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IM420-C
IDEALARC DC- 000
1 October, 2007
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. However, your overall safety
can be increased by proper instal-
lation ... 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.
OPERATOR鈥橲 MANUAL
Copyright 漏 2007 Lincoln Global Inc.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of 鈥淎rc Welding Safety鈥? 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar 驶95
magneto wire as appropriate.
SAFETY
ii ii
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
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? parts with your bare should conform to ANSI Z87. I standards.
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
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
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
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
FUMES AND GASES
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
can be dangerous.
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 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
鈥? Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
鈥? DC Manual (Stick) Welder. your head out of the fume. Use enough
鈥? 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
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically 鈥渉ot鈥?.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5. b. The operation of welding fume control equipment is affected
3.f. Maintain the electrode holder, work clamp, welding cable and
by various factors including proper use and positioning of
welding machine in good, safe operating condition. Replace
the equipment, maintenance of the equipment and the spe-
damaged insulation.
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.g. Never dip the electrode in water for cooling.
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of
electrode holders connected to two welders because voltage
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
between the two can be the total of the open circuit voltage
coming from degreasing, cleaning or spraying operations.
of both welders.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.i. When working above floor level, use a safety belt to protect
ucts.
yourself from a fall should you get a shock.
5.d. Shielding gases used for arc welding can displace air and
3.j. Also see Items 6.c. and 8.
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer始s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 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 7.c. Cylinders should be located:
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI 鈥? Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
鈥? A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically 鈥渉ot鈥? 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 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances鈥?, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or 鈥淧recautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,鈥? available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer始s
through lifting chains, crane cables or other alternate cir-
recommendations.
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B 鈥? Standard for Fire Prevention
During Welding, Cutting and Other Hot Work鈥?, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
SAFETY
iv iv
PR脡CAUTIONS DE S脹RET脡 5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
zones o霉 l始on pique le laitier.
Pour votre propre protection lire et observer toutes les instructions
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales suiv-
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
antes:
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
S没ret茅 Pour Soudage A L始Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse 茅lectrique:
茅chauffement et un risque d始incendie.
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
8. S始assurer que la masse est connect茅e le plus pr茅s possible
quand la machine 脿 souder est en marche. Eviter toujours
de la zone de travail qu始il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d始autres
ou les v茅tements mouill茅s. Porter des gants secs et sans
endroits 茅loign茅s de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire tr茅s attention de bien s始isoler de la masse quand on
age, c芒bles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d始incendie ou d始echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
c芒bles jusqu始脿 ce qu始ils se rompent.
les positions assis ou couch茅 pour lesquelles une grande
partie du corps peut 锚tre en contact avec la masse.
9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble
Ceci est particuli茅rement important pour le soudage de t么les
de soudage et la machine 脿 souder en bon et s没r 茅tat
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
defonctionnement.
produit des fume茅s toxiques.
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
refroidir.
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
e. Ne jamais toucher simultan茅ment les parties sous tension
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
parce que la tension entre les deux pinces peut 锚tre le
du solvant pour produire du phosg茅ne (gas fortement toxique)
total de la tension 脿 vide des deux machines.
ou autres produits irritants.
f. Si on utilise la machine 脿 souder comme une source de
courant pour soudage semi-automatique, ces precautions
11. Pour obtenir de plus amples renseignements sur la s没ret茅,
pour le porte-茅lectrode s始applicuent aussi au pistolet de
voir le code 鈥淐ode for safety in welding and cutting鈥? CSA
soudage.
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie
PR脡CAUTIONS DE S脹RET脡 POUR
du corps.
LES MACHINES 脌 SOUDER 脌
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel,
TRANSFORMATEUR ET 脌
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant appropri茅
ainsi qu始un verre blanc afin de se prot茅ger les yeux du ray-
onnement de l始arc et des projections quand on soude ou
quand on regarde l始arc. 1. Relier 脿 la terre le chassis du poste conformement au code de
b. Porter des v锚tements convenables afin de prot茅ger la l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
l驶arc. bonne mise 脿 la terre.
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables. 2. Autant que possible, I始installation et l始entretien du poste seront
effectu茅s par un 茅lectricien qualifi茅.
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de
soudage. Se prot茅ger avec des v锚tements de protection libres 3. Avant de faires des travaux 脿 l始interieur de poste, la debranch-
de l始huile, tels que les gants en cuir, chemise 茅paisse, pan- er 脿 l始interrupteur 脿 la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur
place.
Mar. 驶93
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
Thank You 鈥⑩?⑩?? as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer始s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change 鈥? This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. 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.
鈥? 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.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
-6-
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
Overload Protection......................................................................................................15
Troubleshooting................................................................................................................16-18
P.C. Board Troubleshooting Guide ..................................................................................19-20
Outline for DC-1000 Troubleshooting Guide.......................................................................21
Connection Diagrams.......................................................................................................22-25
Wiring Diagram ...................................................................................................................26
Parts Lists ...................................................................................................................P146 Series
-7-
TECHNICAL SPECIFICATIONS 鈥? DC-1000
INPUT - THREE PHASE ONLY
Input Current at Rated Output
Standard
Voltage 50% Duty Cycle
100% Duty Cycle 60% Duty Cycle
230/460/60 230/115
193/96.5 215/108
575/60 92
77.2 86
220/380/440/50/60 230/133/115
193/112/96.5 215/124/108
380/500/50/60 133/101
112/85 124/94
415/50/60 121
102 113
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 1000 44
60% Duty Cycle 1140 44
50% Duty Cycle 1250 44
OUTPUT
Output Range Maximum Open Circuit Voltage Auxiliary Power
75V for 60 HZ models See the OPERATION section
150A/16V-1300A/46V
72V for 50/60 HZ models for Auxiliary Power
information by model
RECOMMENDED INPUT WIRE AND FUSE SIZES
TYPE 75掳C TYPE 75掳C TYPE 75掳C
INPUT HERTZ INPUT AMPERE
COPPER WIRE GROUND WIRE (SUPER LAG)
VOLTAGE / RATING ON
IN CONDUIT IN CONDUIT OR BREAKER
FREQUENCY NAMEPLATE
AWG(IEC-MM2) SIZES AWG(IEC-MM2) SIZES SIZE (AMPS)1
30掳C (86掳F) Ambient
230 60 193 000 (85) 4 (21) 300 Amp
460 60 96.5 3 (27) 6 (14) 150 Amp
575 60 77.2 4 (21) 6 (14) 125 Amp
220 50/60 193 000 (85) 4 (21) 300 Amp
380 50/60 112 2 (34) 6 (14) 175 Amp
415 50/60 102 2 (34) 6 (14) 150 Amp
440 50/60 96.5 3 (27) 6 (14) 150 Amp
500 50/60 85 4 (21) 6 (14) 125 Amp
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.75 in 22.25 in 39.0 in 821 lbs.
