Svm123a DC1000

RETURN TO MAIN INDEX
SVM123-A
Return to Master TOC
View Safety Info
TM
IDEALARC DC 1000 July, 1996
For use with Machine Code Numbers: 9919

9920
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation

View Safety Info
... 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.
View Safety Info
SERVICE MANUAL
View Safety Info
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i i
Return to Master TOC SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth known to the State of California to cause cancer, birth
defects, and other reproductive harm. defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline 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 “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
1.g. To prevent accidentally starting gasoline engines while turn-

FOR ENGINE ing the engine or welding generator during maintenance work,
powered equipment. disconnect the spark plug wires, distributor cap or magneto
wire as appropriate.
1.a. Turn the engine off before trou- ___________________________________________________
bleshooting and maintenance work unless the maintenance 1.h. To avoid scalding, do not remove the radiator pressure cap
work requires it to be running. when the engine is hot..
____________________________________________________
1.b. Operate engines in open, well-ventilated areas or vent the
engine exhaust fumes outdoors.
____________________________________________________ ELECTRIC AND MAGNETIC

1.c. Do not add the fuel near an open flame welding arc or when
the engine is running. Stop the engine and allow FIELDS
it to cool before refueling to prevent spilled fuel

from vaporizing on contact with hot engine parts may be dangerous
and igniting. Do not spill fuel when filling tank. If
2.a. Electric current flowing through any conductor causes local-
fuel is spilled, wipe it up and do not start engine
ized Electric and Magnetic Fields (EMF). Welding current
until fumes have been eliminated.
creates EMF fields around welding cables and welding
machines.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in 2.b. EMF fields may interfere with some pacemakers, and
position and in good repair.Keep hands, hair, welders having a pacemaker should consult their physician
clothing and tools away from V-belts, gears, fans before welding.
and all other moving parts when starting, operat-
ing or repairing equipment. 2.c. Exposure to EMF fields in welding may have othe health
effects which are now not known.
2.d. All welders should use the following procedures in order to

____________________________________________________ minimize exposure to EMF fields from the welding circuit:
1.e. In some cases it may be necessary to remove safety guards 2.d.1. Route the electrode and work cables togethe.
to perform required maintenance. Remove guards only when Secure them with tape when possible.
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when 2.d.2. Never coil the electrode lead around your body.
working near moving parts. 2.d.3. Do not place your body between the electrode and
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to work cables. If the elecrode cable is on your right
override the governor or idler by pushing on the throttle con- side, the work cable should also be on your right
trol rods while the engine is running. side.
2.d.4. Connect the work cable to the workpiece as close

as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii ii
ELECTRIC SHOCK ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
can kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” 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
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
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

• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling. products.
3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
iii iii
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv
SAFETY iv
5. Toujours porter des lunettes de sécurité dans la zone de

PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instruc- zones où l’on pique le laitier.
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté 6. Eloigner les matériaux inflammables ou les recouvrir afin de
générales suivantes: prévenir tout risque d’incendie dû aux étincelles.
Sûreté Pour Soudage A L’Arc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. S’assurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail qu’il est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou d’autres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien s’isoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques d’incendie ou d’echauffement des chaines et des
les positions assis ou couché pour lesquelles une câbles jusqu’à ce qu’ils se rompent.
grande partie du corps peut être en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-électrode, la pince de masse, le câble Ceci est particuliérement important pour le soudage de tôles
de soudage et la machine à souder en bon et sûr état galvanisées plombées, ou cadmiées ou tout autre métal qui
defonctionnement. produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir. 10. Ne pas souder en présence de vapeurs de chlore provenant
e. Ne jamais toucher simultanément les parties sous tension d’opérations de dégraissage, nettoyage ou pistolage. La
des porte-électrodes connectés à deux machines à soud- chaleur ou les rayons de l’arc peuvent réagir avec les
er parce que la tension entre les deux pinces peut être le vapeurs du solvant pour produire du phosgéne (gas forte-
total de la tension à vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sûreté,
pour le porte-électrode s’applicuent aussi au pistolet de voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-

téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
PRÉCAUTIONS DE SÛRETÉ POUR
partie du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du 1. Relier à la terre le chassis du poste conformement au code
rayonnement de l’arc et des projections quand on soude de l’électricité et aux recommendations du fabricant. Le dis-
ou quand on regarde l’arc. positif de montage ou la piece à souder doit être branché à
b. Porter des vêtements convenables afin de protéger la une bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste
c. Protéger l’autre personnel travaillant à proximité au
seront effectués par un électricien qualifié.

soudage à l’aide d’écrans appropriés et non-inflamma-
bles. 3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection 4. Garder tous les couvercles et dispositifs de sûreté à leur
libres de l’huile, tels que les gants en cuir, chemise épaisse, place.
pantalons sans revers, et chaussures montantes.
Mar. ‘93
v v
RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page
Safety .....................................................................................................................................................i - iv
Installation ......................................................................................................................................Section A
Technical Specifications ............................................................................................................................A-2
Safety Precautions ....................................................................................................................................A-3
Select Proper Location ..............................................................................................................................A-3
Electrical Input Connections ......................................................................................................................A-3
Reconnect Procedures ..............................................................................................................................A-4
Output Connections ...................................................................................................................................A-8
Operation ........................................................................................................................................Section B
Safety Precautions ...................................................................................................................................B-2
General Description ...................................................................................................................................B-3
Recommended Processes and Equipment ...............................................................................................B-3
Operational Features and Controls ...........................................................................................................B-3
Design Features and Advantages .............................................................................................................B-3
Welding Capacity.......................................................................................................................................B-4
Controls and Settings ................................................................................................................................B-5
Operating Steps.........................................................................................................................................B-6
Remote Control of Machine Operation ......................................................................................................B-6
Welding Proceure Recommendations .......................................................................................................B-6
Semi-Automatic and Automatic Wire Feeding with a DC-1000 and Wire Feeders ............................B6 - B-8
Accessories....................................................................................................................................Section C
Options/Accessories..................................................................................................................................C-2
Meters .......................................................................................................................................................C-2
Remote Output Control (Optional).............................................................................................................C-2
Connections for Wire Feeder Control ...............................................................................................C-2 - C-6
Maintenance ...................................................................................................................................Section D
Safety Precautions ....................................................................................................................................D-2
Routine and Periodic Maintenance ...........................................................................................................D-2
Major Component Locations .....................................................................................................................D-3
Theory of Operation.......................................................................................................................Section E
General Description ...................................................................................................................................E-2
Input Line voltage, Connector, and Main Transformer ..............................................................................E-2
Output, Rectification, Control, and Feedback ............................................................................................E-3
Protection Devices and Circuits (Contactor Hold-In) .................................................................................E-4
SCR Operation ..........................................................................................................................................E-5
Troubleshooting .............................................................................................................................Section F
How to Use Troubleshooting Guide ...........................................................................................................F-2
PC Board Troubleshooting Procedures .....................................................................................................F-3
Troubleshooting Guide ....................................................................................................................F-4 - F-12
Test Procedures ............................................................................................................................F-13 - F-37
Oscilloscope Waveforms...............................................................................................................F-38 - F-44
Replacement Procedures ........................................................................................................................F-45
Retest After Repair ..................................................................................................................................F-63
Electrical Diagrams .......................................................................................................................Section G
Parts Manual..........................................................................................................................................P-146
IDEALARC DC - 1000
Return to Master TOC A-1 INSTALLATION A-1
TABLE OF CONTENTS
-INSTALLATION SECTION-
INSTALLATION..................................................................................Section A
Technical Specifications ........................................................................A-2
Safety Precautions ................................................................................A-3
Select Proper Location ..........................................................................A-3
Stacking ..........................................................................................A-3
Tilting ..............................................................................................A-3
Electrical Input Connections ..................................................................A-3
Fuses and Wire Sizes .....................................................................A-4
Ground Connection.........................................................................A-4
Input Power Supply Connections....................................................A-4
Reconnect Procedures ..........................................................................A-4
Output Connections...............................................................................A-8
Electrode and Work Leads..............................................................A-8
Auxiliary Power ...............................................................................A-8
Connection for Wire Feeder Control ...............................................A-8

Connection for Air Carbon Arc ........................................................A-9
IDEALARC DC-1000
A-2 INSTALLATION A-2
Return to Section TOC
TECHNICAL SPECIFICATIONS – IDEALARC DC - 1000

INPUT - THREE PHASE ONLY
Standard Voltage Input Current at Rated Output
230/460/575 193/96.5/77
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
100% 1000 44
60% 1140 44
55% 1250 44
OUTPUT
Mode Current Range Maximum Open Auxiliary
Constant Current 140 to 1250 Amps Circuit Voltage Power
Constant Voltage 140 to 1250 Amps 75 VDC 115 VAC, 8 Amps
Constant Voltage 140 to 625 Amps

(@500 Amp Stud)
RECOMMENDED INPUT WIRE AND FUSE SIZES
Type 75C Copper Type 75C Copper

Input Fuse (Super Lag) Input Ampere Rating on Ground Wire in
Voltage/Frequency or Breaker Size Nameplate Wire in Conduit
AWG (IEC) Sizes Conduit AWG (IEC)
Sizes
230/60 300 193 000 (85mm2) 4 (25mm2)
430/60 150 96.5 3 (26.7mm2) 6 (16mm2)
575/60 125 77 6 (16mm2) 6 (16mm2)

PHYSICAL DIMENSIONS
Height Width Depth Weight
30.75 in 22.25 in 38.0 in 821 Ibs
(781 mm) (567 mm) (965 mm) (372 kg)
IDEALARC DC-1000
A-3 A-3
INSTALLATION
Read entire Installation Section before installing
the IDEALARC DC-1000.

STACKING HOLE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel should install this
machine.
• Turn the input power OFF at the discon-
nect switch or fuse box before installing or
working on the equipment.
• Do not touch electrically hot parts. STACKING PIN
• Always connect the IDEALARC DC-1000
grounding terminal to a good electrical
earth ground.
____________________________________________________
FIGURE A.1 - Stacking IDEALARC DC-1000
SELECT PROPER LOCATION Machines
Place the IDEALARC DC-1000 where clean, dry air TILTING

can freely circulate in through the front intake and out
The IDEALARC DC-1000 must be placed on a stable,
through the rear louvers. Dirt, dust, or any foreign
level surface so it will not topple over.
material that can be drawn into the machine should be
kept at a minimum. Not following these precautions
can result in the nuisance shutdown of the machine
ELECTRICAL INPUT
because of excessive operating temperatures. CONNECTIONS
STACKING Before installing the machine, check that the input
supply voltage, phase, and frequency are the same as
WARNING the machine’s voltage, phase, and frequency as spec-
FALLING EQUIPMENT can ified on the machine’s rating plate on the Case Front
cause injury. Assembly Control Panel. Connect input power supply
• Do not lift this machine using lift bale if it by removing the rear access panel and connecting to
is equipped with a heavy accessory such

the three line terminals on the input panel. See Figure

as trailer or gas cylinder. A.2 for the location of the machine’s input cable entry
• Lift only with equipment of adequate lifting
capacity. opening and reconnect panel assembly for dual volt-
• Be sure machine is stable when lifting. age machines.
• Do not stack more than two high.
• Do not stack the DC-1000 on top of any other machine.
____________________________________________________
Two IDEALARC DC-1000 machines can be stacked.

Follow these guidelines when stacking:
1. Select a firm, level surface capable of supporting
the total weight of two machines (1642
pounds/744 kilograms).
2. Set the bottom machine in place.
3. Stack the second machine on top of it by aligning
the two holes in the base rails of the second

machine with the two pins on top front of the bot-
tom machine.
NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See FIGURE A.2 - Input Power Supply Connection
Figure A.1.
IDEALARC DC-1000
A-4 A-4
INSTALLATION
FUSE AND WIRE SIZES RECONNECT PROCEDURE

Protect the input circuit with the super lag fuses or Multiple voltage machines are shipped connected to
delay type circuit breakers listed on the Technical the highest input voltage listed on the machine’s rating
Specifications page of this manual for the machine plate. Before installing the machine, check that the
being used. They are also called inverse time or ther- Reconnect Panel in the Input Box Assembly is con-
mal/magnetic circuit breakers. nected for the proper voltage.
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in nui- CAUTION
sance tripping caused by inrush current even when
machine is not being used for welding at high output Failure to follow these instructions can cause immedi-
currents. ate failure of components within the machine.
Use input and grounding wire sizes that meet local ____________________________________________________
electrical codes, or see the Technical Specifications To reconnect a multiple voltage machine to a different
page in this manual. voltage, remove input power and follow the Input
Connection Diagram located on the inside of Case

GROUND CONNECTION
Back Input Access Door. These connection diagrams
are listed below:
Ground the frame of the machine. A ground terminal
marked with the symbol is located inside the Case 1. For 460 single voltage, 230/460 Dual Voltage,
Back of the machine. Access to the rear input panel is 220/440 Dual Voltage, 415 Single Voltage or 575
at the upper rear of the machine. See your local and Single Voltage, refer to Figure A.3a.
national electrical codes for proper grounding meth-
ods. 2. For 380 Single Voltage Machines, refer to Figure
A.3b.
INPUT POWER SUPPLY CONNECTIONS
3. For 380/500 Dual Voltage Machines, refer to
Figure A.3c.
A qualified electrician should connect the input power
supply leads. 4. For 220/380/440 Triple Voltage Machines, refer to
Figure A.3d
1. Follow all national and local electrical codes.
2. Follow Input Supply Connection Diagram located
on the inside of the machine.

3. Use a three-phase line.
4. Remove Input Access Door at upper rear of
machine.
5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input terminals on the recon-
nect panel. See Figure A.2
IDEALARC DC-1000
A-5 A-5
INSTALLATION
WARNING
All input power must be electrically disconnected before touching panel.

____________________________________________________
CONNECTION FOR UNDER 300 VOLTS

1. Mount the movable reconnect panel to the stationary
reconnect panel studs in the position shown, and
secure firmly with the nine hex nuts provided.
2. Conect L1, L2, and L3 input supply lines and H1 and
H2 control transformer leads to the input side of the
reconnect panel.
3. Insulate unused H3 lead terminal with adequate tape
to provide at least 600 volt insulation.
4. Connect terminal marked to ground per National
Electrical Code.
CONNECTION FOR OVER 300 VOLTS

1. Mount the movable reconnect panel center set of
holes to the stationary reconnect panel in the posi-
tion shown, and secure firmly with the six hex nuts
provided. Secure the three remaining hex nuts over
the remaining three studs for future use.
H3 control transformer leads to the input side of the
reconnect panel.
3. Insulate unused H2 lead terminal with adequate tape
to provide at least 600 volt insulation.
Electrical Code.
FIGURE A.3a - Input Connection Diagram

WARNING
____________________________________________________
CONNECTION FOR 380 VOLTS

H3 Control Transformer Leads to the Input
Terminals as shown.
Electrical Code.
FIGURE A.3b - Input Connection Diagram

IDEALARC DC-1000
A-6 A-6
INSTALLATION
WARNING
____________________________________________________

1. Mount the movable reconnect panel to the stationary
reconnect panel studs in the position shown, and
secure firmly with the nine hex nuts provided.
2. Connect L1, L2, and L3 input supply lines and H1
and H2 control transformer leads to the input side of
the reconnect panel.
3. Insulate unused H3 and H4 lead terminal with ade-
quate tape to provide at least 600 volt insulation.
Electrical Code.

1. Mount the movable reconnect panel center set of
holes to the stationary reconnect panel in the posi-
tion shown, and secure firmly with the six hex nuts
provided. Secure the three remaining hex nuts over
the remaining three studs for future use.
and H4 control transformer leads to the input side of
the reconnect panel as shown
Electrical Code.
FIGURE A.3c -Input Connection Diagram

IDEALARC DC-1000
A-7 A-7
INSTALLATION
WARNING
____________________________________________________
CONNECTION FOR 440 VOLTS 50 Hz (460V, 60 Hz.)

