)on the left side of the Input Box (fac-ing the back of the machine). SeeFigure F.1. 4. Locate the Control Transformerprimary ...
Page 55 - FIGURE F.2 - Control Transformer X1 and X2 Test Points
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 & REPAIR F-15 5. Locate Control Transformer leadsX1 and X2 at in line connectors.See Figure F.2. 6. App...
Page 56 - applied to the primary windings of the Main Transformer (T1).
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...
Page 57 - Main Transformer Locations
F-17 TROUBLESHOOTING & REPAIR F-17 TEST DESCRIPTION 1. Disconnect main AC input power tothe machine. 2. I n s p e c t t h e I n p u t C o n t a c t o r ,Reconnect Panel, and primary leadsto the Main Transformer for loose orfaulty connections. See Figure F.3. 3. Apply input power, push start butt...
Page 58 - FIGURE F.4 - Main Secondary Lead Test Points
F-18 TROUBLESHOOTING & REPAIR F-18 a. If one or more of the abovevoltage tests are incorrect,c h e c k f o r l o o s e o r f a u l t ywiring. If the wiring is good,then the Main Transformermay be faulty. NOTE: A long wire with clip or al o n g p r o b e m a y b e r e q u i r e d t or e a c h t h...
Page 59 - From; FIGURE F.5 - Phase Angle Windings Test Points and Firing Board Pin
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 & REPAIR F-19 MAIN TRANSFORMER (T1) VOLTAGE TEST IDEALARC DC-1000 From To Expected VAC Plug Pin Lead Pl...
Page 60 - FIRING BOARD TEST
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 & REPAIR F-20 FIRING BOARD TEST IDEALARC DC-1000 Service and repair should be performed only by Lincoln...
Page 61 - FIGURE F.6 - Firing Board LED and Molex Plug Locations
F-21 TROUBLESHOOTING & REPAIR F-21 TEST PROCEDURE FORNORMAL FIRINGBOARD OPERATION 1. Disconnect main AC input power tothe machine. 2. Remove screws, loosen and lowerthe front panel to access the FiringBoard on the left side of ControlBox facing the machine. 3. Visually inspect the Firing Boardf ...
Page 62 - S C R B r i d g e; Locate and test for 6 to 15 VDC; FIGURE F.7 - Terminal Strip Jumper Wire Connections
F-22 TROUBLESHOOTING & REPAIR F-22 10. Rotate the output control poten - tiometer (R1). As the potentiometeri s t u r n e d c l o c k w i s e , t h e L E D sshould glow brighter. As the poten-tiometer is turned counter-clock-wise, the LEDs should dim. a. I f t h e L E D s g l o w a n dchange in ...
Page 63 - FIGURE F.8 - Output Pilot Relay 4CR Location; R e p l a c e t h e F i r i n g B o a r d i f t h e
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 & REPAIR F-23 15. Test the Output Pilot Relay (4CR) f o r o p e r a t i o n b y r e m o v i n g a n dre...
Page 64 - IF; LED 7 is ON; THEN; Perform Main
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 & REPAIR F-24 FIRING BOARD TEST IDEALARC DC-1000 TABLE F.1 - LED 7, 8 and 9 Check List IF LED 7 is ON L...
Page 65 - CONTROL BOARD TEST
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 & REPAIR F-25 IDEALARC DC-1000 CONTROL BOARD TEST Service and repair should be performed only by Lincol...
Page 66 - FIGURE F.9 Control Board LED and Pin Locations.
F-26 TROUBLESHOOTING & REPAIR F-26 TEST PROCEDURE FORNORMAL CONTROL BOARDOPERATION 1. Remove main supply power to theDC-1000. 2. Remove screws, loosen and lowert h e F r o n t P a n e l t o a c c e s s a n dinspect the Control Board locatedin the right front control box. SeeFigure F.9. 3. Apply ...