781 mm 567 mm 991 mm 372 kg.
1Also called 鈥渋nverse time鈥? or 鈥渢hermal/magnetic鈥? circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
鈥?8鈥?
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鈥? (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. It can be used
and stacking the machines two high to conserve floor space.
for air carbon arc cutting with carbon rods up to and
including 5/8鈥? (15.9mm) dia. The DC-1000 (below
code 9500) is not recommended for stick welding or A permanent lifting eye is located at the top of the machine and
for solid wire and gas in the short arc welding mode. is positioned so that it acts as nearly as possible through the
With the addition of the 500 amp output stud to DC- center of gravity. This lift eye fits under the case of the second
1000 models above code 9500, GMAW procedures machine without interference when stacking.
can be performed. This connection provides the
enhanced lower current arc characteristics required
STACKING
for this type of welding.
WARNING
The DC-1000 is provided with a three position mode
FALLING EQUIPMENT can cause
switch that selects CV Innershield庐, CV Submerged
injury.
Arc or CC (Variable Voltage) Submerged Arc.
鈥? Do not lift this machine using lift bale if
The unit is designed to be used with the NA-5, NA-5R it is equipped with a heavy accessory
and NA-3 automatics, the LT-56 and LT-7 tractors, such as trailer or gas cylinder.
and can also be used with the LN-7, LN-8 or LN-9 鈥? Lift only with equipment of adequate lifting capacity.
semiautomatic wire feeders. 鈥? Be sure machine is stable when lifting.
鈥? Do not stack more than two high.
INSTALLATION 鈥? Do not stack the DC-1000 on top of any other
machine.
WARNING ---------------------------------------------------------------------
ELECTRIC SHOCK can kill. Two DC-1000始s may be stacked by observing the following
safety precautions:
鈥? Have an electrician install and service
this equipment.
1. Make sure the first or bottom unit is setting on a level, well-
鈥? Turn the input power off at the fuse
supported surface.
box before working on equipment.
鈥? Do not touch electrically hot parts.
2. The units must be stacked with their fronts flush, making
---------------------------------------------------------------------
sure the two holes in the base rails of the top unit are over
LOCATION the two pins located on top of the bottom unit.
INPUT WIRING
Even though the machine is designed to operate
under a wide variety of environmental conditions, for
Be sure the voltage, phase and frequency of the input power is
maximum reliability and long life the machine should
as specified on the welder nameplate.
be located in a clean, dry place where there is free cir-
culation of clean air in through the front and out the
Dual voltage (e.g. 230/460) models are shipped connected for
back of the machine. Dirt and dust that can be drawn
the highest voltage. To change the connection, see the connec-
into the machine should be kept to a minimum. Failure
tion diagram pasted to the inside of the access panel in the
to observe these precautions can result in excessive
case back.
operating temperatures and nuisance shutdown of the
machine.
Have a qualified electrician remove the rear access panel and
connect 3 phase AC power to terminals L1, L2 and L3 of the
The case front incorporates a recessed control panel
which protects the controls and minimizes the possi- input panel in accordance with the U.S. National Electrical
bilities of accidental contact. This cover panel can be Code, all local codes and the wiring diagram located inside the
flipped open to permit access to the enclosed control machine.
section.
The welder frame must be grounded. A stud marked with the
The individual case sides are removable for easy symbol located inside the machine near the input panel is
access for internal service or inspection. provided for this purpose. See the U.S. National Electrical Code
for details on proper grounding methods. (See Technical
The case rear is equipped with a removable cover Specifications)
plate, permitting easy access to the input panel.
鈥?9鈥?
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始s rating
inside of Case Back Input Access Door. These con-
plate. Before installing the machine, check that the
nection diagrams for the following codes are listed
Reconnect Panel in the Input Box Assembly is con-
below.
nected for the proper voltage.
CAUTION 1. For Single and Dual Voltage except 380/500 see
Figure 1, (S17172).
Failure to follow these instructions can cause
2. For 220/380/460, see Figure 2, (M14358).
immediate failure of components within the
machine.
3. For 380/500, see Figure 3, (S17344).
When powering welder from a generator be sure
4. For Voltages not listed, see the Input Connection
to turn off welder first, before generator is shut
------------------------------
Diagram pasted on the inside of the Case
down, in order to prevent damage to the welder
Back Input Access Door.
FIGURE 1
鈥? 10 鈥?
FIGURE 2
FIGURE 3
鈥? 11 鈥?
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. The output terminals are located on the lower operating wire feeding equipment. See the appropri-
case front and labeled 鈥?+鈥? and 鈥?-鈥?. There are 1000 ate connection diagram for exact instructions covering
amp rated 鈥?+鈥? terminals on the right side, one 500 the wire feeder being used.
amp rated 鈥?+鈥? terminal near the center and 鈥?-鈥? termi-
nals on the left side. They are fully recessed to mini- With the DC-1000 turned off, the control cable from
mize the possibility of accidental contact by an object the automatic wire feeding equipment is connected to
or a person. Strain relief is provided by the oval holes the terminal strip. A strain relief box connector is pro-
in the base. The leads are run through these oval vided for access into the terminal strip section. A
holes before they are connected to the output termi- chassis grounding screw is also provided below the
nals. terminal strip marked with the symbol for connect-
ing the wire feeding equipment grounding wire. See
The 1000 amp output connections provide the full the appropriate connection diagram for the exact
rated output range of the machine. See Table1 for instructions for the wire feeder being used. A spare
recommended DC-1000 cable sizes for combined hole is provided for an additional box connector if
lengths of electrode and work cables. required.
The 500 amp output connections provide enhanced Connecting for Air Carbon Arc:
lower current arc characteristics, especially for sub-
merged arc and GMAW procedures below 450 amps. a. Turn off all power.
b. Disconnect all wire feed unit control, electrode and
work leads.
Auxiliary Power c. Connect a jumper from 2-4 on terminal strip.
d. Place mode switch in the CV(I) position.
This machine supplies the 115 volt, AC power needed
for operating wire feeding equipment. The power is With the DC-1000 connected for air carbon arc weld-
available from terminals #31 and #32 on the terminal ing, the output terminals will be energized at all times.