1. On reconnect panel, loosen all hex bolts, pull back
movable links, and rotate links to their new positions.
Position each link between the wire terminal and hex
bolt, push the link completely forward, and securely
tighten all hex bolts. Do not remove hex bolts at any
time.
and H4 control transformer leads to input terminals
as shown.
Electrical Code.
CONNECTION FOR 380 VOLTS 50 Hz.

time.
as shown.
Electrical Code.
CONNECTION FOR 220 VOLTS 50 Hz. (230V 60 Hz.)

time.
as shown.
Electrical Code.
FIGURE A.3d - Input Supply Connection Diagram
IDEALARC DC-1000
A-8 A-8
INSTALLATION
OUTPUT CONNECTIONS 3. Connect electrode lead to the desired terminal
(positive or negative) and tighten the output ter-

See Table A.1 for recommended IDEALARC DC-1000 minal nut with a wrench.
cable sizes for combined length of electrode and work
4. Connect the second work lead to the other out-
cables.
put terminal (positive if negative is attached and
TABLE A.1 vice versa) following steps 2 and 3.
Suggested Copper Cable Sizes - 100% Duty Cycle AUXILIARY POWER

Combined Lengths of Electrodes and Work Cables
This machine supplies the 115 volt, AC power need-
Amperes Length Cable Size
ed for operating wire feeding equipment. The power
1000 0 - 250 ft. 3-3/0 is available from terminals #31 and #32 on the termi-
(76.2m) (3 x 85.0 mm2) nal strip. An 8 amp slow blow fuse on the machine
control panel protects the auxiliary power from
CONNECT ELECTRODE AND WORK excessive overloads. The circuit has a 1000 volt-
LEADS TO OUTPUT TERMINALS ampere rating.
The output terminals are located on the lower case CONNECTION FOR SEMI-AUTOMATIC
front and labeled “+” and “-”. See Figure A.4. There OR AUTOMATIC WIRE FEEDER
are 1000 amp rated “+” terminals on the right side, CONTROL
one 500 amp rated “+” terminal near the center and “-”
terminals on the left side. They are fully recessed to With the DC-1000 turned off, the control cable from
minimize the possibility of accidental contact by an the semi-automatic or automatic wire feeding equip-
object or a person. ment is connected to the terminal strip. A strain relief
box connector is provided for access into the termi-
The 1000 amp output connections provide the full nal strip section. A chassis grounding screw is also
rated output range of the machine. provided below the terminal strip marked with the
The 500 amp output connections provide enhanced symbol for connecting the wire feeding equip-
lower current arc characteristics, especially for sub- ment grounding wire. See the appropriate connec-
merged arc and GMAW procedures below 450 amps. tion diagram for the exact instructions for the wire
feeder being used. A spare plugged hole is provided
1. Set the ON/OFF PUSH BUTTON to OFF. in case an additional box connector is required.
2. Insert the electrode lead through the oval opening
NOTE: See the ACCESSORIES Section of this man-

in the lower shelf of the front case, closest to the ual for specific instructions on connecting the follow-
desired polarity (positive or negative). Pull through ing semi-automatic and automatic wire feeders:
enough cable to reach the output terminals.
}
• LN-7
• LN-8 Semi-Automatic Wire Feeders
• LN-9
• NA-3
• NA-5 } Automatic Wire Feeders
• LT-7
• LT-56 } Tractors
FIGURE A-4 - Output Terminals
IDEALARC DC-1000
A-9 A-9
INSTALLATION
3. If necessary, disconnect all wire feeder control
CONNECTION FOR AIR/CARBON ARC

CUTTING OPERATION cable connections from the DC-1000 terminal

strip.
WARNING 4. Remove the leads from the unit by pulling them
through and out of the strain relief box connector
THE OUTPUT TERMINALS ARE ENERGIZED AT (s).
ALL TIMES WHEN THE IDEALARC DC-1000 IS
CONNECTED FOR AIR/CARBON ARC CUTTING. 5. Connect a jumper wire from terminal #2 to termi-
nal #4 on the terminal strip.
____________________________________________________
1. Set ON/OFF PUSH BUTTON to OFF. 6. Set the Welding Mode Switch to the CV(I) position
for air/carbon arc cutting.
2. Locate and open the access door on the Front
Case Assembly.
IDEALARC DC-1000
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-10
NOTES
IDEALARC DC-1000
A-10
B-1 B-1
OPERATION
TABLE OF CONTENTS
-OPERATION SECTION-
OPERATION...................................................................................................................................Section B
Safety Precautions..............................................................................................................................B-2
General Description ............................................................................................................................B-3
Recommended Processes and Equipment............................................................................B-3
Operational Features and Controls........................................................................................B-3
Design Features and Advantages..........................................................................................B-3
Welding Capacity ...................................................................................................................B-4
Controls and Settings .........................................................................................................................B-5
Operating Steps ..................................................................................................................................B-6
Remote Control of Machine Operation ...............................................................................................B-6
Welding Procedure Recommendations ..............................................................................................B-6
Semi-Automatic and Automatic Wire Feeding with a DC-1000 and Wire Feeders.............................B-6
NA-3 Automatic Wire Feeder .................................................................................................B-6
Good Arc Striking Guidelines....................................................................................B-7
Arc Striking with IDEALARC DC-1000 and the NA-3 Start Board ............................B-7
NA-5 Automatic Wire Feeder .................................................................................................B-8
LN-8 Semi-Automatic Wire Feeder ........................................................................................B-8
LN-7 and LN-9 Semi-Automatic Wire Feeders ......................................................................B-8
IDEALARC DC-1000
B-2 B-2
OPERATION
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts such as
output terminals or internal wiring.
•Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
____________________________________________________
FUMES AND GASES

can be dangerous.
• Keep your head out of fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.
____________________________________________________
WELDING, CUTTING and

GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge on containers that
have held combustibles.
____________________________________________________
ARC RAYS
can burn.
• Wear eye, ear and body protection.
____________________________________________________
Only qualified personnel should operate this equip-

ment. Observe all safety information throughout this
manual.
IDEALARC DC-1000
B-3 B-3
OPERATION
GENERAL DESCRIPTION OPERATIONAL FEATURES AND

CONTROLS
The IDEALARC DC-1000 is an SCR-controlled, three
phase, welding and cutting power source. It uses a The IDEALARC DC-1000 comes with the following
single range potentiometer to control: standard controls:
• DOUBLE ON/OFF PUSH BUTTON (Main Power
• Submerged Arc Semi-Automatic or Automatic and 115V Auxiliary)
Welding • OUTPUT CONTROL POTENTIOMETER
• Open Arc Semi-Automatic or Automatic Welding • OUTPUT CONTROL SWITCH (Remote or
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to Machine Control)
5/8” [15.9 mm ] Diameter) • WELDING MODE SWITCH
• With the addition of the 500 ampere output termi- • CONTROL CIRCUIT POLARITY SWITCH
nal on models code 9500 and above, GMAW pro- • POWER SOURCE PILOT LIGHT
cedures can be performed. • DC AMMETER (OPTIONAL)
• DC VOLTMETER (OPTIONAL)
The IDEALARC DC-1000 has a three-position
DESIGN FEATURES AND
Welding Mode Switch to enable the user to operate in

one of three modes: ADVANTAGES

• Constant Voltage (CV) Innershield® The following list of design features will help you
• Constant Voltage (CV) Submerged Arc understand the machine’s total capabilities and how
• Variable Voltage (VV) - Constant Current (CC) you can take advantage of them to get maximum use
Submerged Arc of your machine.
• Excellent arc characteristics for optimum constant
The IDEALARC DC-1000 can be easily connected to voltage submerged arc and Innershield® welding
wire feeding equipment, including: performance.
• A control circuit designed to provide good starting
• Semi-automatic wire feeders LN-7, LN-8, and for a large variety of processes and procedures.
LN-9 • Output Control Potentiometer that provides easy
• Automatic wire feeders NA-3 and NA-5 single range continuous control.
• Tractors LT-56 and LT-7 • Output Control Switch that provides simple switch-
ing from local to remote control.
• Red neon pilot light to confirm that the Input

RECOMMENDED PROCESSES AND Contactor is energized.

EQUIPMENT • Auxiliary power source to provide 115-volt AC
power (1000 VA) to wire feeding equipment.
The IDEALARC DC-1000 is recommended for the fol- • Multi-functional terminal strip for easy connection
lowing welding or cutting processes within its output of wire feeding control cables and switching
capacity of 140 amps to 1250 amps (625 amps at 500 between CV Innershield® and CV Submerged Arc
amp output stud) in the Constant Voltage mode, and welding when using the Dual Process or Dual
140 amps to 1250 amps in the Variable Voltage Procedure Kits.
(Constant Current) mode: • Recessed output terminals to help prevent any
person or object from accidentally coming into
• Submerged Arc Semi-Automatic or Automatic contact with the output current. These terminals
Welding are prominently labeled positive and negative for
• Open Arc Semi-Automatic or Automatic Welding easy identification.
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to • Thermostatically protected power source.
5/8” [15.9 mm] Diameter) • Electronic protection circuit to protect power
source against overloads.
• Input line voltage compensation to provide an

essentially constant output.
• SCR electronically controlled welder output pro-
vides extra long life, especially for highly repetitive
welding applications.
IDEALARC DC-1000
B-4 B-4
OPERATION
• Three circuit solid state control system provides • Enclosure designed with air intake louvers that
maximum performance and circuit protection. keep dripping water from entering the unit, allow-
• Low profile case provides maximum use of space. ing outdoor operation. Transformer, SCR bridge,
• Convenient access to all controls. and choke have special corrosion resistant paint
• Large output lead strain relief openings to prevent for added protection.
terminal and cable damage.
• Easily removed case side, even when stacked.
WELDING CAPABILITY
The IDEALARC DC-1000 has the following duty cycle ratings.
If the duty cycle is exceeded, the thermal protective thermostat will shut off the output of the machine by keeping
the input contactor open until the machine cools to normal operating temperature. The machine can then be
restarted by pushing the ON/OFF push button.
Duty Cycle Amps Volts Hertz

55% (Based on 10 min.) 1250 44 50/60
60% (Based on 10 min.) 1140 44 50/60
100% 1000 44 50/60
IDEALARC DC-1000
B-5 B-5
OPERATION
CONTROLS AND SETTINGS

All operator controls and adjustments are located on the Case Front Assembly of the IDEALARC DC-1000. See
Figure B.1 for the location of each control.
FIGURE B.1 - Control Panel Keys
1. ON/OFF PUSH BUTTON: This push button turns 5. CONTROL CIRCUIT POLARITY SWITCH: This
the machine ON or OFF toggle switch is used to set power source voltage
sensing polarity to match the polarity to which the
2. OUTPUT CONTROL POTENTIOMETER: This
electrode is connected to the machine. This pro-
control provides tapered, continuous control of the
vides the correct polarity at the terminal strip for

machine output. The control can be rotated from
correct operation of the automatic wire feeding
minimum to maximum while machine is under
equipment powered by the auxiliary power from
load to adjust the machine output.
the power source.
3. WELDING MODE SWITCH: This toggle switch is
6. POWER SOURCE PILOT LIGHT: The red neon
used to select the proper welder performance
light glows when the power source input contactor
characteristics for the process being used. There
is energized.
are three modes: CV (Constant Voltage)
Innershield®, CV (Constant Voltage) Submerged 7. VOLTMETER: An optional voltmeter is available.
Arc, and VV (Variable Voltage) CC (Constant
Current) Submerged Arc. 8. AMMETER: An optional ammeter is available.
4. OUTPUT CONTROL SWITCH: This toggle switch

is used to switch between “Output Control at DC-
1000” for local control of machine output and
“Output Control Remote” for remote control of
machine output.
IDEALARC - DC 1000
B-6 B-6
OPERATION
OPERATING STEPS WELDING PROCEDURE
The following procedures are for using the IDEALARC RECOMMENDATIONS

DC-1000 in the local control mode of operation. For Select Welding Mode Switch position based on type of
remote control of the machine, see the Remote welding to be done.
Control of Machine Operation section.
1 Innershield® Welding/Other Open Arc Processes:
Before operating the machine, make sure you have all Use the CV Innershield® mode.
materials needed to complete the job. Be sure you are
familiar with, and have taken all possible safety pre- 2. Submerged Arc Welding: Use the CV Submerged
cautions before starting work. It is important that you Arc mode. If performing high speed welding,
follow these operating steps each time you use the switch between the CV Submerged Arc and the
machine. CV Innershield® mode and use the mode that
produces the best welding results. High Current,
1. Turn on the main AC power supply to the Large Puddle Submerged Arc Welding: Use the
machine. VV (CC) mode.
2. Set the CONTROL CIRCUIT POLARITY SWITCH 3. When the IDEALARC DC-1000 is used for
to the appropriate position. Air/Carbon Arc cutting, use the CV (I) mode and
- Set toggle to “Electrode Negative” position if the initially set the OUTPUT CONTROL POTEN-
electrode is connected to the negative (-) output TIOMETER to “9”. Based on the size of the car-
terminal. bon being used, turn the potentiometer to a lower
setting as required to obtain the best results. You
- Set toggle to “Electrode Positive” position if the can use carbon rods up to 5/8” (15.9 mm) in diam-
electrode is connected to the positive (+) output eter. The welder protection circuit protects the
terminal. machine from extremely high short circuiting puls-
es.
3. Set the WELDING MODE SWITCH to welding
process being used.
SEMI-AUTOMATIC AND
- CV Innershield® AUTOMATIC WIRE FEEDING WITH
- CV Submerged Arc IDEALARC DC-1000 AND WIRE
- VV (CC) FEEDERS
4. Push the ON/OFF PUSH BUTTON to the ON
NA-3 AUTOMATIC WIRE FEEDER
position.
- The red neon light glows. 1. Set the DC-1000 Output Control Switch to
Remote.
- The fan starts.
NOTE: Later model NA-3 automatic wire feeders are
5. Set Output Control Potentiometer to desired volt- capable of cold starts when the NA-3 Mode switch is
age or current. in the CV or VV (CC) mode position. Some earlier
6. Make the weld (NOTE: Terminal #2 and #4 must models are capable of cold starting only in the VV
be connected together to energize the machine (CC) mode position. Cold starting enables you to
output). inch the wire down to the work, automatically stop,
and automatically energize the flux hopper valve.
REMOTE CONTROL OF MACHINE 2. Set the DC-1000 welding mode switch for the
OPERATION desired process: CV Submerged Arc, CV
Innershield® mode or VV (CC) mode.
The toggle switch on the control panel labeled “Output
3. Set the NA-3 mode Switch Position to either CV or
Control at DC-1000” - “Output Control Remote” gives
VV (CC) to match the DC-1000 mode selected in
the operator the option of controlling the machine out-

step 2.
put from a remote location. If in the Remote position, a
wire feeder with remote control capabilities or a 4. Refer to the NA-3 operators manual for instruc-
remote control device such as a K775, must be con- tions on how to use the NA-3 in conjunction with
nected to terminals #75, #76, and #77 to operate. the DC-1000.
Refer to Accessories Section for wire feeder remote
information. 5. Follow the following guidelines for good arc strik-
ing detailed below for each welding mode.
IDEALARC DC-1000
B-7 B-7
OPERATION
GOOD ARC STRIKING GUIDELINES FOR THE ARC STRIKING WITH IDEALARC DC-1000 AND
NA-3 WITH THE IDEALARC DC-1000 IN THE CV THE NA-3 START BOARD
INNERSHIELD®, CV SUBMERGED ARC OR VV
(CC) WELDING MODES. When electrical strikeouts exceed 1 3/4” (44.4 mm) an
NA-3 Start Board may be required to improve arc
Following are some basic arc striking techniques that striking. When the NA-3 Start Board is used to
apply to all wire feed processes. Using these proce- improve arc striking, use the following procedures:
dures should provide trouble-free starting. These pro-
1. Set start time at 0.
cedures apply to single, solid wires and Innershield®
wires. 2. Set NA-3 start current and start voltage at mid
range.
1. Cut the electrode to a sharp point.
3. Set the NA-3 output current and voltage to the
2. Set the NA-3 Open Circuit Voltage Control to the
proper settings for the welding procedure to be
same dial setting as the Arc Voltage Control. If
used.
this is a new welding procedure, a good starting
point is to set the Open Circuit Voltage Control to 4. Turn the Start Board Timer to maximum.
#6.
5. Set Start Board current and voltage control.

NOTE: The open circuit voltage of the IDEALARC

DC-1000 varies from approximately 25 volts to 75 a. Set the Start Board current control to 1-
volts in the CV Innershield or CV Submerged Arc 1/2 dial numbers below that set on the
modes. The open circuit voltage is constant in the NA-3 current control.
VV (CC) mode. b. Set the Start Board voltage control equal
3. Run a test weld. Set proper current, voltage, and with the NA-3 voltage control setting
travel speed. NOTE: These Start Board current and voltage set-
a. For the best starting performance, the tings result in a start-up current that is lower than
NA-3 Open Circuit Voltage Control and the NA-3 current setting and approximately equal
Voltage Control setting should be the with the NA-3 voltage setting for the desired weld-
same. Set the Inch Speed Control for the ing procedure.
slowest inch speed possible. 6. Establish the correct arc striking procedure with
b. To adjust the Open Circuit Voltage Control the NA-3 Start Board timer set at maximum.
to get the best starting performance, make a. For the best starting performance, the
repeated starts observing the NA-3 volt- NA-3 Open Circuit Voltage Control and
meter. Voltage Control setting should be the
When the voltmeter pointer swings smoothly up to the same. Set the Inch Speed Control for the
desired arc voltage, without undershooting or over- slowest inch speed possible.
shooting the desired arc voltage, the Open Circuit b. To adjust the Open Circuit Voltage Control
Voltage Control is set properly. to get the best starting performance, make
If the voltmeter pointer overshoots the desired voltage repeated starts observing the NA-3 volt-
and then returns back to the desired voltage, the meter.
Open Circuit Voltage Control is set too high. This can When the voltmeter pointer swings smoothly up to the
result in a bad start where the wire tends to “Blast off.” desired arc voltage, without undershooting or over-
If the voltmeter pointer hesitates before coming up to shooting the desired arc voltage, the Open Circuit
the desired voltage, the Open Circuit Voltage Control Voltage Control is set properly.
is set too low. This can cause the electrode to stub. If the voltmeter pointer overshoots the desired voltage
4. Start and make the weld. and then returns back to the desired voltage, the
Open Circuit Voltage Control is set too high. This can
a. Cold starts. For cold starts, be sure the result in a bad start where the wire tends to “Blast off.”
work piece is clean and the electrode
makes positive contact with the work If the voltmeter pointer hesitates before coming up to
piece. the desired voltage, the Open Circuit Voltage Control
is set too low. This can cause the electrode to stub.
b. Hot “On the Fly” starts. For hot starts, trav-
el should begin before the wire contacts
the work piece.
IDEALARC DC-1000
B-8 B-8
OPERATION
c. Set NA-3 Start Board current and voltage LN-8 SEMI-AUTOMATIC WIRE FEEDER
as close to the welding procedure current