Page 68 - M a i n T r a n s f o r m e r; P e r f o r m t h e; F i r i n g B o a r d T e s t.; Perform the; SCR Output Bridge; FIGURE F.11 - LED 2 Open Circuit Voltage Test Points
F-28 TROUBLESHOOTING & REPAIR 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 constantvoltage mode, 75 VDC in constantcurrent mode). a. I f o p e n c i r c u i t v o l t a g e I Sp...
Page 70 - STATIC SCR TEST
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 & REPAIR F-30 IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory ...
Page 73 - FIGURE F.14 - Snubber Location and Circuit
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 & REPAIR F-33 5. Repeat Step 4 testing SCR 2, SCR3 , S C R 4 , S C R 5 , a n d S C R 6 . To further che...
Page 74 - ACTIVE SCR TEST
F-34 TROUBLESHOOTING & REPAIR 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 orthe machine operator and will invalidate your factory warranty...
Page 75 - FIGURE F.15 - Firing Board and Control Board Molex Plug Locations; FIRING BOARD
F-35 TROUBLESHOOTING & REPAIR F-35 1. Remove main supply power to theDC-1000. 2. Remove all Molex plugs from theF i r i n g B o a r d a n d C o n t r o l B o a r d .See Figure F.15. ACTIVE SCR TEST IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Secti...
Page 76 - FIGURE F.16 - Heat Sink Assembly Test Points
F-36 TROUBLESHOOTING & REPAIR F-36 3. R e m o v e t h e r e d i n s u l a t i n g p a i n tf r o m h e a t s i n k t e s t p o i n t s . S e eFigure F.16. 4. Perform test procedure as follows.Refer to Figure F.17. Repeat testfor all six SCRs. NOTE: Do not disassemble the heatsinks. ACTIVE SCR TE...
Page 77 - BATTERY TEST; A. Connect SCR into the test circuit as
F-37 TROUBLESHOOTING & REPAIR F-37 5. To test SCRs, construct the circuitoutlined in Figure F.17. Use one 6Vlantern battery. Resistor values arein ohms ±10%. The voltmeter scaleshould be low, approximately 0-5 or0-10 volts. BATTERY TEST Check the battery by shorting leads (A)and (C) and then clo...
Page 78 - NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; SCOPE SETTINGS
TROUBLESHOOTING & REPAIR F-38 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE - NO LOAD IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 50 V/Div.Horizontal Sweep . . . . . 2 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigger . . . . . . . . . . . . . . . Internal SCOPE S...
Page 81 - TYPICAL OUTPUT VOLTAGE WAVEFORM -MACHINE
F-41 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM -MACHINE LOADED CONSTANT VOLTAGE INNERSHIELD MODE IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 20 V/Div.Horizontal Sweep . . . . . 2 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigger . . . . . . . . . . . . . . . Int...
Page 82 - TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE
F-42 TROUBLESHOOTING & REPAIR F-42 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED - 500 AMP OUTPUT TERMINAL CONSTANT VOLTAGE INNERSHIELD MODE IDEALARC DC-1000 Volts/Div . . . . . . . . . . . . . 20 V/Div.Horizontal Sweep . . . . . 2 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigger ....
Page 83 - TYPICAL SCR GATE VOLTAGE WAVEFORM
F-43 TROUBLESHOOTING & REPAIR F-43 TYPICAL SCR GATE VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD MAXIMUM OUTPUT SETTING - NO LOAD IDEALARC DC-1000 SCOPE SETTINGS Volts/Div . . . . . . . . . . . . . . 1 V/Div.Horizontal Sweep . . . . . .5 ms/Div.Coupling . . . . . . . . . . . . . . . . . DCTrigg...
Page 84 - ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
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 & REPAIR F-44 ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHIELD ONE OUTPUT SCR NOT FU...
Page 86 - CLEANING PROCEDURE; FIGURE F.18 - Input Contactor Cover Removal
F-46 TROUBLESHOOTING & REPAIR F-46 CLEANING PROCEDURE 1. Remove main input supply power tothe DC-1000 and remove case topand sides. 2. Locate the input contactor. Using a1/2” wrench, remove the cover plate f r o m t h e i n p u t c o n t a c t o r . M a r k ,label, and remove leads as neces-s a ...