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.
TABLE 1
DC-1000 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable
at 100% Duty Cycle
ELECTRODE, WORK AND #21 LEAD
Cable Length Parallel Cables Cable Size
3 1/0 (53mm2)
Lengths up to 150 ft. (46m)
150 ft.(46m) to 200 ft (61m) 3 2/0 (67mm2)
200 ft.(61m) to 250 ft.(76m) 3 3/0 (85mm2)
鈥? 12 鈥?
OPERATING INSTRUCTIONS Starting the Machine - The push button power 鈥渙n鈥?
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.
ELECTRIC SHOCK can kill.
鈥? Do not touch electrically live parts or
The red light below the stop-start button indicates
electrode with skin or wet clothing.
when the input contactor is energized.
鈥? Insulate yourself from work and
ground.
Output Control - The output control in the center of
鈥? Always wear dry insulating gloves.
the control panel is a continuous control of the
------------------------------------------------------------------------
machine output. The control may be rotated from min.
FUMES AND GASES can be danger-
to max. while under load to adjust the machine output.
ous.
鈥? Keep your head out of fumes.
The machine is equipped with line voltage compensa-
鈥? Use ventilation or exhaust to remove
tion as a standard feature. This will hold the output rel-
fumes from breathing zone.
atively constant except at maximum output of the
------------------------------------------------------------------------
machine, through a fluctuation of +/- 10% of input line
WELDING SPARKS can cause fire or
voltage.
explosion.
鈥? Keep flammable material away.
Output Control at DC-1000 or Output Control
鈥? Do not weld on closed containers.
Remote Switch
------------------------------------------------------------------------
The toggle switch on the control panel labeled 鈥淥utput
ARC RAYS can burn eyes and skin.
Control at DC-1000鈥? / 鈥淥utput Control Remote鈥? gives
鈥? Wear eye, ear and body
the operator the option of controlling the output at the
protection.
machine control panel or at a remote station. For
remote control, the toggle switch is set in the 鈥淥utput
------------------------------------------------------------ Control Remote鈥? position and controlled at the wire
feed unit control or by connecting a K775 control to
See additional warning information at the appropriate terminals (as indicated on the connec-
front of this operator始s manual. tion diagram) on the terminal strip at the front of the
----------------------------------------------------------- machine. For control at the machine control panel, the
toggle switch is set in the 鈥淥utput Control at DC-1000鈥?
position.
NOTE: All P.C. boards are protected by a moisture
Remote Output Control - (Optional)
resistant coating. When the welder is operated, this
coating will 鈥渂ake off鈥? of certain power resistors that
The K775 Remote Output Control consists of a control
normally operate at high temperatures emitting some
box with 28 ft. (8.4m) of four conductor cable. This
smoke and odor for a short time. These resistors and
connects to terminals 75, 76, 77 on the terminal strip,
the P.C. board beneath them may become blackened.
and the case grounding screw so marked with the
This is a normal occurrence and does not damage the
symbol on the machine. These terminals are
component or affect the machine performance.
made available by opening the terminal access cover
TO SET POLARITY on the left side of the case front. This control will give
the same control as the output control on the
Turn off the DC-1000 and connect the electrode cable
machine.
to the 鈥淧ositive鈥? or 鈥淣egative鈥? studs depending upon
the electrode polarity desired. Connect the work cable
Mode Switch
to the other stud. (See 鈥淥utput Connections鈥?).
The toggle switch labeled C (I) Innershield, CV(S)
Set the 鈥淓lectrode Negative-Electrode Positive鈥? switch
Submerged Arc, CC (or Variable Voltage) is used to
to correspond to the polarity of the electrode cable
select the proper welder characteristics for the
connection. This switch setting is necessary for proper
process being used. The CC (or Variable Voltage)
operation of some Lincoln wire feeders and does not
mode is primarily available for use with older wire
change the welding polarity.
feeding equipment such as the LAF-3, LT-34 and so
forth. Use of this type of older equipment requires the
addition of an NL Option Kit.
鈥? 13 鈥?
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. - adjust the NA-3 OCV and inch speed con-
the mode switch position. trols for optimum starting. In general, a low inch speed
and an OCV dial setting identical to the voltage dial
a. Use the CV(I) mode for all FCAW and GMAW setting will provide the best starting.
processes. The CV(I) mode is also used for
air carbon arc using carbon rods up to and To further optimize starting, adjust the OCV by making
including 5/8鈥? (15.9mm) dia. repeated starts and observing the NA-3 voltmeter
action. With proper adjustment of the OCV control, the
Welding with NR庐-151, 202, 203 and other voltmeter needle will swing smoothly up to the desired
electrodes below 20 volts, is not recommend- arc voltage and thus provide repeatable starts.
ed.
If the voltmeter swings above the set voltage and then
b. Use the CV(S) mode for all submerged arc back to the desired welding voltage, the OCV setting
is too high. This usually results in a bad start where
welding. This applies to both low and high
travel speeds. the wire tends to 鈥渂last off鈥?.
If the voltmeter needle hesitates before coming up to
c. The CC (Variable Voltage) mode is available
the desired voltage, the OCV is set too low. This will
for high current large puddle submerged arc
procedures that cannot be done as well with cause the electrode to stub.
the constant voltage mode. CC mode should
3. NA-5 - Set the DC-1000 mode switch to the
be used for 3/16鈥? (4.8mm) diameter electrode
and above where high current surges cause process being used - CV(I) Innershield or CV(S)
machine shutdown when starting. This occurs Sub Arc. Set the DC-1000 machine/remote switch
primarily when the slag ball is not cut from the in the remote position. Set the OCV control four
electrode prior to starting. (Also requires a volts higher than the welding voltage and the inch
wire feeder that has a constant current mode speed at 1/2 the welding wire feed speed for the
- i.e. NA-3S). initial test weld. Adjust the OCV and inch speed as
required for optimum starting. Refer to the NA-5
NOTE: Some processes and procedures may be bet- instruction manual for data regarding the setup of
ter with the mode switch in the other CV position. If controls and modes on the NA-5.
the mode switch position initially selected is not pro-
4. LN-8 - Set the LN-8 mode switch (located on the
ducing the desired results, then place the mode switch
in the other CV position and make a test weld. Then CC board) to the CV position. Set the DC-1000
use the CV mode switch position that gives the mode switch on CV(I) Innershield or CV(S) Sub
desired results. Arc according to the process being used.