and voltage as possible. To use the LN-8 Semi-Automatic Wire Feeder with
IDEALARC DC-1000
NOTE: The Start Board current and volt-
age should be as close as possible to the 1. Set the IDEALARC DC-1000 WELDING MODE
welding procedure current and voltage, SWITCH to either CV Innershield® mode or CV
while still getting satisfactory starts. Submerged Arc mode depending on the welding
d. Set the start time to as low a time as possi- process being used.
ble while still getting satisfactory starts. 2. Set the IDEALARC DC-1000 OUTPUT CONTROL
7. Start and make the weld. SWITCH to the REMOTE position.
3. Set the LN-8 Welding Mode Switch to the CV
IDEALARC DC-1000 POWER SOURCE position. The LN-8 Welding Mode Switch is locat-
SETTING WHEN CONNECTED TO NA-5 ed on the variable voltage VV (CC) board.
AUTOMATIC WIRE FEEDER
4. Refer to the LN-8 Operator’s Manual for instruc-
tions on how to use the LN-8.
When using the IDEALARC DC-1000 with the NA-5

automatic wire feeder, set the controls on the IDE- LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
ALARC DC-1000 as follows for the best performance:
FEEDERS OR OTHER CONSTANT WIRE
1. Turn OFF main AC input power supply to the IDE- FEEDERS
ALARC DC-1000.
2. Connect the electrode cables to terminal To use the LN-7, LN-9, or other constant wire feed
polarity to be used. speed semi-automatic wire feeders with IDEALARC
DC-1000
3. Set the CONTROL CIRCUIT POLARITY SWITCH
1. Set the IDEALARC DC-1000 WELDING MODE
to the same polarity as the electrode cable con-
SWITCH to either CV Innershield® mode or CV
nection.
Submerged Arc mode depending on the welding
4. Set the OUTPUT CONTROL SWITCH to process being used.
REMOTE.
NOTE: These semi-automatic wire feeders cannot be
5. Set the IDEALARC DC-1000 WELDING MODE used in the VV (CC) mode.
SWITCH to the position that matches the welding
2. Set the IDEALARC DC-1000 OUTPUT CONTROL

process being used.
SWITCH.
a. For submerged arc welding, set WELDING
MODE SWITCH TO CV SUBMERGED a. LN-7: Use either an optional K775 Remote
ARC position. Control Box Assembly or set the IDE-
ALARC DC-1000 OUTPUT CONTROL
b. For all open arc welding processes set SWITCH in the Local position.
WELDING MODE SWITCH TO CV
b. LN-9: Refer to the LN-9 Operator’s Manual
INNERSHIELD® position.
for instructions on how to use the LN-9.
6. Set the Open Voltage Control four volts higher
than the welding voltage, and the inch speed at
1/2 the welding wire feed speed for the initial test
weld.
7. Refer to NA-5 Operator’s Manual for instructions
on how to use the NA-5.
IDEALARC DC-1000
C-1 C-1
Return to Master TOC ACCESSORIES
TABLE OF CONTENTS
-ACCESSORIES SECTION-
ACCESSORIES ........................................................................................................................Section C
Options/Accessories....................................................................................................................C-2
Meters..........................................................................................................................................C-2
Remote Output Control................................................................................................................C-2
Connections for Wire Feeder Control ..........................................................................................C-2
NA-3, or LT-7 ..................................................................................................................C-2
NA-5 ................................................................................................................................C-3
LN-8 ................................................................................................................................C-4
LN-9 ................................................................................................................................C-5
LN-7 ................................................................................................................................C-6
IDEALARC DC-1000
C-2 C-2
ACCESSORIES
CONNECTING THE NA-3 OR LT-7 TO
OPTIONS/ACCESSORIES
• Remote Control Box Assembly (K775) IDEALARC DC-1000

• LN-7
•
•
}
LN-8 Semi-Automatic Wire Feeders
LN-9
1. Disconnect main AC input power to the IDE-
ALARC DC-1000.
• NA-3
• }
NA-5 Automatic Wire Feeders
2. Set IDEALARC DC-1000 ON/OFF PUSH BUT-
TON to OFF.
• LT-7 and LT-56 Tractors
3. Connect the wire feeder control cable leads to the
METERS IDEALARC DC-1000 terminal strip as shown in
Figure C.1.
Optional factory-installed voltmeter and ammeter are
available.
REMOTE OUTPUT CONTROL -

(OPTIONAL)
The K775 Remote Output Control consists of a control

box with 28 ft. (8.4 m) four conductor cable. This con-
nects to terminals #75, #76, #77 on the terminal strip,
and the case grounding screw marked with the sym-
bol on the machine. These terminals are made
available by opening the terminal access cover on the
case front. This control will give the same control as
the output control on the machine.
CONNECTIONS FOR SEMI-AUTO-

MATIC OR AUTOMATIC WIRE
FEEDER CONTROL
1. Set the ON/OFF PUSH BUTTON to OFF.
2. Locate and open the hinged access door on the
Front Case Assembly. FIGURE C.1 - NA-3 or LT-7 Wire Feeder

Connection to the IDEALARC DC-1000
3. Insert control cable through the strain relief box
connector and pull enough cable through to reach
4. Connect the wire feeder control cable ground lead
the terminal strip.
to the frame terminal marked .
4. Connect the automatic wire feeder control cable to
the terminal strip. See corresponding connection CAUTION
diagram in this section of the manual, or the The IDEALARC DC-1000 must be properly grounded.
instructions included with the wire feeder.
____________________________________________________
5. Connect the wire feeder grounding wire to the
chassis ground screw marked with the symbol . 5. Extend wire feeder control cable lead #21 so it
can be connected directly to the work piece.
NOTE: The IDEALARC DC-1000 Auxiliary Power
Circuit (at #31 and #32 on the terminal strip) supplies a. Make a bolted connection using AWG #14
115-volt AC power to the wire feeding equipment. The or larger insulated wire.
circuit has a 1000 volt ampere rating. An 8-amp slow
b. Tape the bolted connection with insulating

blow fuse on the machine’s control panel protects the
tape.
auxiliary power supply from excessive overloads or
short circuits. NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.
c. Keep the #21 lead electrically separate
from the work cable circuit and connection.
IDEALARC DC-1000
C-3 C-3
ACCESSORIES
d. Tape the #21 lead to work cable for ease 5. Extend wire feeder control cable lead #21 so it
of use. can be connected directly to the work piece.

6. Connect the welding cables as shown in Figure a. Make a bolted connection using AWG #14
C.1. or larger insulated wire.
NOTE: Welding cables must be of proper capacity for b. Tape the bolted connection with insulating
the current and duty cycle for immediate and future tape.
applications.
NOTE: An S-16586-X remote voltage sensing work
NOTE: The connection diagram shown in Figure C.1 lead is available for this purpose.
shows the electrode connected for positive polarity.
To change polarity: c. Keep the #21 lead electrically separate
from the work cable circuit and connection.
a. Set the IDEALARC DC-1000 ON/OFF
PUSH BUTTON to OFF. d. Tape the #21 lead to work cable for ease
of use.
b. Move the electrode cable to the Negative
(-) output terminal. 6. Connect NA-5 wire feeder control jumpers on the
Voltage Control Board. See NA-5 Operator’s

c. Move the work cable to the Positive (+) Manual.

output terminal.
a. Connect red jumper on Voltage Control
d. Set the IDEALARC DC-1000 CONTROL Board to pin “S.”
CIRCUIT POLARITY SWITCH to NEGA-
TIVE. b. Connect white jumper on Voltage Control
Board to pin “B.”
e. Reverse the leads at the back of the
ammeter and voltmeter on the wire feeder 7. Connect the welding cables as shown in Figure
automatic control box. C.2.
NOTE: Welding cables must be of proper capacity for
CONNECTING THE NA-5 TO THE the current and duty cycle for immediate and future
IDEALARC DC-1000 applications.
NOTE: For optimum performance, use the NA-5 with

IDEALARC DC-1000 codes 8288 and above.

ALARC DC-1000.
2. Set the IDEALARC DC-1000 ON/OFF PUSH
BUTTON to OFF.
IDEALARC DC-1000 terminal strip as shown in
Figure C.2.
NOTE: If using a K215 control cable, connect con-
trol cable leads #75 to #75 on the terminal strip,
#76 to #74 on the terminal strip, and #77 to #73
on the terminal strip.
CAUTION
The IDEALARC DC-1000 must be properly grounded.

____________________________________________________ FIGURE C.2 - NA-5 Wire Feeder Connection to
the IDEALARC DC-1000
IDEALARC DC-1000
C-4 C-4
ACCESSORIES
NOTE: The connection diagram shown in Figure C.2


To change polarity:
a. Set the IDEALARC DC-1000 ON/OFF
PUSH BUTTON to OFF.
b. Move the electrode cable to the Negative
(-) output terminal.
c. Move the work cable to the Positive (+)
output terminal.
d. Set the IDEALARC DC-1000 CONTROL
CIRCUIT POLARITY SWITCH to NEGA-
TIVE.
e. Refer to NA-5 operator’s manual for proper
control box polarity connections.
NOTE: For proper NA-5 operation, the electrode

cables must be secured under the clamp bar on the
left side of the NA-5 Control Box.
FIGURE C.3 - LN-8 Wire Feeder Connection
CONNECTING THE LN-8 TO THE
to the IDEALARC DC-1000
IDEALARC DC-1000
6. Connect lead #75(A) to #75 on the terminal strip.
1. Set the ON/OFF PUSH BUTTON to the OFF pos-
tion. 7. Connect lead #76(B) to #76 on the terminal strip.
2. Disconnect AC input power to the IDEALARC DC- 8. Connect lead #77(C) to #77 on the terminal strip.
1000. 9. Connect the welding cables as shown in Figure
3. Connect the wire feeder control cable leads to the C.3.
DC-1000 terminal strip. See Figure C.3. NOTE: Welding cables must be of proper capacity for
4. Connect the wire feeder control cable ground lead the current and duty cycle for immediate and future
to the frame terminal marked . applications.

10. Set the DC-1000 output control switch to the
CAUTION ”Output Control Remote” position.
The IDEALARC DC-1000 must be properly grounded. NOTE: The connection diagram shown in figure C-3
shows electrode connected positive. To change polari-
____________________________________________________
ty:
5. Extend the wire feeder control cable #21 lead so it a. Set the IDEALARC DC-1000 ON/OFF
can be connected directly to the work piece. PUSH BUTTON to OFF.
a. Make a bolted connection using AWG #14 b. Move the electrode cable to the Negative
or larger insulated wire. (-) output terminal.
b. Tape the bolted connection with insulating c. Move the work cable to the Positive (+)
tape. output terminal.
NOTE: An S-16586-X remote voltage sensing work d. Set the IDEALARC DC-1000 CONTROL
lead is available for this purpose. CIRCUIT POLARITY SWITCH to NEGA-

TIVE.
c. Keep the #21 lead electrically separate
from the work cable circuit and connection. e. Refer to LN-8 operator’s manual for proper
control box polarity connections.
d. Tape the #21 lead to the work cable for
ease of use.
IDEALARC DC-1000
C-5 C-5
ACCESSORIES
CONNECTING THE LN-9 WIRE FEEDER
TO THE IDEALARC DC-1000

1. Set the ON/OFF PUSH BUTTON to the OFF pos-
tion.
2. Disconnect AC input power to the IDEALARC DC-
1000.
DC-1000 terminal strip. See Figure C.4.
CAUTION
____________________________________________________
5. Extend the wire feeder control cable #21 lead so it

can be connected directly to the work piece.
a. Make a bolted connection using AWG #14 FIGURE C.4 - LN-9 Wire Feeder Connection
or larger insulated wire. to the IDEALARC DC-1000
11. Set the DC-1000 output control switch to the
b. Tape the bolted connection with insulating ”Output Control Remote” position.
tape.
NOTE: The connection diagram shown in figure C-4
NOTE: An S-16586-X remote voltage sensing work shows electrode connected for positive polarity. To
lead is available for this purpose. change polarity:
c. Keep the #21 lead elecrically separate a. Set the IDEALARC DC-1000 ON/OFF
from the work cable circuit and connection. PUSH BUTTON to OFF.
d. Tape the #21 lead to the work cable for b. Move the electrode cable to the Negative
ease of use.
(-) output terminal.

6. Connect lead #75(A) to #75 on the terminal strip. c. Move the work cable to the Positive (+)
7. Connect lead #76(B) to #74 on the terminal strip. output terminal.
8. Connect lead #77(C) to #73 on the terminal strip. d. Position the positive-negative switch on
the power source to correspond to the
9. Connect the welding cables as shown in Figure polarity of the electrode cable connection.
C.4.
e. Refer to LN-9 operating manual for
Note: Welding cables must be of proper capacity for required polarity connections.
the current and duty cycle for immediate and future
applications.
10. Connect LN-9 wire feeder jumpers on voltage
board as follows: See LN-9 operator’s manual.
a. White jumper on voltage board to pin “S”
b. Blue jumper on voltage board (later mod-

els) or on start board (earlier models) to

pin “B”.
IDEALARC DC-1000
C-6 C-6
ACCESSORIES
CONNECTING THE LN-7 WIRE FEEDER TO

THE IDEALARC DC-1000
1. Set the IDEALARC DC-1000 ON/OFF PUSH

BUTTON to OFF.
ALARC DC-1000.
3 Connect the wire feeder control cable leads to the
IDEALARC DC-1000 terminal strip as shown in
Figure C.5.
CAUTION

____________________________________________________
5. PERFORM THIS STEP ONLY IF THE LN-7 IS

EQUIPPED WITH A METER KIT.
Extend wire feeder control cable lead #21 so it can be FIGURE C.5 - LN-7 Wire Feeder Connection to
connected directly to the work piece. the IDEALARC DC-1000
a. Make a bolted connection using AWG #14 NOTE: Welding cables must be of proper capacity for
or larger insulated wire. the current and duty cycle for immediate and future
applications.
b. Tape the bolted connection with insulating
tape. NOTE: The connection diagram shown in Figure C.5
NOTE: If the work cable length is less than 25 feet To change polarity:
and the connections to the work piece are secure,
then wire feeder control cable lead #21 can be con- a. Set the IDEALARC DC-1000 ON/OFF
nected directly to the DC-1000 terminal strip. PUSH BUTTON to OFF.
NOTE: An S-16586-X remote voltage sensing work b. Move the electrode cable to the Negative
lead is available for this purpose. (-) output terminal.
b. Keep the #21 lead electrically separate c. Move the work cable to the Positive (+)
from the work cable circuit and connection. output terminal.
c. Tape the #21 lead to work cable for ease d. Set the IDEALARC DC-1000 CONTROL
of use. POLARITY SWITCH to NEGATIVE.
6. Connect the welding cables as shown in Figure

C.5.
IDEALARC DC-1000
D-1 D-1
Return to Master TOC MAINTENANCE
TABLE OF CONTENTS
-MAINTENANCE SECTION-
MAINTENANCE...................................................................................................Section D
Safety Precautions....................................................................................................D-2
Routine and Periodic Maintenance...........................................................................D-2
Major Component Locations.....................................................................................D-3
IDEALARC DC - 1000
D-2 D-2
MAINTENANCE
SAFETY PRECAUTIONS 3. Inspect the electrode cables for any slits or punc-
tures in the cable jacket, or any condition that
would affect the proper operation of the machine.
WARNING
Perform Periodically:
ELECTRIC SHOCK
CAN KILL Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure
D.1.
Only qualified personnel should
perform this maintenance. • Main transformer and choke
Turn the input power OFF at the disconnect switch or • Electrode and work cable connections.
fuse box before working on this equiptment.
• SCR rectifier bridge and heat sink fins.
Do not touch electrically hot parts.
• Control board.
____________________________________________________
• Firing board.
ROUTINE AND PERIODIC
MAINTENANCE • Fan Assembly.