Page 87 - DO NOT APPLY INPUT POWER TO; Examine contacts for signs of wear.; CONTACTOR REPLACEMENT; REMOVAL; Secondary Thermostat
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 & REPAIR F-47 DO NOT APPLY INPUT POWER TO T H E D C - 1 0 0 0 W I T HT H E C O N T A C T O RC O V E R P...
Page 89 - SCR OUTPUT BRIDGE REPLACEMENT
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 & REPAIR F-49 IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory train...
Page 90 - Remove input power to machine.; FIGURE F.22 - Preparation For SCR Output Bridge Removal
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 & REPAIR SCR OUTPUT BRIDGEREMOVAL 1. Remove input power to machine. 2. Using a 5/16 (8mm) nut driver or...
Page 91 - C u t a n y n e c e s s a r y c a b l e t i e s t o
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 & REPAIR F-51 10. C u t a n y n e c e s s a r y c a b l e t i e s t o allow for the SCR bridge assemblyremov...
Page 92 - FIGURE F.24 - Individual SCR Assembly Heat Sink Removal
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 & REPAIR REMOVAL OF INDIVIDUALSCR HEAT SINK ASSEMBLIES 1. Using a 9/16” wrench, remove twonuts, flat wa...
Page 94 - Feed the J4 gate lead Molex plug
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 & REPAIR 7. Using a 3/8” socket wrench, attachthe two screws (one on each side)holding the SCR assembly...
Page 95 - REMOVAL AND REASSEMBLY OF LIFT BAIL
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 & REPAIR F-55 IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory train...
Page 96 - REMOVAL OF LIFT BAIL
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 & REPAIR REMOVAL OF LIFT BAIL 1. Remove input power to machine. 2. Using a 5/16 (8mm) nut driver or fla...
Page 98 - MAIN TRANSFORMER REMOVAL AND INSTALLATION
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 & REPAIR IDEALARC DC-1000 Service and repair should be performed only by Lincoln Electric factory train...
Page 99 - MAIN TRANSFORMER DISASSEMBLY AND ASSEMBLY; FIGURE F.26 - Main Transformer Disassembly
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 & REPAIR F-59 MAIN TRANSFORMER DISASSEMBLY AND ASSEMBLY IDEALARC DC-1000 FIGURE F.26 - Main Transformer Disa...
Page 100 - L i f t B a i l R e m o v a l; MAIN TRANSFORMER DISASSEMBLY
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 & REPAIR MAIN TRANSFORMERDISASSEMBLY 1. P e r f o r m L i f t B a i l R e m o v a l Procedure. 2. Remov...
Page 101 - L i f t B a i l I n s t a l l a t i o n; Replace any cable ties or restraints; TRANSFORMER INSTALLATION
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 & REPAIR F-61 TRANSFORMERREASSEMBLY 1. Using a hoist, carefully lift the topiron onto the assembly. Lightly ...
Page 103 - Variable Voltage; RETEST AFTER REPAIR; Constant Voltage Innershield
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 & REPAIR OPEN CIRCUIT VOLTAGES Mode Input Hertz Open Circuit Volts Variable Voltage 60 74/76 DC Auxilia...
Page 105 - ELECTRICAL DIAGRAMS
G-1 ELECTRICAL DIAGRAMS G-1 IDEALARC DC-1000 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- DIAGRAMS........................................................................................Section GWiring Diagram (Codes 9919, 9920) ...........................................................G-2Operat...
Page 108 - Operating Schematic
G-3 ELECTRICAL DIAGRAMS IDEALARC DC1000 Operating Schematic T S 2 2 1 4 2 3 1 3 2 T S 3 R 1 S 4 - A S 4 - C C V I C V I C V S C V S S 3 2 C R L 1 L 2 L 3 1 C R S T A R T S T O P R 1 C R 2 C R S E C O N D A R Y P R I M A R Y S H U N T 2 1 5 2 1 5 2 1 0 2 1 0 2 2 6 2 3 8 7 5 3 C R 2 2 0 2 1 5 C U R R ...