5. LN-7, LN-9 and other constant wire feed units -
2. NA-3 - The NA-3 should be set for the mode being
Set the DC-1000 mode switch on CV(I) Innershield
used on the power source. If using either of the
or CV(S) Sub Arc according to the process being
CV modes, the NA-3 CC board switch should be
used. If using an LN-9, refer to the LN-9 instruction
set for CV. If the power source is used in the CC
manual for further instructions on its use. If using
mode, then the NA-3 CC board mode switch
an LN-7, it will be necessary to use either a K775
should be placed in the CC position.
Remote Control or operate the DC-1000 with the
machine/remote switch in the machine position.
All the NA-3始s when used with the DC-1000 are capa-
ble of cold starting with the constant current board NL Option Kit (Not Required with NA-3, NA-5, LT-7
mode switch in CC. Cold starting permits the wire to or LT-56).
be inched down to the work, automatically stop, and
automatically energize the flux hopper valve. All NA- The K783 NL Option Kit (for field installation) is
3始s made after September, 1976 are capable of cold designed to permit use of the obsolete NA-2, LAF-3,
starting on either CV or CC settings of the constant LT-3 and LT-3 section of the LT-34 tractor. It provides
current board. the necessary DC control power for the operation of
the equipment and the necessary circuitry for proper
On the NA-3, set the open circuit voltage control to the inching, cold starting and arc striking. In using the NL
same dial setting as the arc voltage control. If the pro- Option Kit, a K775 remote field control is required and
cedure has not yet been established, a good starting is included as part of the kit. Installation instructions
point is to set the OCV to #6. are included with the NL Option Kit.
鈥? 14 鈥?
MAINTENANCE
WARNING
ELECTRIC SHOCK can kill.
鈥? Have an electrician install and service
this equipment.
鈥? Turn the input power off at the fuse
box before working on equipment.
鈥? Do not touch electrically hot parts.
---------------------------------------------------------------------
GENERAL MAINTENANCE
1. The fan motors have sealed bearings which
require no service.
2. In extremely dusty locations, dirt may clog the air
channels causing the welder to run hot. Blow out
the welder with low pressure air at regular inter-
vals as required to eliminate excessive dirt and
dust buildup on internal parts.
OVERLOAD PROTECTION
The power source is thermostatically protected with
two proximity thermostats against overload or insuffi-
cient cooling. One thermostat is located on the trans-
former secondary Negative Output Lead, and the
other thermostat is located on the choke coil. The
thermostats are connected in series in the machine
control circuit so that if an excessive overload is
applied to the machine, or the machine should receive
insufficient cooling on either the main transformer,
SCR bridge assembly or choke, the input contactor
would open and remain open until the machine cools.
It can then be manually restarted by operating the
start push button.
The power source is also protected against heavy
overloads on the SCR bridge assembly through an
electronic protection circuit. This circuit senses an
overload on the power source and opens the input
contactor should the overload remain for a predeter-
mined time. The predetermined time varies with the
amount of overload; the greater the overload, the
shorter the time. The input contactor will remain open
until the power source is manually started with the
start push button.
The control board is designed with adequate protec-
tion so that no damage will occur if the remote control
leads are shorted together or are grounded to the
case. The machine will automatically shut down if
such faults do occur.
An 8-amp fuse located on the machine control panel
protects the 115 volt auxiliary AC circuit (#31 and #32)
from overload. If replacing, use the same type and
size fuse.
鈥? 15 鈥?
TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
鈥? Have an electrician install and service
this equipment.
鈥? Turn the input power off at the fuse
box before working on equipment.
鈥? Do not touch electrically hot parts.
---------------------------------------------------------------------
Trouble Cause What To Do
Input contactor (1CR) chatters. a. Repair or replace.
a. Faulty input contactor (1CR).
b. Check input power.
b. Low line voltage.
c. Repair relay.
c. Faulty 2CR relay.
a. Replace if blown - look for reason
a. Supply line fuse blown.
Machine input contactor does not
first.
operate.
b. Check pilot transformer T2 and
b. Contactor power circuit dead.
associated leads.
c. Check input voltage at contactor.
c. Broken power lead.
d. Check voltage against instruc-
d. Wrong input voltage.
tions.
e. Check for overheating; make sure
e. Secondary or choke thermostat
fan is operating and there is no
open.
obstruction to free air flow.
Replace faulty thermostat.
f. Replace coil.
f. Open input contactor coil.
g. Replace switch.
g. Faulty stop/start push button
switch.
h. Replace relay.
h. Faulty 2CR relay.
i. Replace control board. See P.C.
i. Defective control board.
board troubleshooting guide.
a. Check and replace if necessary.
a. Defective start/stop push button.
Input contactor pulls in when start
b. Repair or replace.
b. Defective 1CR interlock.
button is pressed, but immediately
c. Check 73, 74, 75, 76 or 77 for
c. Ground fault between control ter-
drops out.
ground to negative output circuit.
minals 73, 74, 75, 76 or 77 and
negative output terminal.
d. Remove short.
d. Short on output terminals with 2-4
jumpered.
e. Replace control board. See P.C.
e. Defective control board.
board troubleshooting guide.
a. Repair connection.
a. Electrode or work lead loose or
Machine input contactor operates but
broken.
no output when trying to weld.
b. Repair.
b. Open main transformer (T1) pri-
mary or secondary circuit.
c. Check relay pull-in by connecting
c. Output pilot relay 4CR not operat-
a jumper across terminals 2 and 4
ing or faulty.
on DC-1000 terminal strip.
Replace if faulty.
d. All nine light emitting diodes
d. Firing circuit P.C. board not con-
(LED1 thru LED9) must be lit. See
nected or is faulty.
P.C. board troubleshooting guide.
e. Repair.
e. If using 500 amp stud, choke cir-
cuit may be open.
鈥? 16 鈥?
Trouble Cause What To Do
Machine has maximum output but a. Check position of switch.
a. Output control switch (SW3) in
not control. wrong position.
b. Check switch and replace if faulty.
b. Output control switch faulty.
c. Check wiring and control and fir-
c. Open in feedback circuitry.
ing circuit P.C. board wiring har-
ness plugs.
d. All light emitting diodes must be
d. Faulty control or firing circuit P.C.
Machine has minimum output and lit, except LED4 on the con-
boards.
no control. trol/fault board. See P.C. board
troubleshooting guide.
e. Check and replace potentiometer
e. Output control potentiometer cir-
if faulty. Check wiring of Lead #75.
cuit open (Lead 75).
a. Check 73, 74, 75, 76 or 77 for
a. Terminals 73, 74, 75, 76 or 77
Machine does not have maximum grounded to positive output. ground to positive output circuit.
output.