.....................................................................................
1. Disconnect input AC power supply lines to the NOTE: The fan motor has sealed bearings which
machine before performing periodic maintenance, require no maintenance.
tightening, cleaning, or replacing parts. See
Figure D.1
Perform the following daily:

1. Check that no combustible materials are in the
welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.
IDEALARC DC - 1000
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-3
IDEALARC DC-1000
MAINTENANCE
FIGURE D.1 - Major Component Locations
D-3
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-4
NOTES
IDEALARC DC-1000
D-4
E-1 E-1
Return to Master TOC THEORY OF OPERATION
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
THEORY OF OPERATION SECTION. ................................................................Section E
General Description............................................................................................E-2
Input Line Voltage, Contactor, and Main Transformer .......................................E-2
Output Rectification, Control, and Feedback......................................................E-3
Protection Devices and Circuits (Contactor Hold-In) ..........................................E-4
SCR Operation. ..................................................................................................E-5
FIGURE E.1 Block Logic Diagram

IDEALARC DC-1000
E-2 E-2
THEORY OF OPERATION
GENERAL DESCRIPTION
The DC 1000 is an SCR - controlled DC power range potentiometer ouptut control. It can be used
source. It is designed to be controlled with a single for submerged arc or open arc automatic and semi-
automatic welding.
FIGURE E.2 - Input Line Voltage, Contactor and Main Transformer

INPUT LINE VOLTAGE, CONTAC-

TOR, AND MAIN TRANSFORMER
The desired three phase power is connected to the age, low current input power to a low voltage, high
DC-1000 through an Input Contactor located in the current output. The finishes or “neutrals” of the
input box at the rear of the machine. Two phases of the main secondary coils are connected together and
input lines are also connected to the Control the six starts of the secondary windings are con-
Transformer which supplies power to the Contactor nected to the rectifier assembly. In addition, the
Hold-In Circuit. The Contactor Hold-In Circuit will dis- main transformer also has an isolated 115 VAC
able the Input Contactor if the DC-1000 is overloaded auxiliary winding that supplies 115 VAC to operate
or overheated. the cooling fan and offers 8 amps of auxiliary power
to operate wire feeding equipment. The three 75

A Reconnect Panel allows the user to configure the
VAC phase angle windings are also housed in the
machine for the desired input voltage. This AC input
Main Transformer assembly. These windings pro-
voltage is applied to the primary of the Main
vide power and “timing” to the Firing Board.
Transformer. The transformer changes the high volt-
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
IDEALARC DC-1000
E-3 THEORY OF OPERATION E-3
FIGURE E.3- Output, Rectification, Control and Feedback

OUTPUT RECTIFICATION,
CONTROL, AND FEEDBACK
The neutrals of the Main Transformer secondary proper amount of energy to the gates of the power
windings are connected together and the six starts SCRs. When this gate signal is applied, at the cor-
are connected to the six SCR assemblies to form a rect time, the SCR will turn “ON”. The amount of
six phase output. This six phase AC output from the “ON” time versus “OFF” time determines the output
Main Transformer secondary is rectified and con- of the machine. See SCR Operation.
trolled through the SCR bridge. Output current is
The Pilot Relay signals the Firing Board circuit to
sensed at the shunt, and output voltage is moni-
supply gate pulses to the SCR Bridge. Closing of
tored at the welding output terminals. This feedback
the Pilot Relay (a “dry” closure of leads #2 and #4)
information is processed in the control board. The
also brings the Latching Resistor into the machine
control board compares the commands of the Mode
output circuit. The Latching Resistor provides a
switch and the Output Control Potentiometer (or
pre-load for the SCR Bridge.
Remote Control) with the feedback information and
sends the appropriate signal to the Firing Board. In later models (above code 9500) a Choke and
separate 500 amp output terminal is provided to
The Firing Board is a three phase circuit. Each
enhance lower current arc characteristics, espe-
phase provides two firing pulses, one for each of
cially for submerged arc and GMAW procedures

the two Silicon Controlled Rectifiers (SCR) con-
below 450 amps.
trolled by that phase. The firing circuit supplies the
IDEALARC DC-1000
E-4 E-4
THEORY OF OPERATION
FIGURE E.4 - Protection Devices and Circuits (Contactor Hold-In)
PROTECTION DEVICES AND

CIRCUITS (CONTACTOR HOLD-IN)
Two thermostats protect the DC-1000 from exces-

The DC-1000 is also protected against high current
sive operating temperatures. Excessive operating
overloads. This electronic protection circuit senses
temperatures may be caused by a lack of cooling air
an overload on the power source and opens the
or operating the machine beyond the duty cycle and
input contactor should the overload remain for a
output rating. If excessive operating temperature
predetermined time. If the overload is great the
should occur, the thermostat(s) will deactivate the
machine will shut down immediately. The input con-
input contactor, turning the machine off. The input
tactor will remain open until the start push button is
contactor will remain open until the machine cools.
operated.
The machine can then be restarted by operating the
start push button. The Remote Control circuit is also protected from
“grounds” or voltage intrusions. If the #73, #74, #75,
Upon restart, if the fan does not turn or the air intake
#76 or #77 leads come in contact with either of the
louvers are obstructed, then the input power must
machine’s output cables, the DC-1000 will only
be removed and the fan problem or air obstruction
operate at a minimum output or the input contactor
be corrected.
will open.
IDEALARC DC-1000
E-5 E-5
THEORY OF OPERATION
FIGURE E.5 - SCR Operation

SCR OPERATION
A silicon controlled rectifier (SCR) is a three termi- An SCR is fired by a short burst of current into the
nal device used to control rather large currents to a gate. This gate pulse must be more positive than
load. An SCR acts very much like a switch. When a the cathode voltage. Since there is a standard PN
gate signal is applied to the SCR it is turned ON and junction between gate and cathode, the voltage
there is current flow from anode to cathode. In the between these terminals must be slightly greater
ON state the SCR acts like a closed switch. When than 0.6 V. Once the SCR has fired it is not neces-
the SCR is turned OFF there is no current flow from sary to continue the flow of gate current. As long as
anode to cathode thus the device acts like an open current continues to flow from anode to cathode the
switch. As the name suggests, the SCR is a rectifi- SCR will remain on. When the anode to cathode
er, so it passes current only during positive half current drops below a minimum value, called hold-
cycles of the AC supply. The positive half cycle is ing current, the SCR will shut off. This normally
the portion of the sine wave in which the anode of occurs as the AC supply voltage passes through
the SCR is more positive than the cathode. zero into the negative portion of the sine wave. If
the SCR is turned on early in the positive half cycle,
When an AC supply voltage is applied to the SCR, the conduction time is longer resulting in greater
the device spends a certain portion of the AC cycle SCR output. If the gate firing occurs later in the
time in the on state and the remainder of the time in cycle the conduction time is less resulting in lower
the off state. The amount of time spent in the ON SCR output.
state is controlled by the Gate.
IDEALARC DC-1000
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-6
NOTES
IDEALARC DC-1000
E-6
F-1 F-1
TROUBLESHOOTING & REPAIR
TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTION-

TROUBLESHOOTING AND REPAIR SECTION ...............................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
Safety Precautions.................................................................................................................F-3
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide ..........................................................................................................F-4
Output Problems .............................................................................................................F-4
Function Problems ..........................................................................................................F-9
Welding Problems .........................................................................................................F-11
Test Procedures
Control Transformer (T2) Voltage Test .........................................................................F-13
Main Transformer (T1) Voltage Test .............................................................................F-16
Firing Board Test...........................................................................................................F-20
Control Board Test ........................................................................................................F-25
Static SCR Test.............................................................................................................F-30
Active SCR Test ............................................................................................................F-34

Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform Constant Current Mode ..................................F-38
No Load
Normal Open Circuit Voltage Waveform Constant Voltage ............................................F-39
Innershield - Maximum Output Setting - No Load
Normal Open Circuit Voltage Waveform Constant Voltage ............................................F-40
Innershield - Minimum Output Setting - No Load
Typical Output Voltage Waveform - Machine Loaded Constant Voltage........................F-41
Innershield Mode
Typical Output Voltage Waveform - Machine Loaded ....................................................F-42
500 Amp Output Terminal Constant Voltage Innershield Mode
Typical SCR Gate Voltage Waveform Constant Voltage................................................F-43
Innershield Maximum Output Setting - No Load
Abnormal Open Circuit Voltage Waveform Constant Voltage ........................................F-44
Innershield One Output SCR Not Functioning Maximum Output Setting
Replacement Procedures
Input Contactor Cleaning and or Replacement .............................................................F-45
SCR Output Bridge Replacement .................................................................................F-49
SCR Output Bridge Removal..................................................................................F-50
Removal of Individual SCR Heat Sink Assemblies.................................................F-52
SCR Heat Sink Installation .....................................................................................F-53
SCR Output Bridge Installation...............................................................................F-53
Removal and Reassembly of Lift Bail ...........................................................................F-55
Removal of Lift Bail.................................................................................................F-56
Reassembly of Lift Bail ...........................................................................................F-57
Main Transformer Removal and Installation .................................................................F-58
Main Transformer Disassembly and Assembly ......................................................F-59
Main Transformer Disassembly ..............................................................................F-60
Coil Removal and Replacement .............................................................................F-60
Transformer Reassembly .......................................................................................F-61
Retest After Repair ..............................................................................................................F-63
IDEALARC DC-1000
F-2 F-2
HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to STEP 3. RECOMMENDED

help you locate and repair possible machine
COURSE OF ACTION
malfunctions. Simply follow the three-step
procedure listed below. The last column labeled “Recommended
STEP 1 LOCATE PROBLEM Course of Action” lists the most likely com-
ponents that may have failed in your
(SYMPTOM). machine. It also specifies the appropriate
test procedure to verify that the subject
Look under the column labeled “PROBLEM
component is either good or bad. If there
(SYMPTOMS)”. This column describes
are a number of possible components,
possible symptoms that the machine may
check the components in the order listed to
exhibit. Find the listing that best describes
eliminate one possibility at a time until you
the symptom that the machine is exhibiting.
locate the cause of your problem.
Symptoms are grouped into the following
categories: output problems, function prob- All of the referenced test procedures
lems, and welding problems. referred to in the Troubleshooting Guide are

described in detail at the end of this chap-
STEP 2 PERFORM EXTERNAL ter. Refer to the Troubleshooting and Repair
TESTS. Table of Contents to locate each specific
Test Procedure. All of the specified test
The second column labeled “POSSIBLE points, components, terminal strips, etc. can
AREAS OF MISADJUSTMENT(S)” lists the be found on the referenced electrical wiring
obvious external possibilities that may con- diagrams and schematics. Refer to the
tribute to the machine symptom. Perform Electrical Diagrams Section Table of
these tests/checks in the order listed. In Contents to locate the appropriate diagram.
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
_____________________________________________________________
IDEALARC DC-1000
F-3 F-3
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the P.C. Board from the static-shielding

WARNING bag and place it directly into the equipment. Don’t
ELECTRIC SHOCK can kill. set the P.C. Board on or near paper, plastic or
cloth which could have a static charge. If the P.C.
Have an electrician install and Board can’t be installed immediately, put it back in
service this equipment. Turn the static-shielding bag.
the input power OFF at the
fuse box before working on - If the P.C. Board uses protective shorting
equipment. Do not touch elec- jumpers, don’t remove them until installation is
trically hot parts. complete.
_______________________________ - If you return a P.C. Board to The Lincoln Electric

Company for credit, it must be in the static-shield-
CAUTION: Sometimes machine failures appear to ing bag. This will prevent further damage and
be due to PC board failures. These problems can allow proper failure analysis.
sometimes be traced to poor electrical connections.
To avoid problems when troubleshooting and 4. Test the machine to determine if the failure
replacing PC boards, please use the following pro- symptom has been corrected by the replace-
cedure: ment PC board.
1. Determine to the best of your technical ability NOTE: It is desirable to have a spare (known
that the PC board is the most likely component good) PC board available for PC board trou-
causing the failure symptom. bleshooting.
2. Check for loose connections at the PC board to NOTE: Allow the machine to heat up so that all
assure that the PC board is properly connect- electrical components can reach their operating
ed. temperature.
3. If the problem persists, replace the suspect PC 5. Remove the replacement PC board and sub-
board using standard practices to avoid static stitute it with the original PC board to recreate
electrical damage and electrical shock. Read the original problem.
the warning inside the static resistant bag and
perform the following procedures: a. If the original problem does not reap-
pear by substituting the original board,
P.C. Board can be damaged by static electricity. then the PC board was not the prob-
lem. Continue to look for bad connec-

- Remove your body’s static tions in the control wiring harness,
charge before opening the junction blocks, and terminal strips.
static-shielding bag. Wear an
anti-static wrist strap. For b. If the original problem is recreated by
safety, use a 1 Meg ohm the substitution of the original board,
resistive cord connected to a then the PC board was the problem.
grounded part of the equip- Reinstall the replacement PC board
ATTENTION ment frame. and test the machine.
Static-Sensitive
Devices - If you don’t have a wrist 6. Always indicate that this procedure was fol-
Handle only at strap, touch an unpainted, lowed when warranty reports are to be submit-
Static-Safe grounded, part of the equip- ted.
Workstations ment frame. Keep touching
the frame to prevent static NOTE: Following this procedure and writing on the
Reusable build-up. Be sure not to touch warranty report, “INSTALLED AND SWITCHED PC
Container any electrically live parts at BOARDS TO VERIFY PROBLEM,” will help avoid
Do Not Destroy the same time. denial of legitimate PC board warranty claims.
- Tools which come in contact with the P.C. Board

must be either conductive, anti-static or static-dissi-
pative.
IDEALARC DC-1000
F-4 F-4
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical Contact the Lincoln Electric

Damage is Evident. Service Dept. (216) 383-2531
or 1-800-833-9353 (WELD)
The Machine is dead - The Input 1. Check for blown or missing 1. The.Start/Stop button (S1)
contactor does not operate. fuses in input lines. may be faulty- Check for prop-
er operation. See wiring dia-
2. Check the three-phase input gram.
line voltage at the machine.
The input voltage must match 2. The Control Transformer (T2)
the rating plate and reconnect may be faulty. Perform the

panel. Control Transformer Test .
3. The primary or secondary

thermostats may be open.
Check or replace. Also check
the associated wiring. See
wiring diagram.
4. The pilot relay (2CR) may be

faulty. Check or replace. See
wiring diagram.
5. The input contactor coil may

be open. See wiring diagram.
6. The Control board may be

faulty - Replace.
Input contactor (1CR) chatters. 1. The input line voltage may be 1. The pilot relay (2CR) may
low. Check all three phases. have bad contacts. Check or
replace relay.
2. Make sure input line voltage
matches machine rating and 2. Check for loose or faulty
reconnect panel. wiring between pilot relay
(2CR) and input contactor
(1CR) coil connections.
3. The input contactor (1CR)

may be faulty - Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC DC-1000
F-5
F-5 TROUBLESHOOTING & REPAIR


OUTPUT PROBLEMS
Input contactor pulls in when start 1. Make sure input voltages 1. The 1CR interlock may be
button is pressed but immediately match machine rating and faulty. Replace if necessary.
drops out when start button is reconnect panel.
released. 2. The Start/Stop button may be
2. Remove all external wires faulty. Check or replace.
attached to terminal strip (2, 4,
31, 32, 73, 74, 75, 76, 77). If 3. Check internal remote control
contactor (1CR) functions cor- circuit (leads 73, 74, 75, 76
rectly, there may be a ground and 77) and switch SW3 for
or negative intrusion on the grounds or shorts.
remote control leads (73, 74,
75, 76, or 77). There may also 4. The control board may be
be a short at the welder output faulty - Replace.

terminals.
3. If the problem persists after

performing steps #1 and #2,
the problem is in the DC-
1000.
CAUTION
IDEALARC DC-1000
F-6 F-6


OUTPUT PROBLEMS
Machine input contactor operates 1. Install a jumper from #2 to #4 1. Check operation of output
but machine has no weld output. on machine terminal strip. If pilot relay (4CR). There
Fan runs and pilot light glows. machine weld output is should be 115 VAC present
restored, the problem is in the on leads #31 and #4 at (4CR)
wire feeder or control cable. when #2 and #4 are jumpered
together at the terminal strip.
2. If remote control is not being
used, make certain the output a. If the correct voltage is pre-
control switch (SW3) is in the sent and the relay does not
“OUTPUT CONTROL AT DC activate, the relay may be
1000” position. faulty - Replace.
3. Check 8 AMP fuse in the front b. If the 115 VAC is missing,

panel. Replace if blown. check the associated wiring
for loose or faulty connec-
4. Check for loose or faulty weld tions. See wiring diagram.
cable connections.
2. Check the output control
potentiometer (R1) and asso-
ciated circuitry for loose or
faulty connections. See wiring
diagram.
3. Perform Main Transformer

Test
4. Perform Firing Board Test.

5. Perform Control Board Test.
6. Perform SCR Output Bridge

Test.
CAUTION
IDEALARC DC-1000
F-7 F-7


OUTPUT PROBLEMS
Machine has maximum weld out- 1. If remote control is being 1. Check output control switch
put and no control. used, put output control switch (SW3) and associated wiring.
(SW3) in “OUTPUT CON-
TROL AT DC-1000” position 2. Check feedback leads #222
and control weld output with (negative output terminal) and
the output control (R1) at DC- #215, #210(output shunt) for
1000. If the problem is solved, loose or faulty connections.
check the remote control unit See wiring diagram.
(or wire feeder) and associat-
ed control cable. 3. Check the #75 lead for conti-
nuity (zero ohms) from the
output control potentiometer

(R1) to the control board plug
10J1. See wiring diagram.
4. Perform Firing Board Test.
5. Perform Control Board Test.

Test.
Machine has minimum output 1. If a remote control unit is NOT 1. Check the output control
and no control. connected to the terminal strip potentiometer (R1) and asso-
#73, #74,#75, #76, and/or #77 ciated wiring.
terminals, the output control
switch must be in the “OUT- 2. Check the output control

PUT CONTROL AT DC-1000” switch (SW3) the welding
position. mode switch (SW4) and asso-
ciated wiring.
2. If a remote control cable is
connected to terminals #73, 3. Perform the Control Board
#74, #75, #76, and/or #77, the Test.
leads may be shorted to the
positive weld output. 4. Perform the Firing Board
Test.
3. Make certain the three phase
input voltage is correct and 5. Perform the SCR Output
matches the machine rating Bridge Test..
and the reconnect panel.
6. Perform Main Transformer
Test.
CAUTION
IDEALARC DC-1000
F-8 F-8


OUTPUT PROBLEMS
The machine does not have max- 1. Check all three-phase input 1. Check the output control
imum weld output. lines at the DC-1000. Make potentiometer (R1) and asso-
sure input voltages match ciated circuitry for loose or
machine rating and reconnect faulty connections. See wiring
panel. diagram.
2. Put output control switch 2. Perform Control Board Test.

(SW3) in “OUTPUT CON-
TROL AT DC-1000” position. 3. Perform Firing Board test .
If problem is solved, then
check remote control unit or 4. Perform Main Transformer
wire feeder. Test.

Test.
CAUTION
IDEALARC DC-1000
F-9 F-9


FUNCTION PROBLEMS
Machine shuts off (input contac- 1. Remove all welding cables 1. Check for grounds and or
tor drops out) when the welder and control cables from the shorts in the #73, #74, #75,
output terminals are electrically DC-1000. Jumper #2 to #4 at #76, #77 circuit. See wiring
energized. (#2 to #4 closure at the terminal strip. If the diagram.
terminal strip.) machine does NOT shut off
and normal open circuit volt- 2. Check for grounds and shorts
age is present at the welder in the welder output terminals
output terminals, the problem and associated leads. See
is external to the DC-1000. wiring diagram.
Either the remote leads #73,
#74, #75, #76 or #77 are 3. Check the output shunt and
grounded to the negative out- associated leads. See wiring

put cable, or there is a short diagram.
on the welding output termi-
nals. 4. Perform the Control Board
Test.
2. If the machine still shuts off
when all control and welding
cables are removed, then the
problem is internal to the DC-
1000.
The DC-1000 will NOT shut off 1. Contact your local Lincoln 1. The input contactor (1CR)
when the Stop button is pushed. Authorized Field Service contacts may be stuck closed.
Facility. Check and replace if neces-
sary.
2. The Interlock contacts (part of

1CR) may be faulty. Replace
if necessary.
3. The Start/Stop button may be

faulty. Check or replace.
CAUTION
IDEALARC DC-1000
F-10 F-10
Observe all Safety Guidelines detailed througout this manual


FUNCTION PROBLEMS
The weld output terminals are 1. Remove any external leads 1. Check for an internal short
always electrically “hot”. hooked to #2 and #4 on the between leads #2 and #4. See
terminal strip. If the problem wiring diagram.
disappears, the fault is in the
control cable or wire feeder. 2. The Pilot Relay (4CR) may be
stuck closed. Check or
2. If some open circuit voltage is replace.
present (over 3 VDC.) after
performing Step #1, then the 3. Perform Firing Board Test.
problem is within the DC-
1000. 4. Perform Control Board Test.
5. Perform the SCR Output

Bridge Test.
6. The SCR Snubber(s) may be

“leaky”. Check or replace. See
wiring diagram.
CAUTION
IDEALARC DC-1000
F-11 F-11


WELDING PROBLEMS
Poor arc starting when the DC- 1. Make sure the proper welding 1. Check the 3CR reed switch.
1000 is in the CV Sub-Arc or CV procedures are being used The voltage from lead #215 to
Innershield Modes. (wire feed speed, arc voltage lead #220 should be 8 VDC
and wire size). when the DC-1000 is in an
idle condition (on but not
2. Check weld cables for loose welding). When the machine
or faulty connections. is producing welding current,
the reed switch (3CR) should
close and the voltage from
#215 to #220 should drop to
zero.
2. Perform the Firing Board

Test.
3 Perform the SCR Output

Bridge Test.
4. The control board may be

faulty - Replace.
Poor arc characteristics in all 1. Check for the correct input 1. Check the Mode Switch
processes. voltages on the three phase (SW4) and the associated
input lines at the DC-1000. wiring for loose or faulty con-
nections. See wiring diagram.
2. Make sure the proper welding
procedures are being used 2. Check the 3CR reed switch.

(wire feed speed, arc voltage The voltage from lead #215 to
and wire size). lead #220 should be 8 VDC
when the DC-1000 is in an
3. Check the welding cables for idle condition. When the
loose or faulty connections. machine is producing welding
current, the reed switch (3CR)
should close and the voltage
from #215 to #220 should
drop to zero.
3. Perform the Firing Board

Test.
4. Perform the SCR Output

Bridge Test.
5. The control board may be

faulty - Replace.
CAUTION
IDEALARC DC-1000
F-12 F-12


WELDING PROBLEMS
Poor performance (including arc 1. Change the welding cable(s)

outages) while welding at low to the 500 amp terminal (later
current (less than 450 amps) models only).
when connected to 1000 amp (+)
output terminals.
The machine frequently shuts off 1.The output current demand 1. The choke thermostat may be
while using the 500 amp (+) out- may be over 500 amps, caus- faulty - Replace.
put terminal (later models only). ing the choke to overheat.
Change the welding cable(s)
to the 1000 amp output termi-

nals.
CAUTION
IDEALARC DC-1000
F-13 F-13
CONTROL TRANSFORMER (T2) VOLTAGE TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or
the machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
bleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will determine if the correct voltage is being:
a. applied to the primary of the control transformer.
b. induced on the secondary winding of the control transformer.
MATERIALS NEEDED
Volt/Ohm Meter (Multimeter)
IDEALARC DC-1000 wiring diagrams (See Electrical Diagram Section of Manual).
IDEALARC DC-1000
F-14 F-14

FIGURE F.1 - Control Transformer Lead Location
TEST PROCEDURE
1. Disconnect main AC input power to 4. Locate the Control Transformer
the machine. primary leads (H1, H2, H3, etc.).

See wiring diagram.
2. Remove the Top and Case Sides.
NOTE: Unused leads should be
3. Locate the Control Transformer (T2)
taped. Check for loose or faulty
on the left side of the Input Box (fac-
connections.
ing the back of the machine). See
Figure F.1.
IDEALARC DC-1000
F-15 F-15
FIGURE F.2 - Control Transformer X1 and X2 Test Points
5. Locate Control Transformer leads 7. If 115 VAC is not present between

X1 and X2 at in line connectors. leads X1 and X2, test for correct
See Figure F.2. main AC input power to the Control
Transformer primary windings (H1,
6. Apply power and test for 115 VAC
H2, H3, etc.) See wiring diagram.
between leads X1 to X2.
If the correct main AC input power to

the Control Transformer is present, and
the secondary voltage is not correct,
the Control Transformer may be faulty.
Replace.
IDEALARC DC-1000
F-16 F-16
MAIN TRANSFORMER (T1) VOLTAGE TEST

WARNING
manual.
tests/repairs safely, contact the Lincoln Electric service department for technical troubleshoot-
ing assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will determine if the correct voltages are being:
a. applied to the primary windings of the Main Transformer (T1).
b. induced on the secondary winding, auxillary windings, and phase angle windings.
MATERIALS NEEDED
IDEALARC DC-1000 wiring diagrams (See Electrical Diagram Section of Manual).
IDEALARC DC-1000
F-17 F-17
FIGURE F.3 - Input Contactor, Reconnect Panel, and Primary Leads to

Main Transformer Locations
TEST DESCRIPTION
1. Disconnect main AC input power to 5. Test with an AC voltmeter for

the machine. proper main AC input voltage from
the output side of the Input
2. Inspect the Input Contactor, Contactor. (1CR). See wiring dia-
Reconnect Panel, and primary leads gram.

to the Main Transformer for loose or
faulty connections. See Figure F.3. T1 to T2.
3. Apply input power, push start button, T2 to T3.
and make sure the Input Contactor
T1 to T3.
(1CR) energizes.
a. If correct voltage is pre-
4. Test with an AC voltmeter for proper
sent, the Contactor is
main AC input voltage to the line
working properly.
side of the Input Contactor (1CR).
See wiring diagram. b. If the correct voltage is not
present for any or all of the
L1 to L2.
three phases, the contac-
L2 to L3. tor may be faulty.
L1 to L3. 6. Test with an AC voltmeter for
approximately 60 VAC from each
a. If proper voltage is not pre- of the six main transformer sec-

sent in any or all of the three ondary leads to the common buss
phases, check input fuses connected to the negative output
and leads. terminal. See Figure F.4.
IDEALARC DC-1000
F-18 F-18
FIGURE F.4 - Main Secondary Lead Test Points
a. If one or more of the above b. If the wiring is good, then the

voltage tests are incorrect, Main Transformer may be
check for loose or faulty faulty.
wiring. If the wiring is good,

8. Remove the screws from the control
then the Main Transformer
box cover. It does not have to be
may be faulty.
completely removed to perform this
NOTE: A long wire with clip or a test.
long probe may be required to
reach the lower middle lead. 9. Test with an AC voltmeter for 75
VAC for each phase angle winding
7. Test for 115 VAC between leads as shown. See Figure F.5.
#31 to #32 on the terminal strip.
These can be accessed through NOTE: If the main supply voltage
the front panel assembly door. varies, the Main Transformer volt-
ages will vary proportionately. See
a. If the 115 VAC is not pre- Figure F.5.
sent, check for loose or
faulty wiring or blown fuse.
If necessary, untape and
track the continuity of leads
#31 and #32 through the

entire harness.
IDEALARC DC-1000
F-19 F-19
From To Expected VAC

Plug Pin Lead Plug Pin Lead
J5 2 #203 J5 4 #204 75 VAC
J5 7 #205 J5 3 #206 75 VAC
J5 9 #207 J5 8 #208 75 VAC
FIGURE F.5 - Phase Angle Windings Test Points and Firing Board Pin
Location
IDEALARC DC-1000
F-20 F-20
FIRING BOARD TEST

WARNING
manual.

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test determines whether or not the Firing Board is receiving the correct voltages and
gate signals. The LED’s (Light Emitting Diodes) will help you determine if the Firing Board is
generating gate signals to the main SCR’s.
MATERIALS NEEDED

IDEALARC DC-1000 Wiring Diagram and Firing Board Schematic Diagram (See Electrical
Diagram Section of Manual).
IDEALARC DC-1000
F-21 F-21
FIRING BOARD TEST
FIGURE F.6 - Firing Board LED and Molex Plug Locations
TEST PROCEDURE FOR

NORMAL FIRING
BOARD OPERATION
1. Disconnect main AC input power to

the machine. WARNING

2. Remove screws, loosen and lower JUMPERING LEADS 2 AND 4 ELEC-
the front panel to access the Firing TRICALLY ENERGIZES MACHINE’S
Board on the left side of Control OUTPUT TERMINALS. DO NOT
Box facing the machine. TOUCH ELECTRICALLY HOT COM-
PONENTS.
3. Visually inspect the Firing Board ______________________________________
for loose or faulty connections.
7. Locate LEDs 1 thru 6. Each LED
4. Reconnect the input power and should glow with equal brightness.
turn the DC-1000 on.
NOTE: LEDs 1 through 6 indicate that
5. Locate LEDs 7, 8, and 9 on the the gate firing signals are being gener-
Firing Board. See Figure F.6. Each ated to send to each of the output
LED should be ON and equally SCRs.
bright. Use Table F.1 to check LED
8. Set the output control switch (SW3)
operation.
in the “Output Control at DC-1000”

6. Connect a jumper wire from termi- position.
nal #2 to terminal #4 on the termi-
9. Set the welding mode switch
nal strip. These can be accessed
(SW4) in either of the “CV” posi-
through the Front Panel Assembly
tions.
door. See Figure F.7.
IDEALARC DC-1000
F-22 F-22
FIRING BOARD TEST
FIGURE F.7 - Terminal Strip Jumper Wire Connections
10. Rotate the output control poten- 11. Locate and test for 6 to 15 VDC
tiometer (R1). As the potentiometer between leads #231 and #215 on
is turned clockwise, the LEDs the Firing Board in the CV mode.
should glow brighter. As the poten- When the output control poten-
tiometer is turned counter-clock- tiometer (R1) is rotated, the DC
wise, the LEDs should dim. voltage between leads #231 and
#215 should vary from 6 to 15 VDC.
a. If the LEDs glow and
change in brightness equal- 12. If an LED continues to be lit and
ly as the potentiometer is should not be, a circuit may be
turned and the problem faulty on the Firing Board between
continues, then the SCR a Molex plug and LED. Replace

bridge may be faulty. Firing Board.
Perform the SCR Bridge
Test. 13. If the DC voltage does NOT vary,
as potentiometer (R1) is rotated,
b. If any or all of LEDs 1 the Control Board may be faulty.
through 6 do not glow, or
do not change in brightness 14. Locate and test for approximately
equally as the potentiome- 5.8 VDC between leads #231 and
ter is turned, continue to #215 on the Firing Board in VV
next step. (CC) mode. When the output con-
trol potentiometer (R1) is rotated,
c. If one or two LEDs stay the DC voltage between leads #231
bright or dim while the oth- and #215 should NOT vary and
ers change, this could indi- should remain at a constant approx-
cate either an open or imate 5.8 VDC.
shorted gate or a faulty
NOTE: The DC voltage may vary
snubber on the related SCR

assembly. Perform SCR slightly at the lower portion of the

Bridge Test. range.
IDEALARC DC-1000
F-23 F-23
FIRING BOARD TEST
15. Test the Output Pilot Relay (4CR) and closing. If the Output Pilot
for operation by removing and Relay (4CR) does not close when
replacing the jumper wire repeat- energized, check for loose or faulty
edly from terminal #2. See Figure wiring. See Wiring Diagram and
F.7. This should cause the relay Figure F-8.
contacts to open and close. The
16. Replace the Firing Board if the
contacts can be seen closing and
above voltage and control relay
opening through the clear plastic
tests are passed. It may be faulty.
relay case or can be heard opening
FIGURE F.8 - Output Pilot Relay 4CR Location

IDEALARC DC-1000
F-24 F-24
FIRING BOARD TEST
TABLE F.1 - LED 7, 8 and 9 Check List
IF THEN
LED 7 is ON AC power is being supplied to the Firing Board from
leads #203 and #204 connected to the phase angle wind-
ing in the Main Transformer.
LED 7 is OFF or is DIM- The proper AC voltage may not be reaching Firing Board.
MER than other LEDs Check for loose or faulty connections. Perform Main
Transformer Test.

Transformer Test.

Transformer Test.
IDEALARC DC-1000
F-25 F-25
CONTROL BOARD TEST
WARNING
manual.
tests/repairs safely, contact the Lincoln Electric service department for technical trou-

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will determine if the Control Board is receiving the correct voltages and feedback
signals.
MATERIALS NEEDED

IDEALARC DC-1000 Wiring Diagram and Control Board Schematic (See Electrical Diagram
Section of Manual).
IDEALARC DC-1000
F-26 F-26
CONTROL BOARD TEST
FIGURE F.9 Control Board LED and Pin Locations.

TEST PROCEDURE FOR
NORMAL CONTROL BOARD
OPERATION
1. Remove main supply power to the 7. LED 4 should NOT be lit. LED 4
DC-1000. should light only if there is a “fault”
condition.
2. Remove screws, loosen and lower
the Front Panel to access and 8. LED 2 should be lit indicating output
inspect the Control Board located voltage feedback is being supplied
in the right front control box. See to the Control Board. With the
Figure F.9. Output Control Switch (SW3) in the
“Output Control At DC-1000”
3. Apply the correct three-phase input
(Panel) position and the Welding
power to the DC-1000. Turn on the

Mode Switch (SW4) in a CV posi-
machine.
tion, LED 2 should change in bright-
4. Connect a jumper wire from termi- ness as the Output Control
nal #2 to terminal #4 on the termi- Potentiometer is rotated. As the
nal strip. These can be accessed open circuit voltage is increased,
through the front panel assembly LED 2 should get brighter and vice
door. See Figure F.7. versa.
9. LED 5 indicates a control signal
WARNING (lead #231) is being supplied to the
JUMPERING LEADS 2 AND 4 ELEC- firing circuit. As the output is varied,
TRICALLY ENERGIZES MACHINE’S LED 5 should change in brilliancy
OUTPUT TERMINALS. DO NOT from bright (at low output) to dim (at
TOUCH ELECTRICALLY HOT COM- high output). When the Weld Mode
PONENTS. Switch (SW4) is in the CC (Stick)
______________________________________ position, the open circuit voltage is
at maximum, and LED 5 will be very
5. LED 1 should be lit indicating the dim or not lit.

presence of 115 VAC at leads
#255 to #256 Plug J1.
6. LED 3 should be lit indicating
power is being applied to the fault
protection relay (2CR).
IDEALARC DC-1000
F-27 F-27
CONTROL BOARD TEST
POSSIBLE PROBLEMS
PERTAINING TO THE
CONTROL BOARD
IF LED 1 does not light, when the
start switch is ON.
1. Check for 115 VAC at leads #255 c. Test for continuity (zero
to #256 plug J1 ohms) from lead #256 plug
J1 at the Control Board to
a. If the correct voltage is not
the pilot light. See wiring dia-
present, check leads #255
gram.
and #256 and associated
wiring for loose or faulty d. If the 115 VAC is present at
connections. See wiring dia- leads #255 to #256 at plug
gram and Figure F.10. J1 and LED 1 does not light,

the Control Board may be
b. Remove main supply power
faulty. Replace.
to the DC-1000. Test for
continuity (zero ohms) from
lead #255 plug J1 at the
Control Board to lead #212
at the Start/Stop Button.
FIGURE F.10 - LED 1 Test Points
IDEALARC DC-1000
F-28 F-28
CONTROL BOARD TEST
IF LED 2 does not light when #2 and See wiring diagram and Figure
#4 are jumpered together. F.11.
1. Check for the presence of open cir- 3. Test for continuity (zero ohms) from
cuit voltage at the weld output ter- the negative output terminal to lead
minals (27 to 75 VDC in constant #222 at plug J1 on the Control
voltage mode, 75 VDC in constant Board. See wiring diagram.
current mode).
4. If the previous tests do not reveal
a. If open circuit voltage IS the problem then the Control Board
present at the output termi- may be faulty. Replace.
nals, then check for open
circuit voltage from lead 5. If open circuit voltage is NOT mea-
#222 (-) plug J1 to lead sured at the weld output terminals,
#215 (+) plug J2 on the then check the Output Choke and
associated heavy current carrying