Machine has output but trips off a. Check and replace if blown after
a. One input fuse blown.
immediately when wire feed unit checking for reason for blown
fuse.
start button is pressed.
b. Check for open and repair.
b. One phase of main transformer
open.
c. All light emitting diodes must be lit
c. Faulty control or firing circuit P.C.
on both P.C. boards, except LED4
boards.
on control/fault board. See P.C.
board troubleshooting guide.
d. Check and replace if faulty.
d. Output control potentiometer
defective.
e. Repair.
e. Output control potentiometer
leads open - 76, 77, 226, 236,
237, 238.
Variable or sluggish welding arc. a. Check internally and externally for
a. Machine has either an internal or
any shorts and remove or repair.
external short circuit on the out-
put.
b. Replace control board. See P.C.
b. Faulty control P.C. board.
board troubleshooting guide.
c. Check for grounded 73, 74, 75,
c. Terminals 73, 74, 75, 76, 77
76, 77.
grounded to negative output termi-
nal.
Machine will not shut off. a. Check and clean all connections.
a. Poor work or electrode connec-
tion.
b. Check table in instruction manual.
b. Welding leads too small.
c. Check procedures for recom-
c. Welding current or voltage too
mended settings.
low.
d. Check and replace if defective.
d. Defective main SCR bridge.
Output control not functioning on a. Check and replace if necessary.
a. Input contactor contacts frozen.
the machine(1). b. Check and replace if necessary.
b. Faulty 2CR relay.
If connected to an LN-9 or NA-5, disconnect leads 73, 74, 75 before troubleshooting.
(1)
鈥? 17 鈥?
Trouble Cause What To Do
Output control not functioning on a. Place switch in 鈥淥utput Control
a. Output control switch in wrong
remote control. Remote鈥?.
position.
b. Check and replace if found faulty.
b. Faulty output control switch.
c. Check and replace if found faulty.
c. Faulty remote control potentiome-
(Voltage from 75 to 77 should be
ter.
3 to 5V).
d. Check all leads and connections,
d. Leads or connections open in con-
internal or remote, for continuity;
trol circuit.
repair if necessary.
e. All light emitting diodes must be lit
e. Faulty firing or control circuit P.C.
on both P.C. boards, except LED4
board.
on control/fault board. See P.C.
board troubleshooting guide.
Poor starting on CV(S) Sub-Arc. a. See instruction manual and proce-
a. Improper procedures or setting of
dures.
controls.
b. Repair connections.
b. Poor electrode or work connec-
tion.
c. Check reed switch voltage leads
c. 3CR reed switch inoperative.
216 to 220. Idle voltage is about
8V; when welding, voltage must
go to zero.
d. Replace. See P.C. board trou-
d. Faulty control board.
bleshooting guide.
Poor bead shape or erratic arc on a. See instruction manual and proce-
a. Improper procedures.
CV(S) Sub-Arc. dures.
b. Check reed switch per item c. of
b. Defective 3CR reed switch.
previous Table above.
c. Replace. See P.C. board trou-
c. Faulty control board.
bleshooting guide.
d. Check and replace if defective.
d. Defective main SCR bridge.
Poor starting on CV(I) Innershield a. Replace.
a. Defective 3CR reed switch.
and CV(S) Sub-Arc. b. Replace.
b. Faulty control board.
Poor arc characteristics on CV(I) a. Place mode switch in CV(I)
a. Mode switch in CV(S) Sub-Arc
Innershield or other open arc Innershield mode.
mode.
processes. b. Check and replace if defective.
b. Defective main SCR bridge.
鈥? 18 鈥?
Trouble Cause What To Do
Poor arc characteristics on all a. Check and replace if defective.
a. Defective control board.
processes. See P.C. board troubleshooting
guide.
b. Check and replace if defective.
b. Defective firing board.
See P.C. board troubleshooting
guide.
c. Check and replace if defective.
c. Defective main SCR bridge.
Poor performance (including arc out- a. Use the 500 amp 鈥?+鈥? output stud.
a. Insufficient output inductance.
ages) while welding at low current
(less than 450 amps) when connect-
ed to 1000 amp 鈥?+鈥? output studs.
Machine frequently shuts off while a. Use the 1000 amp 鈥?+鈥? output
a. Effective current demand well
using the 500 amp 鈥?+鈥? output stud. studs.
over 500 amperes.
P.C. BOARD TROUBLESHOOTING GUIDE
WARNING
ELECTRIC SHOCK can kill.
鈥? Have an electrician install and service
this equipment.
鈥? Turn the input power off at the fuse
box before working on equipment.
鈥? Do not touch electrically hot parts.
---------------------------------------------------------------------
3. LED3 indicates power is being applied to fault pro-
Machine settings for P.C. board troubleshooting.
tection pilot relay 2CR to turn on the input contac-
Disconnect all leads to the wire feeder and jumper ter-
tor.
minals #2 and #4 on DC-1000. Output Control at DC-
1000. Mode switch in the CV(I) position.
4. LED4 indicates when overcurrent protection circuit
CONTROL/FAULT PROTECTION P.C. BOARD is being activated.
5. LED5 indicates a control signal is being supplied
1. LED1 indicates AC input voltage is present at pins
to the firing circuit. As the output control is varied,
255-256. If not lit, check the voltage across the
LED5 should change brilliancy from bright at low
secondary winding of the control transformer, T2.
output to dim at high output.
The voltage should be approximately 115 volts. If
not, the problem is in the power supply and not the
FIRING CIRCUIT P.C. BOARD
P.C. board.
All nine light emitting diodes must be lit when the
2. LED2 indicates welder output voltage is being sup-
power source is turned on and the wire feed arc start
plied to the control circuit. If not lit, check to make
button is pressed or a jumper is connected between 2
certain lead 222 from pin 2 of the 15-pin control
and 4.
circuit P.C. board connector is connected to the
power source negative output lead and is not bro-
ken.
鈥? 19 鈥?
PROCEDURE FOR REPLACING P.C. BOARDS
1. Lights 7, 8, and 9 indicate AC power being sup-
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. board. Turn the cedure must be followed:
machine on and check the following voltages:
1. Visually inspect P.C. board in question. Are any of
the components damaged? Is a conductor on the
back side of the board damaged? All P.C. boards
Light That Check AC Voltage Voltage Should
are protected by a moisture resistant coating.