Control Board See Figure

F.11. leads for loose or faulty connec-
tions.
b. If open circuit voltage is
NOT present at the Control • Perform the Main Transformer
Board, then check leads Test.
#222 and #215 and associ- • Perform the Firing Board Test .
ated wiring for loose or • Perform the SCR Output Bridge
faulty connections. See Test.
wiring diagram. Remove If the previous tests do not reveal the
main supply power to the problem then the Control Board may be
DC-1000. faulty. Replace.
2. Test for continuity (zero ohms)
from the output shunt to lead #215
at plug J2 on the Control Board.
FIGURE F.11 - LED 2 Open Circuit Voltage Test Points
IDEALARC DC-1000
F-29 F-29
CONTROL BOARD TEST
IF LED 3 does not light when the 2. If the above procedures do not
Start Button is depressed (but LED 1 reveal the problem, then the
does light). Control board may be faulty-
Replace.
The Fault Protection Relay (2CR) is not
receiving supply voltage (24 VDC) and IF LED 5 does not light and varies in
the Input Contactor (1CR) will not stay brightness when #2 and #4 are
closed. Check to see if LED 4 lights or jumpered together, while the Output
“flickers” when the Start Button is held Control Potentiometer is rotated .
in.
The Control Board may be faulty-
If LED 4 lights, Replace.
1. There may be a “short” at the NOTE: The Weld Mode Switch (SW4)
welder output terminals or the must be in the CV position and the
remote control circuit (leads #73, Output Control Switch (SW3) in the
#74, # 75, #76 and #77) may be “Output Control at DC-1000” position.
shorted to the negative welding Also check the Output Control
voltage. Check the weld output ter- Potentiometer and associated circuitry.
minals and associated leads and
also the remote control circuitry.
See wiring diagram.
IDEALARC DC-1000
F-30 F-30
STATIC SCR TEST
WARNING
manual.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
The Static SCR Test is a quick check to determine if an SCR is shorted or “leaky”. See
machine waveform section for normal and abnormal SCR waveforms.
MATERIALS NEEDED
Analog ohmeter Volt/Ohm Meter (Multimeter)

DC-1000 Wiring Diagrams (See Electrical Diagram Section of Manual).
IDEALARC DC-1000
F-31 F-31
STATIC SCR TEST
TEST PROCEDURE
1. Remove main supply power to the 2. Remove all Molex plugs from the
DC-1000. firing board and control board. See
Figure F.12.
FIRING BOARD
CONTROL BOARD
FIGURE F.12 - Firing and Control Board Molex Plug Locations.
IDEALARC DC-1000
F-32 F-32
STATIC SCR TEST
FIGURE F.13 - SCR Heat Sink Assembly Test Points.
3. Remove the red insulating paint a. If a low resistance is indicat-

from heat sink test points. See ed in either direction, dis-

Figure 13. connect the snubber circuit
(See wiring diagram) and
NOTE: DO NOT DISASSEMBLE THE retest SCR 1. If a low resis-
HEAT SINKS. tance is still indicated, SCR
4. Using an analog ohmmeter, test the 1 is faulty - Replace. If a
resistance from anode to cathode of very high or infinite resis-
SCR 1. Reverse the meter leads tance is indicated without
and check from cathode to anode of the snubber circuit, then
SCR 1. (R x 1000 SCALE) replace the snubber circuit,
See Figure F.14.
IDEALARC DC-1000
F-33 F-33
STATIC SCR TEST
FIGURE F.14 - Snubber Location and Circuit
5. Repeat Step 4 testing SCR 2, SCR

3, SCR 4, SCR 5, and SCR 6.
To further check the SCRs’ functions
use an SCR tester and proceed to
Active SCR Test.

IDEALARC DC-1000
F-34 F-34
ACTIVE SCR TEST
WARNING
manual.

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
The Active SCR Test will determine if the device is able to be gated “ON” and conduct current
from anode to cathode.
MATERIALS NEEDED
An SCR tester as outlined in this procedure.

DC-1000 Wiring Diagram (See Electrical Diagrams Section of this manual).
IDEALARC DC-1000
F-35 F-35
ACTIVE SCR TEST
1. Remove main supply power to the 2. Remove all Molex plugs from the
DC-1000. Firing Board and Control Board.
See Figure F.15.
FIRING BOARD
CONTROL BOARD
FIGURE F.15 - Firing Board and Control Board Molex Plug Locations
IDEALARC DC-1000
F-36 F-36
ACTIVE SCR TEST
FIGURE F.16 - Heat Sink Assembly Test Points
3. Remove the red insulating paint NOTE: Do not disassemble the heat
from heat sink test points. See sinks.
Figure F.16.
4. Perform test procedure as follows.
Refer to Figure F.17. Repeat test

for all six SCRs.
IDEALARC DC-1000
F-37 F-37
ACTIVE SCR TEST
FIGURE F.17- Silicon Controlled Rectifier (SCR) Test Setup

5. To test SCRs, construct the circuit NOTE: Do not disassemble the heat
outlined in Figure F.17. Use one 6V sinks.
lantern battery. Resistor values are
in ohms ±10%. The voltmeter scale 6. With switch SW1 closed, close
should be low, approximately 0-5 or switch SW2 for two seconds and
0-10 volts. release. The voltmeter should read
3 to 6 volts before and after switch
BATTERY TEST SW2 is released. If the voltmeter
does not read, or reads only while
Check the battery by shorting leads (A) SW2 is depressed, the SCR or bat-
tery is defective (repeat Battery

and (C) and then close switch SW1.

Replace battery if voltage is less than Test Procedure).
4.5 volts.
7. Open switch SW1, disconnect the
A. Connect SCR into the test circuit as gate lead (G) and reverse the (A)
shown (A) lead to anode (C) lead to and (C) leads on the SCR. Close
cathode and (G) lead to the gate. switch SW2. The voltmeter should
read zero. If the voltage is higher
B. Close switch SW1 (switch SW2 than zero, the SCR is shorted.
should open), voltmeter should read
zero. If the voltmeter reads higher 8. Replace any SCR assembly that
than zero the SCR is shorted. does not pass test in Step 4.
IDEALARC DC-1000
F-38 F-38
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
CONSTANT CURRENT MODE - NO LOAD

This is the typical DC open circuit volt-

age waveform generated from a proper-
ly operating machine. Note that each SCOPE SETTINGS
vertical division represents 50 volts and
that each horizontal division represents Volts/Div. . . . . . . . . . . . . 50 V/Div.
2 milliseconds in time. Horizontal Sweep . . . . . 2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . DC
Note: Scope probes connected at Trigger . . . . . . . . . . . . . . . Internal
machine output terminals: (+) probe to
positive 1000 Amp terminal, (-) probe to

negative terminal.
IDEALARC DC-1000
F-39 F-39
CONSTANT VOLTAGE INNERSHIELD - MAXIMUM

OUTPUT SETTING - NO LOAD

Volts/Div. . . . . . . . . . . . . 50 V/Div.
that each horizontal division represents
Horizontal Sweep . . . . . 2 ms/Div.
2 milliseconds in time.
Coupling . . . . . . . . . . . . . . . . . DC

negative terminal.
IDEALARC DC-1000
F-40 F-40
CONSTANT VOLTAGE INNERSHIELD

MINIMUM OUTPUT SETTING - NO LOAD

2 milliseconds in time. Horizontal Sweep . . . . . 2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . DC
negative terminal
IDEALARC DC-1000
F-41 F-41
TYPICAL OUTPUT VOLTAGE WAVEFORM -MACHINE
LOADED CONSTANT VOLTAGE INNERSHIELD MODE


2 milliseconds in time. The machine Horizontal Sweep . . . . . 2 ms/Div.
was loaded with a resistance grid bank. Coupling . . . . . . . . . . . . . . . . . DC
The grid bank meters read 600 amps at Trigger . . . . . . . . . . . . . . . Internal
44 VDC.
Note: Scope probes connected at

machine ouput terminals: (+) probe to
negative terminal.
IDEALARC DC-1000
F-42 F-42
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE
LOADED - 500 AMP OUTPUT TERMINAL

CONSTANT VOLTAGE INNERSHIELD MODE

ly operating machine. Note that each
vertical division represents 20 volts and SCOPE SETTINGS
that each horizontal division represents
2 milliseconds in time. The machine Volts/Div. . . . . . . . . . . . . 20 V/Div.
was loaded with a resistance grid bank. Horizontal Sweep . . . . . 2 ms/Div.
The grid bank meters read 400 amps at Coupling . . . . . . . . . . . . . . . . . DC
36 VDC. Trigger . . . . . . . . . . . . . . . Internal

positive 500 amp terminal, (-) probe to
negative terminal.
IDEALARC DC-1000
F-43 F-43
TYPICAL SCR GATE VOLTAGE WAVEFORM

MAXIMUM OUTPUT SETTING - NO LOAD
This is the typical SCR gate pulse volt-

age waveform. The machine was in an
open circuit condition (no load) and SCOPE SETTINGS
operating properly. Note that each verti-
cal division represents 1 volt and that Volts/Div. . . . . . . . . . . . . . 1 V/Div.
each horizontal division represents 5 Horizontal Sweep . . . . . .5 ms/Div.
milliseconds in time. Coupling . . . . . . . . . . . . . . . . . DC
Note: Scope probes connected at SCR Trigger . . . . . . . . . . . . . . . Internal
gate and cathode: (+) probe to gate, (-)

probe to cathode.
IDEALARC DC-1000
F-44 F-44
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

ONE OUTPUT SCR NOT FUNCTIONING
MAXIMUM OUTPUT SETTING
This is NOT the typical DC output volt-

age waveform. One output SCR is not
functioning. Note the “gap” in the wave- SCOPE SETTINGS
form. One SCR gate is disconnected to
simulate an open or nonfunctioning out- Volts/Div. . . . . . . . . . . . . 50 V/Div.
put SCR. Each vertical division repre- Horizontal Sweep . . . . . 2 ms/Div.
sents 50 volts and each horizontal divi- Coupling . . . . . . . . . . . . . . . . . DC
sion represents 2 milliseconds in time. Trigger . . . . . . . . . . . . . . . Internal

positive 1000 amp terminal, (-) probe to
negative terminal.
IDEALARC DC-1000
F-45 F-45
INPUT CONTACTOR (1CR) CLEANING AND/OR REPLACEMENT

WARNING
manual.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
7/16” socket wrench
1/2” open end wrench
Phillips head screwdriver
Flat head screwdriver

Low pressure air source
IDEALARC DC-1000
F-46 F-46
CLEANING PROCEDURE
1. Remove main input supply power to from the input contactor. Mark,
the DC-1000 and remove case top label, and remove leads as neces-
and sides. sary to access the two nuts and
washers on the studs. See Figures
2. Locate the input contactor. Using a F.18 and F.19.
1/2” wrench, remove the cover plate
FIGURE F.18 - Input Contactor Cover Removal

FIGURE F.19 - Input Contactor Removal

IDEALARC DC-1000
F-47 F-47
WARNING CONTACTOR REPLACEMENT

DO NOT APPLY INPUT POWER TO
THE DC-1000 WITH REMOVAL
THE CONTACTOR
COVER PLATE 1. Using a 11/16” wrench, remove
REMOVED. POWER leads L1, L2, L3 and output power
APPLIED WITHOUT leads from 1CR contactor. Mark
COVER PLATE IN and label all leads for proper recon-
POSITION MAY CAUSE SEVERE nection. See Figure F.19.
ARCING RESULTING IN BODILY 2. Remove lead #257 at secondary
INJURY. thermostat. See Figure F.20 and
________________________________________
refer to Wiring Diagram. Remove
3. Blow out any dirt or dust from in any cable ties and/or harness
and around contacts. looms as necessary.
4. Examine contacts for signs of wear. 3. Remove the contactor interlock

leads from quick disconnects (leads
5. If contacts are stuck together or 211 and 212) and from resistor R3.
overheated, parts of the contactor, See Figure F-21 and refer to Wiring
or the entire assembly, should be Diagram.
replaced.
4. Remove input contactor using a
7/16” socket wrench. Remove the
four mounting bolts, nuts, and asso-
ciated washers (or loosen the two
bottom bolts and nuts, and remove
the top two).
FIGURE F.20 - Lead #257 at FIGURE F.21 - Lead #211 and #212
Secondary Thermostat Quick Disconnects
IDEALARC DC-1000
F-48 F-48
INSTALLATION 3. Attach leads from contactor coil.

Attach any cable ties and/or har-
1. Install input contactor using a 7/16” ness looms cut at removal. Attach
socket wrench. Attach the four lead #257 at secondary thermostat.
mounting bolts, nuts, and associat- See Figure F.20.
ed washers (or tighten the two bot-
tom bolts and nuts, and attach the 4. Using a 11/16” wrench, attach
top two). leads L1, L2, L3 and output power
leads to 1CR contactor. See Figure
2. Attach leads to contactor interlock. F.19.
Connect quick connects on leads
#211 and #212. See Figure F.21. NOTE: Ensure all leads are connected
correctly. See Wiring Diagram.
IDEALARC DC-1000
F-49
TROUBLESHOOTING & REPAIR F-49
SCR OUTPUT BRIDGE REPLACEMENT

WARNING
manual.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
1/2” long-handled flat rachet wrench

Lincoln E1868 (Dow Corning #340) heat sink compound
IDEALARC DC-1000
F-50
SCR OUTPUT BRIDGE

REMOVAL
1. Remove input power to machine. 6. Using a 5/16” socket remove the
screw and small reed switch lead
2. Using a 5/16 (8mm) nut driver or flat (#210) from the left, top rear SCR
head screw driver, remove 20 heat sink.
screws (ten per side) to remove
case sides and 2 screws to remove NOTE: It may be necessary to move or
top. remove the output choke to gain access
to the bottom anode leads. For access
3. Using a 5/16 (8mm) nut driver or flat to the bottom middle screw, nut, and
head screw driver, remove 6 associated washers, a long handled flat
screws, then lower the front control ratchet is recommended.
panel.
7. Identify and label the six trans-
4. Remove the J4 gate lead Molex former secondary (heavy alu-
plug from firing board, and feed the minum) leads that connect to the
plug down through the hole in bot- anodes of the SCR heat sink
tom of the PC board compartment. assemblies. Using a 1/2” socket
and open-end wrench, remove the
5. Using a 9/16” socket and open-end
secondary leads (see Figure F.22).
wrench, remove the two bolts and
nuts holding the shunt assembly to 8. Support the SCR bridge assembly
the two positive buss leads con- with a lift hook or rope.
nected to the SCR bridge. See
Figure F.22. 9. Using a 3/8” socket wrench,
remove the two screws (one on
each side) holding the SCR assem-
bly rails to the front panel assem-
bly.
FIGURE F.22 - Preparation For SCR Output Bridge Removal

IDEALARC DC-1000
F-51

FIGURE F.23 - SCR Output Bridge Removal
10. Cut any necessary cable ties to NOTE: Upon reassembly, apply a thin
allow for the SCR bridge assembly layer of Lincoln E1868 (Dow Corning
removal. 340) heat sink compound to all bolted

electrical connections on the aluminum
11. Using a 1/2” socket wrench, remove heat sinks.
the four screws (2 on each side)
holding the transformer side panels CAUTION
and SCR assembly rails to the main
transformer. See Figure F.23. UPON REASSEMBLY, THE SCR
BRIDGE ASSEMBLY MUST BE ELEC-
12. Remove leads #217 and #222 from TRICALLY ISOLATED FROM
resistor R2 located on the lift bail GROUND.
assembly. Remove resistor R2 _______________________________________
using a 7/16” wrench.
15. Place insulators between SCR
13. With the 5/16” socket wrench, bridge assembly and the output
remove the bottom six screws hold- rectifier mounting bracket (see
ing the front panel assembly to the Figure F.23). Check for electrical
base. Carefully pull the front panel isolation with an analog ohmmeter.
forward to allow room to remove the
SCR bridge assembly. CAUTION

14. Clear all leads and carefully remove MINIMUM ACCEPTABLE RESIS-
the SCR bridge assembly. TANCE TO GROUND IS 500,000
OHMS.
_______________________________________
IDEALARC DC-1000
F-52
FIGURE F.24 - Individual SCR Assembly Heat Sink Removal
REMOVAL OF INDIVIDUAL
SCR HEAT SINK ASSEMBLIES

1. Using a 9/16” wrench, remove two
nuts, flat washers, and lock wash- CAUTION
ers from the SCR assembly mount-
DO NOT DISASSEMBLE THE SCR
ing studs. See Figure F.24.
FROM THE HEAT SINK. MACHINE
2. Using a 5/16 (8mm) nut driver or DAMAGE MAY RESULT. REPLACE
flat head screw driver, remove THE SCR ONLY AS AN ASSEMBLY.
snubber ground wire attachment. _______________________________________
The snubber assembly can now be
removed. Replace if necessary.
3. Carefully remove the positive buss
bar from the heat sink in question.
It may be necessary to remove the
buss bar completely.
4. Carefully slide the SCR assembly

from the mounting studs.
Replacement will be made with a
new SCR assembly.
IDEALARC DC-1000
F-53

SCR HEAT SINK SCR OUTPUT BRIDGE

INSTALLATION INSTALLATION
NOTE: Upon reassembly, apply a thin NOTE: Upon reassembly, apply a thin
layer of Lincoln E1868 (Dow Corning layer of Lincoln E1868 (Dow Corning
#340) heat sink compound to all bolted #340) heat sink compound to all bolted
electrical connections on the aluminum electrical connections on the aluminum
heat sinks, including positive buss bar. heat sinks.
1. Slide a new SCR assembly onto the 1. Support the SCR bridge assembly
mounting studs. with a lift hook or rope.
2. Carefully attach the positive buss 2. Clear all leads and carefully posi-
bar onto the heat sink which had

tion the SCR bridge assembly in

been removed. If it had been nec- place.
essary to remove the buss bar,
replace it at this time. 3. Place insulators between SCR
bridge assembly and the output
3. Align snubber assembly in position rectifier mounting bracket. See
on SCR output bridge assembly. Figure F.23. Check for electrical
isolation with an analog ohmmeter.
4. Using a 9/16” wrench, secure the
Minimum acceptable resistance to
SCR output bridge and snubber
ground is 500,000 ohms.
assemblies with two nuts, flat wash-
ers, and lock washers. 4. With the 5/16” socket wrench,
attach bottom six screws securing
5. Using a 5/16 (8mm) nut driver or flat
the front panel assembly to the
head screw driver, attach snubber
base. Carefully push the front panel
assembly ground wire with screws
rearward into position.
previously removed.
5. Attach resistor R2 to the unit using
a 7/16” wrench Secure leads #217

and #222 to resistor R2.
6. Using a 1/2” socket wrench, attach
the four screws (2 on each side)
holding the transformer side panels
and SCR assembly rails to the main
transformer.
IDEALARC DC-1000
F-54
7. Using a 3/8” socket wrench, attach 10. Using a 9/16” socket and open-end
the two screws (one on each side) wrench, attach the two bolts and
holding the SCR assembly rails to nuts holding the shunt assembly to
the front panel assembly. See the two positive buss leads con-
Figure F-23. nected to the SCR bridge.
NOTE: It may have been necessary to 11. Feed the J4 gate lead Molex plug
move or remove the output choke to up through the hole in bottom of the
gain access to the bottom anode leads. PC board compartment. Attach the
For access to the bottom middle screw, plug onto the firing board.
nut, and associated washers, a long
handled flat ratchet is recommended. 12. Secure any cable ties removed pre-
viously to allow for the SCR bridge
8. Using a 1/2” socket and open-end assembly removal.
wrench, attach the secondary leads

that connect the anodes of the SCR 13. Using a 5/16 (8mm) nut driver or
heat sink assemblies to the six flat head screw driver, attach 20
transformer secondary (heavy alu- screws (ten per side) to attach the
minum) leads as labeled during dis- case sides. Attach the top using 2
assembly. similar screws.
9. Using a 5/16” socket attach the 14. Raise the front control panel into
small reed switch lead (#210) to the position, and, using a 5/16 (8mm)
left, top rear SCR heat sink using nut driver or flat head screw driver,
the screw previously removed. secure in position using 6 screws.
IDEALARC DC-1000
F-55
REMOVAL AND REASSEMBLY OF LIFT BAIL

WARNING
manual.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
IDEALARC DC-1000
F-56
FIGURE F.25 - Lift Bail Removal

REMOVAL OF LIFT BAIL

1. Remove input power to machine. 6. Using a 9/16” socket wrench,
remove the four bolts and associat-
2. Using a 5/16 (8mm) nut driver or flat
ed washers mounting the lift bail to
head screw driver, remove 20
the base assembly. See Figure
screws (ten per side) to remove
F.25.
case sides and 2 screws to remove
top. 7. Loosen or remove any cable or wire
ties necessary for lift bail removal.
3. Remove two leads, #217 and #222
from resistor R2. 8. Carefully remove the lift bail by lift-
ing straight up and clear.
4. Using a 3/8” socket wrench, remove
the two screws holding the input
contactor bracket to the lift bail.
5. Using a 9/16” socket wrench,

remove the four bolts mounting the

lift bail to the main transformer
assembly.
IDEALARC DC-1000
F-57

REASSEMBLY OF LIFT
BAIL
1. Place the lift bail onto the IDE- 4. Using a 3/8” socket wrench, attach
ALARC DC-1000 from the top, low- the two screws holding the input
ering straight onto the unit. contactor bracket to the lift bail.
2. Using a 9/16” socket wrench, attach 5. Reattach leads #217 and #222 to
the four bolts and associated wash- resistor R2.
ers mounting the lift bail to the base
assembly. 6. Reattach or reconnect any cables
or wire ties previously removed.
3. Using a 9/16” socket wrench, attach
the four bolts mounting the lift bail 7. Using a 5/16 (8mm) nut driver or
to the main transformer assembly. flat head screw driver, attach 20

screws (ten per side) to secure
case sides, and 2 screws to secure
top.
IDEALARC DC-1000
F-58
MAIN TRANSFORMER REMOVAL AND INSTALLATION

WARNING
manual.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
IDEALARC DC-1000
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-59
IDEALARC DC-1000
FIGURE F.26 - Main Transformer Disassembly

MAIN TRANSFORMER DISASSEMBLY AND ASSEMBLY
F-59
F-60 F-60
MAIN TRANSFORMER DISASSEMBLY
MAIN TRANSFORMER COIL REMOVAL AND

DISASSEMBLY REPLACEMENT
1 Label and disconnect leads to the
1. Perform Lift Bail Removal coils that are being removed or
Procedure. replaced (see Wiring Diagram).
2. Remove lead #271 from resistor R3 2 Refer to Figure F.26 for proper coil
(located near the input contactor). locations (top, bottom, left, right,
3. Separate the in-line connectors and center) of primary and sec-
from leads #211 and #212. See ondary coils. If secondary coils are
Figure F.21. to be replaced, it will be necessary
to cut the leads and TIG weld upon
4. Remove lead #256 from the choke reassembly.
thermostat.
3. Remove the coils:
5. Remove lead #220 from the reed

switch (3CR). a. Some prying and jolting may be
necessary to free the coils from
6. Cut any necessary cable ties or the iron.
restraints and clear the leads nec-
essary for the removal of the top b. Note placement of insulation
transformer iron. and wedges for reassembly
(especially primary coil to lami-
7. Using a 3/8” socket wrench, remove nation insulation and secondary
two screws mounting the input con- to primary insulation).
tactor bracket to the case back
assembly. With leads attached, 4. Replace the coils:
carefully pull assembly up and out a. Be sure to replace all insulation
of the way. Set assembly aside. and wedges that were removed
8. Using a 1/2” socket wrench, move (lamination to coils, and primary
16 screws (8 on each side) from the to secondary coils).
transformer side brackets. Taking
b. Using a high temperature

note of placement, remove the four industrial epoxy, such as
brackets and two bottom spacers. Lincoln E1603, glue the coils in
See Figure F.26. place by applying the epoxy to
9. Using a 3/4” wrench, remove the six the coil sides along the lamina-
nuts and lock washers from the tion, cell insulation, and
transformer threaded rods. It may wedges.
be necessary to hold the threaded c. Glue the secondary coils in
rods to keep them from turning. place from the iron to the coil
10. Using a hoist, carefully lift the top sides.
iron from the assembly. Note the 5. Re-TIG weld the secondary coil
placement of shims and insulators. leads (if previously cut).
NOTE: Some prying and jolting may be 6. When reconnecting any aluminum
necessary to free the iron from the coils. leads, apply a thin layer of Dow
Replace any coils that may be faulty. If Corning 340 Heat Sink Compound
any heavy aluminum secondary coils to mating surfaces.

are to be replaced, identify and label all
leads to the transformer. The leads will
have to be cut and then TIG welded
upon reassembly.
IDEALARC DC-1000
F-61 F-61
TRANSFORMER INSTALLATION
TRANSFORMER
REASSEMBLY
1. Using a hoist, carefully lift the top 5. With leads still attached, carefully
iron onto the assembly. Lightly tap reposition the input contactor brack-
on the top of the iron. et onto the case back assembly.
Using a 3/8” socket wrench, secure
2. Position the transformer threaded in position using two screws
rods securing the transformer. removed previously.
Using a 3/4” wrench, secure the six
nuts and lock washers. It may be 6. Attach lead #220 onto the reed
necessary to hold the threaded rods switch (3CR).
to keep them from turning. Tighten
nuts to 39 - 41 Ft.-Lbs. 7. Attach lead #256 onto the choke
thermostat.
3. The primary coils should be ground

tested at 2700 VAC for one second. 8. Reconnect lead #211 and #212 to
The secondary coils should be the in-line connectors.
ground tested at 1500 VAC for one 9. Attach lead #271 onto resistor R3.
second. The primary to secondary
insulation should be tested at 2700 10. Perform Lift Bail Installation
VAC for one second. Procedure.
4. Install the four brackets and two 11. Replace any cable ties or restraints
bottom spacers in the position which were cut to remove the top
noted at disassembly. Using a 1/2” transformer iron.
socket wrench, secure in position
with 16 screws (8 on each side)
onto the transformer side brackets.
IDEALARC DC-1000
NOTES
IDEALARC DC-1000
F-62
F-63 F-63
RETEST AFTER REPAIR
Testing is required after the removal of any mechanical part that could affect the machine’s
electrical characteristics, or if any electrical components are repaired or replaced.
INPUT IDLE AMPS AND WATTS

Input Volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW
230/3/60 14.0 2.0
460/3/60 7.0 2.0
575/3/60 5.6 2.0
OPEN CIRCUIT VOLTAGES

Mode Input Hertz Open Circuit Volts

Variable Voltage 60 74/76 DC
Auxiliary Output (#31-#32) 60 122/124 AC
MAXIMUM ACCEPTABLE OUTPUT VOLTAGE - AT MINIMUM OUTPUT

SETTINGS
Mode Input Hertz Load
Constant Voltage Innershield 60 140 Amps @ 14/18 VDC
MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT

SETTINGS
Mode Input Hertz Load
Variable Voltage 60 1250 Amps @ 47/52 VDC
Constant Voltage Submerged Arc 60 1250 Amps @ 47/52 VDC
Constant Voltage Submerged Arc 60 625 Amps @ 53/58 VDC
at 500 Amp Terminal
IDEALARC DC-1000
NOTES
IDEALARC DC-1000
F-64
G-1 G-1
Return to Master TOC ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
DIAGRAMS........................................................................................Section G
Wiring Diagram (Codes 9919, 9920) ...........................................................G-2
Operating Schematic ...................................................................................G-3
Control PC Board (G1585) Layout ..............................................................G-4
Firing PC Board (G1486-5 and above) Layout ............................................G-5
Control PC Board (G1585) Schematic ........................................................G-6
Firing PC Board (G1486-5 and above) Schematic ......................................G-7
Output Snubber (M14312) Schematic .........................................................G-8
IDEALARC DC-1000
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES
IDEALARC DC-1000
G-2 ELECTRICAL DIAGRAMS G-2
Wiring Diagram (Codes 9919, 9920)
CENTER TERMINAL OUTPUT CONTROL

TO GROUND PER
ON FUSE HOLDER
NATIONAL ELECTRICAL R1
METER KIT
CODE
(OPTIONAL) 236 75
237 238
N.C. SW4 CC
9008
32A CVI
X1 216
211 T2 H1 NEG 31 CVS
H1 VM
+ -
L
4 211
222 226
SHT.
TO 1CR H2
NO.
L1 1 7 216 226
F1
START STOP
3 PHASE H2 5 TO SW3
POWER H3 AM 222
L2 2 8 215
PRIMARY +
WIRING DIAGRAM
-
IDEALARC DC-1000
SUPPLY POS 21 266
230 229
6
S U P ' S ' D ' G L8234

COILS SW1 H4 SW2 224 221
255 32 76 77
L3 3 9 212 2
210
X2 215
R3
21
31
32
77
74
73
76
75
2
4
SINGLE OR DUAL VOLTAGE INPUT PANEL
5 7 T.S.2 T.S.3
SHOWN CONNECTED FOR LOW VOLTAGE 271 271 255
2CR B
A
PILOT 235
REF.
R
SUBJECT
TO T2
EQUIP.
LIGHT
E.
TO GROUND PER
Y PO
CLEVELAND, OHIO U.S.A.
T H E L I N C O L N E L E C T R I CTC
NATIONAL ELECTRICAL 31
TO 233
266 1 1 221
J.J.
CODE S 256
1 2 3 2 2 222
1CR
CHK
S S S 32A 3 3 230
S S 256 229 4 4
T1 S J2
257 257A 215 5 5 220
203 205
D A T E 7-30-92
207 6
224 6
H1 6 31 7 7 233
NONE
12 4 5 6 SECONDARY CHOKE 73
8 J1 8
13 14 15 238 74
TO THERMOSTAT THERMOSTAT 9 231
SCALE
L1 1 7 4
3 PHASE H3 10 S S 10 75
N.A. FAN 1
S 210 11 226
POWER MOTOR J3
L2 2 8 5 204 206 215 2 12 235
208
D R DAD
SUPPLY 11 7 8 9 32A 13 255
215 CONTROL 14 256
L3 3 9 6 214
31 P.C. BOARD
4 5 6
S S S B
TO PRIMARY COILS 4CR
10 11 12
380 VOLTS OR TRIPLE VOLTAGE INPUT PANEL A
7 8 9
SHOWN CONNECTED FOR 380 VOLTS N.B.
4 215
SEC 217 G3 1 1 214

TO T2 R2 222 G6 2 2 203
TO T1 AUXILIARY WINDING
TO GROUND PER 3
222 G1 J4 3 206
NATIONAL ELECTRICAL TO 4 4 204
G4
1CR - G5 5 5 215
CODE 222 6
210 G2 6 215
J5 7 205
3CR 220 1
SEC A 8 208
2
No.
OUTPUT B 9 207
3 10
R A N CSht.
231
E
H1 SNUBBER
11-19-93C
2-19-93G
4
3-19-93D
B' 11
N O T H E R W I S E S P E C I F I E D T O L ECh'ge.
P.C. BOARD J7
5 12
M A T E R I A L T O L E R A NtC E ( " " ) T O A G R E E

C
TO
.5 OF A DEGREE
L1 7 4 13 C' 6
500 AMP 7
3 PHASE 1
WITH PUBLISHED STANDARDS.

H2 Y
.002
TO G1 GATE LEADS OUTPUT 8
.02
A' 2 X
POWER L2 8 5 14 J6
PRIMARY G3 TO FIRING CIRCUIT 3 Z
ON HOLE SIZES PER E2056

SUPPLY 216 FIRING
ON 3 PLACE DECIMALS IS
ON 2 PLACE DECIMALS IS
G5 P.C. BOARD 4
COILS CIRCUIT
L3 9 6 15
P.C. BOARD
ON ALL ANGLES IS
SCR SNUBBERS L1
380/ 500 VOLTS OR 460/ 575 VOLTS SCR SCR SCR

OUTPUT SHUNT
SS
1 3 5
MNALTEI O
INPUT PANEL 50 MV
NOT TO BE REPRODUCED, DISCLOSED OR USED

NOTES:
T H I S S H E E T C O N T A I N S P R O P R I E T A R Y I N F O RU
SHOWN CONNECTED FOR LOW VOLTAGE
N.A. 13, 14, AND 15 CONNECTIONS PRESENT
ND IS
WITHOUT THE EXPRESS PERMISSION OF

O W N E D B Y THE LINCOLN ELECTRIC ACO.
215 210
+
ON 380/500 AND 460/575 MACHINES
THE LINCOLN ELECTRIC CO.

LEGEND + -
ONLY.
1000 AMP
SW1 INPUT POWER
OUTPUT N.B. 10,11, AND 12 CONNECTIONS NOT
SW2 ELECTRODE POLARITY
SCR SCR SCR PRESENT ON 380V. OR TRIPLE
SW3 OUTPUT CONTROL
2 4 6
SW4 WELDING MODE VOLTAGE MACHINES.
F1 8 AMP SLOW BLOW FUSE N.C. CONNECTIONS TO H2, H3, OR H4
R1 10K OHM POTENTIOMETER
DEPENDS ON INPUT VOLTAGE. SEE
R2 30 OHM, 300 W
INPUT SUPPLY CONNECTION
R3 10 OHM, 50 W (20W ON EARLIER MODELS) G6 GATE LEADS
T1 MAIN POWER TRANSFORMER INSTRUCTIONS. H4 CONNECTION
G4 TO FIRING CIRCUIT
T2 CONTROL TRANSFORMER G2 P.C. BOARD APPEARS ON 380V AND TRIPLE
L1 LOW CURRENT WELDING CHOKE VOLTAGE MACHINES ONLY.