Was Off Between Pins of Be Approx.
Plug P5
When the welder is operated, this coating will
鈥渂ake off鈥? of certain power resistors that normally
7 P5 Pins 2 & 4 75 VAC
operate at high temperatures emitting some
(Wires 203, 204)
smoke and odor for a short time. These resistors
8 P5 Pins 7 & 3 75 VAC
and the P.C. board beneath them may become
(Wires 205, 206)
blackened. This is a normal occurrence and does
not damage the component or affect the machine
9 P5 Pins 9 & 8 75 VAC
performance.
(Wires 207, 208)
a. If there is no damage to the P.C. board, insert
鈥? If approximately 75 VAC is present, turn the
a new one and see if this remedies the prob-
machine off, plug P5 back into firing board. Turn
lem. If the problem is remedied, replace the
the machine back on and check to see if the light
old P.C. board and see if the problem still
or lights are on. If the light or lights are not on
exists with the old P.C. board.
replace the firing P.C. board.
1) If the problem is no longer present with the
鈥? If the 75 VAC was not present, then check the
old board, check the P.C. board harness
wiring.
plug and P.C. board plug for corrosion,
contamination, or oversize.
2. Lights 1 through 6 indicate gate signals are being
2) Check leads in the harness for loose con-
supplied to the main power SCR始s 1 through 6
nections.
respectively. If light 5 on the control circuit and
lights 7 through 9 on the firing circuit are lit and
b. If there is damage to the P.C. board, refer to
lights 1 through 6 are not lit, check lead 231
the Troubleshooting Guide
between the firing circuit and the control circuit
that it is not broken and is connected to each
Molex connector. If the lead shows continuity and
lights 1 through 6 are not lit, replace the firing cir-
cuit P.C. board. If any one of the lights 1 through 6
is not lit and lights 7 through 9 are lit, replace the
firing circuit P.C. board.
鈥? 20 鈥?
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 鈥淥N鈥?. 2 AND 4 CLOSED)
CHECK CONTROL BOARD
LED5
IF ON
IF OFF
CHECK FIRING BOARD
CHECK LED1
LED始S
ALL
IF OFF IF ON
NINE LIGHTS
SHOULD
CHECK AC REPLACE
BE ON
INPUT TO CONTROL
CONTROL BOARD
BOARD -
IF YES IF NO
POSSIBLE
DEFECTIVE
T2 TRANSFORMER CHECK GATE LEAD CHECK LIGHTS
CONNECTIONS 7,8,9
TO SCR始S
IF ONE IF ON AND
OR MORE OTHER LIGHTS
ARE OUT ARE OUT
MACHINE HAS OUTPUT CHECK AC INPUT
(Jumper 2-4) BUT TRIPS TO BOARD, REPLACE
OFF IMMEDIATELY 203-204, 205-206 FIRING
207-208 -- POSSIBLE BOARD
DEFECTIVE
AUXILIARY
CHECK FOR SHORT CHECK LEADS WINDINGS ON MAIN
BETWEEN ELECTRODE AND 73, 74, 75, 76, 77 FOR TRANSFORMER
WORK LEADS, REMOVE GROUND TO
EXTERNAL LEADS FROM NEGATIVE OUTPUT CHECK FOR OPEN
THE OUTPUT TERMINALS TERMINAL IN LEADS 203, 204
205, 206, 207, 208
ERRATIC WELDING
IF TROUBLE STILL PERSISTS,
CHECK LED 3 ON
CHECK PROCEDURE
CONTROL BOARD
CHECK MODE SWITCH FOR PROP-
IF LIGHT GOES ON, THEN ER POSITION FOR PROCESS
QUICKLY OUT WHEN START BEING USED
BUTTON IS PRESSED,
CONTROL BOARD IS CHECK LED始S 1 THRU 6 FOR
DEFECTIVE AND SHOULD EQUAL BRILLIANCY
BE REPLACED
IF LIGHTS ARE NOT ALL APPROXI-
MATELY EQUALLY BRIGHT,
REPLACE FIRING P.C. BOARD
鈥? 21 鈥?
CONNECTION OF DC-1000 WITH NL OPTION KIT TO LAF-3 (Obsolete)
N.C.
POWER SOURCE
4
N.B.
2
82 21 2 31 32
4 73 74 75 76 77
1
NL OPTION
10
21
10
6
67 21 75 76
4 2 31 32 77
32
E D
31
CONNECT THE RED LEAD TO
22 TERMINAL 22
POSITIVE
NEGATIVE
N.A.
F C 75
75
76
76
77
77
1
21
N.D.
GND
35 VOLT CONTROL
K775 REMOTE CONTROL
EXCITER
MOUNTED AT LAF-3
TO LAF-3
18 45 29 5
2 1 10
6 21 32 31
4
CONTROL BOX
M13321
8-2-90F
ELECTRODE CABLE TO TAPE UP LEADS
AUTOMATIC EQUIPMENT NOT USED
TO WORK
N.A. On all DC-1000 and DC-1500 units N.D. Alternative 500 amp positive terminal The 4/0 cables shown will handle up to
with codes above 8234 extend lead connection provided on DC-1000 1000 amps at 80% duty cycle. For higher
67 and connect it to the electrode models above code 9500 only. currents or duty cycle add additional cables
cable going to the automatic equip- to the power source output studs.
ment. This diagram shows the electrode connect-
ed positive. To change polarity, turn power For best arc striking when connected to an
N.B. On DC-1500 units below code 8234 source off, reverse the electrode and work LAF-3 make the following change inside
this is 67 and the LAF-3 #67 lead can leads at the power source and position the the LAF-3 control unit. Remove the blue
be connected either to the #67 termi- switch on the power source and NL Option jumper lead connected between #1 on the
nal or the electrode cable terminal as Kit to the proper polarity. Also reverse the coil of the main relay and #7 on the coil of
shown. Terminal 82 not present on leads on the back of the ammeter and volt- the transfer relay. (The main relay is the
later D.C. 1500始s and all DC-1000始s. meter in the LAF-3 control box. upper right relay when facing the left end of
the control box. The transfer relay is just to
N.C. Terminals 73 and 74 not present on Contactor drop out delay switch on the NL the left of the main relay.)
earlier DC-1500始s. Option Kit must be in the 鈥淥n鈥? position.
CONNECTION OF DC-1000 TO LN-8
Connect the control cable ground lead to the frame terminal
TO LN- 8 INPUT
marked near the power source terminal strip. The power
CABLE PLUG
source must be properly grounded.
POWER SOURCE
CONTROL CABLE
*If using an older control cable: Connect lead #75 to #75 on ter-
minal strip, connect lead #76 to #76 on terminal strip, connect
lead #77 to #77 on terminal strip.
GND
N.A. Welding cables must be of proper capacity for the current
73 74
31 32
21 75 76 77
4 2
C
and duty cycle of immediate and future applications.
}*
B
A
N.B. Extend lead 21 using #14 or larger insulated wire physi-
cally suitable for the installation. An S16586-[ ] remote
voltage sensing work lead is available for this purpose.
32
31
Connect it directly to the work piece keeping it electrically
2
separate from the welding work lead circuit and connec-
4
tion. For convenience, this extended #21 lead should be
21
taped to the welding work lead.
N.B. &
N.C. NEGATIVE POSITIVE
N.C. Tape up bolted connection.
N.D. Alternative 500 amp positive terminal connection provided
on DC-1000 models above code 9500 only.
N.D.
ELECTRODE CAB LE TO
WIRE FEED UNIT
Above diagram shows electrode connected positive. To change
polarity, turn power source off, reverse the electrode and work
N.A.
leads at the power source and position the switch on power
} TO WORK
S17176 source to proper polarity.
8-2-90F
鈥? 22 鈥?
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.
N.B. Extend lead 21 using #14 or larger insulated wire phys-
TO NA- 5 INPUT
ically suitable for the installation. An S16586-[ ] remote
CABLE PLUG
N.J. N. F.
voltage sensing work lead is available for this purpose.
CONTROL CABLE
Connect it directly to the work piece keeping it separate
from the welding work cable connection to work piece.
For convenience, this extended #21 lead should be
taped along the welding work cable.
73 74
31 32
21 75 76 77
4 2
N.C. Tape up bolted connection.
}
A
B N. F.
E
N.D. Connect the NA-5 control cable ground lead to the
C
frame terminal marked near the power source ter-
32
minal strip. The power source must be properly ground-
31
ed.
2
4
GND
N.E. If using an older automatic control cable with leads 75,
76, 77: Connect lead 75 to #75 on terminal strip, con-
POSITIVE
NEGATIVE
21
nect lead #76 to #74 on terminal strip, connect lead
#77 to #73 on terminal strip.
N.B. & N.C.
N.D.
N.F. Connect the jumpers on the NA-5 voltage board as fol-
N.K.
lows: Connect RED jumper to pin 鈥淪鈥?, Connect WHITE
B OLT TO CAB LES
FROM NA- 5 WIRE
jumper to pin 鈥淏鈥?.
CONTACT ASSEM B LY
N.A.
} N.G. Set the DC-1000 or DC-1500 controls as follows: Set
CONNECT TO WORK
the control switch to 鈥淥utput Control Remote鈥?. For
N.C. & N.H.
Submerged Arc Processes set the switch to 鈥淐.V.
S16889 Submerged Arc鈥?. For Open Arc Processes, set the
8-2-90F mode switch to 鈥淐.V. Innershield鈥?.
N.H. For proper operation, the electrode cable must be
snugged under the clamp bar on the left side of the NA-
5 control box.
Above diagram shows electrode connected positive. To change
polarity turn power off, reverse the electrode and work leads at N.J. Terminals #73 and #74 were not present on DC-1500
the power source, position the positive - negative switch on the machines below code 8294. These earlier code
power source to correspond to the polarity of the electrode cable machines are not suitable for use with the NA-5.
connection. Refer to NA-5 operating manual for required NA-5
control box polarity connections. N.K. Alternative 500 amp positive terminal connection pro-
vided on DC-1000 models above code 9500 only.
N.L. Alternate submerged arc mode available for improved
arc stability in high current, large puddle, slow travel
procedures by making special connections on both DC-
1500 and NA-5.
On DC-1500 Control Board (G1530-2 and superseding)
remove red and blue jumpers from 鈥淔R鈥? pins and reconnect
to corresponding 鈥淪R鈥? pins.
On NA-5 Voltage Board (G1556-1 and superseding) white
jumper must be connected to pin 鈥淒鈥?.
NA-5 pin 鈥淒鈥? connection may also be used for some proce-
dures on DC-1500 without control board jumpers, DC-1500
with control board jumpers on 鈥淔R鈥? pins or DC-1000.
鈥? 23 鈥?
CONNECTION OF DC-1000 WITH NL OPTION KIT TO LT-3 or LT-34 (Obsolete)
N.C.
POWER SOURCE
N.B.
4
2
1
82 21 4 73 74 75 76 77
2 31 32
NL OPTION
10
21
10
6
67 21 4 2 31 32 75 76 77 32
D
E 31
CONNECT THE RED LEAD TO
22
TERMINAL 22
NEGATIVE POSITIVE
N.A.
F 75
C 75
76
35 VOLT CONTROL 76
N.D. 77
EXCITER 21 1 77
GND
K-775 REMOTE CONTROL
MOUNTED AT TRACTOR
10 4 21
6 1 2 31
59 61
41 42 43 44 58
LT-3 REMOTE
DC CONTROL
BOLT & TAPE
BOX TO LT-3 TRACTOR
7 CONNECTIONS
CONTROL BOX
31
2 1 32 41 42 43 44 58 61
59
29 5
SPARE
M13322
TAPE UP SPARE LEADS (NOT USED)
ELECTRODE CABLE TO
8-2-90F
AUTOMATIC EQUIPMENT
TO WORK
N.A. On all DC-1000 and DC-1500始s N.D. Alternative 500 amp positive terminal The 4/0 cables shown will handle up to
above Code 8234 extend lead 67 connection provided on DC-1000 1000 amps at 80% duty cycle. For higher
and connect it to the electrode cable models above code 9500 only. currents or duty cycle add additional cables
going to the automatic equipment. to the power source output studs.
This diagram shows the electrode connect-
N.B. On DC-1500 units below code 8234 ed positive. To change polarity, turn power
this is #67 and the LT-3 or LT-34 #67 source off, reverse the electrode and work
lead can be connected either to the leads at the power source and position the
#67 or the electrode cable terminal switch on the power source and NL Option
as shown. Terminal 82 not present Kit to the proper polarity. Also reverse the
on later D.C. 1500始s and all DC- leads on the back of the ammeter and volt-
1000始s. meter in the LT-3 control box.
N.C. Terminals 73 & 74 not present on Contactor drop out delay switch on the NL
earlier DC-1500始s. Option Kit must be in the 鈥淥n鈥? position.
CONNECTION OF DC-1000 OR DC-1500 to NA-3, LT-5 or LT-7
Connect the control cable ground lead to the frame terminal
TO AUTOMATIC
marked near the power source terminal strip. The
CONTROL BOX
POWER SOURCE
power source must be properly grounded.
CONTROL CABLE
N.D.
*If using an older control cable: Connect lead #75 to #75 on termi-
nal strip, connect lead #76 to #76 on terminal strip, connect lead
#77 to #77 on terminal strip.
GND
73 74
31 32
21 75 76 77
4 2
}*
C
N.A. Welding cables must be of proper capacity for the current
B
and duty cycle of immediate and future applications.
A
N.B. Extend lead 21 using #14 or larger insulated wire physically
32
suitable for the installation. An S16586-[ ] remote voltage
31
2
sensing work lead is available for this purpose. Connect it
4
directly to the work piece keeping it electrically separate from
21
the welding work lead circuit and connection. For conve-
N.B. &
N.C.
nience, this extended #21 lead should be taped to the weld-
POSITIVE
NEGATIVE
ing work lead.
N.C. Tape up bolted connection.
}
N. E. ELECTRODE CAB LE TO
AUTOM ATIC EQUIPM ENT
S15534 N.D. Terminals 73 & 74 not present on earlier DC-1500.
8-2-90F
N.A.
} N.E. Alternative 500 amp positive terminal connection provided
TO WORK
on DC-1000 models above code 9500 only.
Above diagram shows electrode connected positive. To change
polarity, turn power source off, reverse the electrode and work
leads at the power source and position the switch on power
source to proper polarity. Also reverse the leads on the back of
the ammeter and voltmeter in the automatic control box.
鈥? 24 鈥?
CONNECTION OF DC-1000 TO LN-7
N.A. Welding cables must be of proper capacity for the current and
TO LN-7 INPUT
duty cycle of immediate and future applications.
CABLE PLUG
POWER SOURCE
N.B. Extend lead 21 using #14 or larger insulated wire physically suit-
LN-7 CONTROL CABLE
able for the installation. An S16586-[ ] remote voltage sensing
work lead is available for this purpose. Connect it directly to the
N.E.
work piece keeping it electrically separate from the welding work
73 74
31 32
21 75 76 77
4 2
lead circuit and connection. For convenience, this extended #21
lead should be taped to the welding work lead. (This extended
#21 lead connection replaces the need to employ the remote
32
work lead accessory on LN-7 meter kits which have a direct work
31
2
lead jack. An LN-7 not equipped with a meter kit does not require
4
lead 21 to be extended.)
GND
N.C. Tape up bolted connection.
POSITIVE
NEGATIVE 21
N.D.
N.D. Connect the control cable ground lead to the frame terminal
marked near the power source terminal strip. The power
N.B. & N.C.
source must be properly grounded.
N.F.
S17177
ELECTRODE CABLE TO
LN-7 CONDUCTOR BLOCK
8-2-90F N.E. Terminal strip for remote voltage control pot. when used.
N.A.
} TO WORK
N.F. Alternative 500 amp positive terminal connection provided on
Above diagram shows electrode connected positive. To change
DC-1000 models above code 9500 only.
polarity, turn power off, reverse the electrode and work leads at
the power source and position the switch on power source to
proper polarity.
CONNECTION OF DC-1000 TO LN-9
N.A. Welding cables must be of proper capacity for the current and
duty cycle of immediate and future applications.
N. F.
TO LN- 9 INPUT
CABLE PLUG
N.B. Extend lead 21 using #14 or larger insulated wire physically suit-
POWER SOURCE
able for the installation. An S16586-[ ] remote voltage sensing
CONTROL CABLE
work lead is available for this purpose. Connect it directly to the
work piece keeping it separate from the welding work cable con-
nection to work piece. For convenience, this extended #21 lead
should be taped along the welding work cable. (This extended
73 74
31 32
21 75 76 77
4 2
#21 lead connection replaces the need to employ the remote
work lead accessory on LN-9始s which have a direct work lead
}
A
jack.)
B N. E.
C
32
N.C. Tape up bolted connection.
31
2
N.D. Connect the LN-9 control cable ground lead to the frame terminal
4
marked near the power source terminal strip. The power
GND
source must be properly grounded.
POSITIVE
NEGATIVE
21
N.E. If using an older automatic control cable with leads 75, 76, 77;
N.D.
Connect lead 75 to #75 on terminal strip, connect lead #76 to
#74 on terminal strip, connect lead #77 to #73 on terminal strip.
N.B. & N.C.
N.H.
ELECTRODE CAB LE TO
S17185 N.F. The LN-9 voltage control jumpers must be connected as follows
WIRE FEED UNIT
(Refer to LN-9 operating manual): White jumper on voltage board
8-2-90F
N.A.
to pin 鈥淪鈥?. Blue jumper on voltage board (later units only) or on
} CONNECT TO WORK
start board (earlier units). To pin 鈥淏鈥?.
Above diagram shows electrode connected positive. To change
polarity, turn power off, reverse the electrode and work leads at N.G. Set the DC-1000 controls as follows: Set the control switch to
the power source, position the positive-negative switch on the 鈥淥utput Control Remote鈥?. For Submerged Arc Processes, set the
power source to correspond to the polarity of the electrode cable mode switch to 鈥淐.V. Innershield鈥?.
connection. Refer to LN-9 operating manual for required polarity
connections. N.H. Alternative 500 amp positive terminal connection provided on
DC-1000 models above code 9500 only.
鈥? 25 鈥?
DC-1000 WIRING DIAGRAM
鈥? 26 鈥?
L9008
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTES
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa moja- fuera del 谩rea de trabajo. cuerpo.
da.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des v锚te- G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
ments mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e elec- G Mantenha inflam谩veis bem guarda- G Use prote莽茫o para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piraci贸n. mentaci贸n de poder de la m谩quina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilaci贸n o
ATTENTION
aspiraci贸n para gases.
French
G D茅branchez le courant avant G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G Utilisez un ventilateur ou un aspira- l鈥檈ntretien. ouverts ou avec les dispositifs de
protection enlev茅s.
teur pour 么ter les fum茅es des zones
WARNUNG
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom v枚llig 枚ff- oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie f眉r gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G N茫o opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G Desligue a corrente antes de fazer
G Use ventila莽茫o e exhaust茫o para moventes.
servi莽o. G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
G N茫o toque as partes el茅tricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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