1CR INPUT CONTACTOR
2CR FAULT PROTECTION RELAY CONNECTOR CAVITY NUMBERING SEQUENCE
L 9008
3CR CURRENT ACTIVATED REED SWITCH

(VIEWED FROM COMPONENT SIDE OF BOARD)
4CR OUTPUT PILOT RELAY
J3 J6 J4 J2, J7 J5 J1
ELECTRICAL SYMBOLS PER E1537
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
IDEALARC DC1000
Operating Schematic
G 2147
L3
L2
L1
255
START
STOP
271
211 212
H3 2CR
R3
1CR
H2 120VAC 1CR R
H1 256 257
T2 SECONDARY PRIMARY
222
216
S2
31
1CR 1CR 1CR

21
1 2 3 32A
203 205
4 TO GROUND 4 5 6 207
4CR
2 7 8 9
222
31
31
10
204 11 206 12 208 "-" OUTPUT STUD
TI
32 FAN MOTOR 120VAC
500 AMP OUTPUT

F1 32A
TS 2
OUTPUT CHOKE
8A
R2
4CR OUTPUT
214 216 SNUBBER
PCB
4CR
SCR1 SCR3
13J1
SCR5
14J1
OUTPUT
5J2
4CR
SHUNT
215
5J11
"+"
210
OUTPUT STUD
220 215 210

SCR2 SCR4 SCR6
CC 1J1
CURRENT REED SW. 221
3CR 256 255 215 50mV @ 1300Amps
CLOSED WITH OUTPUT CURRENT
CVI +55V
215 CVS
STARTING LOGIC
POWER SUPPLY
+16V
S4-B 215 - 6.2V
- 10V
CC S4-A
SET POINT
1J5
CVI 229 214 FIRING BD. ENABLE
6J2 5J5
CVS 215
7J2 6J5
73 215
CONTROL PCB
8J1
74
10J1 4J5 2J6 SCR1 & SCR2
75 204 GATE DRIVE 3J4
X FIRING CIRCUIT G1
73 2J5 75 VAC 1J7
203 A
11J1
A' GATE DRIVE 6J4
74 R1 226 231 8J7 G2
75
FAULT DETECT.
8J2
238 3J5
206 1J6 SCR3 & SCR4
76 7J5 75 VAC Y FIRING CIRCUIT GATE DRIVE 1J4
S3 205 G3
2J7
B
77 231
CC B' GATE DRIVE 4J4
5J7 G4
3J1
CVI
TS 3
230
266
1J2 CONTROL AMP
CVS 9J1
S4-C FIRING SIGNAL 10J5
231
VOLTAGE FEEDBACK 3J6

8J5 231 Z
CC 4J2 208 6J7
C GATE DRIVE 5J4
9J5 75 VAC G5
CVI 224
5J7
C'
207 SCR5 & SCR6
CVS FIRING CIRCUIT G6
GATE DRIVE 2J4
222
S4-B 235
SHUTDOWN
12J1
235
OVERLOAD DETECT.
CURRENT FEEDBACK 2CR
7J1
FIRING PCB
236
210 215 236
2J11 1J3 2J3

T H I S S H E E T C O N T A I N S P R O P R I E T A R Y I N F O RU
MNALTEI O
SNS OTHERWISE SPECIFIED TOLERANCE EQUIP.
O W N E D B Y THE LINCOLN ELECTRIC ACO. ND IS ON HOLE SIZES PER E2056 4-27-90 T H E L I N C O L N E L E C T R I C TC
Y PO
E. TRANSFORMER WELDERS
ON 2 PLACE DECIMALS IS .02
NOT TO BE REPRODUCED, DISCLOSED OR USED 2-19-93L CLEVELAND, OHIO U.S.A.
ON 3 PLACE DECIMALS IS .002
SUBJECT OPERATING SCHEMATIC
WITHOUT THE EXPRESS PERMISSION OF ON ALL ANGLES IS . 5 O F A D E G R E E3-19-93D SCALE NONE
G 2147
M A T E R I A L T O L E R A NtC E ( " " ) T O A G R E E SHT.
THE LINCOLN ELECTRIC CO. WITH PUBLISHED STANDARDS. DR C.S. D A T E 7-31-92 CHK J.J. REF. S U P ' S ' D ' G 3-1-90 NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
IDEALARC DC1000
Control PC Board (G1585) Layout
ITEM REQ'D. PART No. IDENTIFICATION
C1,C18,C20 3 S16668-5 .022/50
C2 1 S13490-48 47/160
C3 1 S13490-19 1.8/20
C4,C8,C11,C12 4 S13490-39 18/15
C5,C6,C7,C13,C24,C25, 9 S13490-102 .047/100
C28,C29,C30
C10 1 S13490-27 2.7 MFD 75V

C15 1 S13490-63 .47/50
C16,C26 2 S13490-35 50/16
C17 1 S13490-67 2/50
C21,C27 2 T11577-28 .22/100
C22 1 S13490-42 1.0/35

C9,C14,C19,C23 4 T11577-38 .02/600
X X X X
D1,D2,D3,D4 4 T12199-2 1N4007
D5,D6,D7,D8,D9,D10,D11,D12,D13,D14,D15,
X X X X D16,D17,D18,D19,D20,D23,D24,D25,D26,
30 T12199-1 1N4004
X X X X D27,D28,D29,D30,D31,D32,D33,D34,D35,
D12
R73
R148
D36
R74
X X X X
DZ9
R113
R37
R1 R3
C5
X X
R112
R142
DZ1 1 T12702-34 IN5353
R26 X X X X DZ2 1 T12702-33 1N5347B

X X X X DZ3 1 T12702-18
1N821
DZ4 1 T12702-27 1N4740
DC1000 CONTROL
DZ7
DZ5,DZ11 2 T12702-31 1N5237B
G1585-[ ] DZ6,DZ9,DZ12,DZ13 4 T12702-29 1N4744A

R38
R133
R27
R4
R82
1 T12702-30 1N5225B
D1
D2
DZ7
D3
D4
1N5253B
D26
D23
D24
D35
DZ8,DZ14 2 T12702-12
C6
R83 DZ10 1 T12702-15 1N5231B
TP1 DZ15 1 T12702-19 1N4742A
R13
DZ1
DZ3
DZ2
C2 R70 L1 1 T12218-4 33 mH
C29 LED1,LED2,LED3,LED4,LED5 5 RED LED
LED2 + T13657-2
C10 C17
Q1,Q3 2 T12704-68 2N4401
LED1 Q4 QU2 QU1
R79 Q2,Q5,Q6,Q7,Q8,Q9 6 T12704-36 2N4857
D5 LED3
R50 Q4 1 T12704-69 2N4403
R2 D18 QU1,QU2 2 T12707-4 2N6027
R55
R146 R46 D13 R71 R1,R113 200 15W
T12300-47
D28
R147
R143
C18
D8
D7
D9
DZ6
R5
R6
R84
R24
R17
R85
R19
R18
R16
R22
R25
R20
R23
2
C4
D17 R2,R146 S19400-1503 150K 1/4W
DZ8
Q2 Q7
J1
R54 SCR1 R3 1 T14648-15 700 5W
C3
R4 1 T14648-7 470 5W
D32
R106
R107
R56
R99
DZ14
L1 R5,R15,R24,R103,R115 5 S19400-1004 1M 1/4W

R115
R28
LED4 R6,R22,R59,R60,R86,R87, 9
DZ10
S19400-1001 1K 1/4W
C23 R105,R106,R107
LED5
R15
R14
R32
D25
R7,R8 2 S19400-2671 2.67K 1/4W

Q6 C9
C26 R9,R76,R90,R95,R96 5 S19400-2213 221K 1/4W
2
C19 R10,R63 T10812-39 50K 1/2W
DZ12
DZ5
R40 R11 1 S19400-2673 267K 1/4W
D30
R100
R105
R104
DZ4
R86
R31
R52
R53
R12,R35,R53,R91,R92,R93 6 S19400-6812 68.1K 1/4W

C13
R110
R103
R102
D6
R41 C27
R94
R80
R88
R89
R90
R91
R92
R13 1 S19400-3010 301 1/4W
X1
Q8 C11
DZ15
R57
D34 R14 1 S19400-4752 47.5K 1/4W

R16,R28,R30,R31,R32,R62,R71,R77 8 S19400-4751 4.75K 1/4W
Q1
R34
J2
C24 R17,R20 2 S19400-3922 39.2K 1/4W
R18,R25,R29,R57,R88 5 S19400-1502 15.0K 1/4W

C20 C21 R19,R78,R79,R100 4 S19400-1003 100K 1/4W
R21,R61,R85 3 S19400-4750 475K 1/4W

D33
R111
R145
R136
C1
R30
R29
R77
R12
R11
R58
C30
C25
X2
D27
2
C7
R23,R147 S19400-20R0 20.0 1/4W

Q5
R47
R76
D20
R26,R38 2 T10812-68 1K 1/2W

R78
R87
C8
D29
C16 R27,R37,R58,R81 4 S19400-2211 22.1K 1/4W

R34 1 T10812-67 100K 1/2W
R9 R39 1 T10812-77 20K 1/2W
DZ11
R40,R64,R65 3 S19400-1501 1.5K 1/4W
R39 R10
D19
R41,R47,R97 3 267 1/4W
D36
R7 S19400-2670
R108
D31
R98
R93
R96
R95
R97
C22
C15
DZ13
D14
D10
R62
R61
R59
R21
R60
R35
R81
R46,R70,R74,R148 4 S19400-3320 332 1/4W

D16
C12
C28
Q9
C14
R65
D15
D11
R66
R48 1 S19400-4753 475K 1/4W

Q3
R64 R50,R83,R143 3 S19400-1301 1.3K 1/4W
R63 R52,R99,R110 3 S19400-2212 22.1K 1/4W

J3
R8
R114 R54 1 T12732-3 27K 1W
R48
R55,R56,R104 3 S19400-8252 82.5K 1/4W
R66,R111,R136 3 S19400-47R5 47.5 1/4W

R73,R102,R114 3 T14231-3 15 .5W
R80,R94,R98 3 S19400-1002 10K 1/4W
R82,R133 2 S19400-1620 1.3K 1/4W

R84 1 S19400-6810 1.3K 1/4W
R89 1 S19400-6811 6.81K 1/4W
R108 1 S19400-1000 100 1/4W

R112,R142 2 S19400-75R0 75.0 1/4W

R145 1 S19400-2432 24.3K 1/4W
SCR1 1 S15161-17
TP1 1 T13640-11 45J
X1,X2 2 S15128-4
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
IDEALARC DC1000
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Firing PC Board (G1486-5 and above) Layout
J7
J4
J5
J6
LED9
R57
R49
D9
D23
D28
D32
D33
D31
D29
D24
DZ3
R41
R42
R45
D25
D26
D27
R51
LED8
R56
R50
R55
QU1
QU2
QU3
D4
D8
LED7
D30
C25
C26
R40
R64
R46
R47
R65
R48
D22
D1
D2
C11
C12
C10
D3
D6
D7
TP1
TP2
TP3
DZ1
DZ2
C27
R43
R44
R52
R53
R66
R54
D5
C5
SCR4
SCR5
SCR6
R61
R62
R63
C4
C7
C8
C6
C9
LED2
LED4
LED6
R13 R15
R14
D37
C16 C17 C18
D39
C22
C23
C24
D19
D10
R31
R32
R33
D20
D11
D21
D12
R19 R20 R21
R25 R26 R27
R37 D38 R38 R39
SCR1
SCR2
SCR3
R58
R59
R60
C1
C2
C3
LED1
LED3
LED5
R10 R11 R12

D35
D36
C13 C14 C15

D34
C19
C20
C21
D13
D16
D14
D17
D15
D18
R28
R29
R30
R16 R17 R18
R22 R23 R24 1/4W 150
R34 R35 R36
FIRING BOARD
1/4W 1.5 K
G1486-5
1/4W 475
R9
1/4W 2.67 K
1/4W 26.7 K
1/2W 5.1
R3
R6
R4
R1
R2
R5
1/4W 332K
R7
R8
IDEALARC DC1000
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Control PC Board (G1585) Schematic
J2
STARTING LOGIC
POWER SUPPLY SOURCE POINT

DZ5
L 8556
C27
EARTH GROUND CONNECTION

68.1K 6.81K 10K 5
8.2V .22
R89
R80
CONTROL BOARD SCHEMATIC

22.1K
R91
TO POS. OUTPUT STUD
500mW 215
R110
100V C24
VOLTAGE NET
COMMON CONNECTION
.047
FRAME CONNECTION
10 100V SW4
SHT.
6
CVS CR3
NO.
8
"K" X2 X2 "L"
7
DC-1000
CURRENT
TEST POINT
9 D34 ACTIVATED 12
5
"LOW" WITH OUTPUT REED SWITCH 220
1N4004 CVI
SUPPLY
HIGH WITH NO OUTPUT lm224 14
VOLTAGE OR CURRENT. lm224 VOLTAGE BELOW 10V. X2 "J"
68.1K 10K 5
(FOR START-LOW CLAMP) 221K 15.0K (FOR V.V. TAIL-OUT) J1
R88
R94
13
R92
LABELS
CC
R90
1
221 "LOW" WITH

J1
lm224 OUTPUT CURRENT
"P" 68.1K (FOR O.C.V. BOOST)
R93
D6 267
-10V C28 DZ11
1N4004 C15
SUP'S'D'G.
R97
.047 8.2V D25
-10V .47
H D36 100V 500mW 1N4004
50V
"M" 1N4004
LOW WITH NO OUTPUT 10K +16V
2 C9
UNLESS OTHERWISE SPECIFIED)

CURRENT. ("P" DELAYED "H" R98 X2
SUBJECT
FOR FAST RESPONSE 1 R14
UNLESS OTHERWISE SPECIFIED)
EQUIP.
332 STARTING CIRCUITS.) .02
TYPE
R108 47.5K
R46
3
lm224 600V
J.J.
D19 100
ERROR AMPLIFIER R15 DZ4
1N4004
(UNLESS OTHERWISE SPECIFIED)

Q2
10V
Q7 2N4857 C26 1.00M Q1
221K 221K 1W
2N4857 50 600mA
R95
R96
9
CHK.
100K 1.3K V F.B. R28
15V 40V D
R103 "J"
R79
R50
X1 8
"H" R115 "P" 4.75K R32
1.00M 10
1.00M V REF. R31 lm224 4.75K
THE LINCOLN ELECTRIC CO.

DZ15 J1
LAST NO. USED

V F.B. -10V 4.75K 231
C20 9
NONE
03-13-90
12V
CLEVELAND, OHIO U.S.A.

SW.4 -10V .022
M F D ( .022/50V
266 1W
ELECTRICAL SYMBOLS PER E1537

1.00K 1.00K
R107
+16V
148
50V
R86
1/4W
CONTROL SIGNAL
30
36
J2
GENERAL INFORMATION
DZ14 CVS 1 TO FIRING BOARD
C-
D-
R-
25V K
267 Q6
R47
500mW C10 J1 230 DZ12 2N4857 CW
CVI
SCALE
3
R34
DATE
2.7 15V 82.5K
1A, 400V
1.50K
R104
C11
RESISTORS = Ohms (
75V 266 1W
R40
CC "K" 100K
C16
82.5K R102 R57 50
CAPACITORS =
D30
R55
1.00K
R106
15V 1N4004
15 15.0K
18
DIODES =
D13 1/2W 15V MAX CONTROL
LED2 22.1K 221K
R58
1N4004 2.21K VOLTS TRIM
R76
R99 267
R100
JLV
SW4 Q8 100K
1.00K LED5
R41
R105
D32 2N4857
1N4004
DR.
DZ10 CVS D20
R56
TO NEGATIVE 82.5K 5.1V 1N4004

CVI
R54
OUTPUT STUD 27K 500mW "H"

1W L1
J1
222 2
CC
33mH C25
TO 50mV @ 1300 AMP SHUNT .047
C13
C21 100V
"N" -10V 68.1K
68.1K .22 R52 215 210
"M" D31 -6.2V R12
R35
100V 22.1K 100V CURRENT FEEDBACK + - 221K
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
1N4004
.047
R9
VOLTAGE FEEDBACK
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

229 R53
J2 2 1
4 R21 R11
1.3K +16V 68.1K
475 J3 J3 267K
R83
C22 1.50K
1.0 R7
2
35V R64
2.67K 50K 1
R114
X1
15 Q3 13 D11
C12 D15
R10
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

600mA X1 D14 CW C14 D10 3
1.3K 18 14 47.5 1N4004
R63
.02 CW 1N4004
R66
40V
R143
15V
12 50K 600V
lm224 lm224
R81 R60 R59 1N4004 1N4004 1.50K R8
2.21K 1.00K 1.00K R65 2.67K +55V
2-19-93G
DZ8 +16V
Ch'ge.Sht.No.
25V R4 +16V
500MW B D16
R48
Q9 475K 470
1N4004
5W C
Q4 2N4857 C23 POWER SUPPLY
DZ13 475 200
.02
R62
4.75K
R61
15W
600mA 15V
600V J1
40V 1W 255 13 R1
-6.2V
UNLESS OTHERWISE SPECIFIED TOLERANCE

"L"
150K 150K
R146
D1
ON ALL ANGLES IS + .5 OF A DEGREE
WITH PUBLISHED STANDARDS

R2
ON 3 PLACE DECIMALS IS + .OO2

ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
MATERIAL TOLERANCE ("t") TO AGREE

1N4007 DZ1
-10V A
16V
+55V 120V. AC 5W DZ3
+16V + C2
47 6.2V
D5 TP1
LED1 D2 160V .4W
1N4004 150V 1N4007
DZ6 OVER-CURRENT AND FAULT PROTECTION
D9 45J
+16V
NUMBER.
15V 681 D28 39.2K 700 -6.2V
1N4004
R20
R3
1W 4.75K D8 1N4004 1.00K

R84
5W J1 D4
R6
R16
1N4004 256 14 R113 1N4007

235 DZ2
J1
12 200 10V 301
R13
15W D3 5W
475 100K D17
R5
R85
1.00M 1N4007
R147
R19
SCR1 1N4004
N.A.
NOTES :
R24
1.00M 332
R17
-10V
R70
4.75K
R71
QU1 20 4A -10V
LED4
39.2K C3 2N6027 400V
D7 1.8 CR2
1N4004 20V
R23
C17 LED3
C4
QU2 15.0K 20 2 100K
18
R18
2N6027 50V
R78
1.00K D18
15V
R22
R25
C18
15.0K .022 1N4004 1.00K C7
R87
R77
R30
Q5 4.75K 4.75K
50V .047
J1 233
2N4857 100V
7
D29 +16V
"N" V REF.
1N4004
-10V J1 75 SW.4A C8
DZ7
10 18
C6 CVS 15.0K
15V
R29
3V
"N" .047 D26 "H" R39
500mW 75 224 4
100V 1N4004 J2 4
10K CVI 6
CW 20K
1K C1
DZ9 VV C19
R1
24.3K
R38
R145
R82 R133 .022 X2
15V .02 X1
V.V. MIN.
1W CW 50V
162 162 76 600V
R37
2.21K SW.3 TRIM LM224

226 J1 LM224
C5
D23 11
.047 C.V.I. MIN.
77 11
100V 1N4004 TRIM 11
C.V.S. MAX. D27 D33
1K 238 OUTPUT TRIM AND
J2 1N4004
R26
TRIM R73 8 1N4004

R74 R148 REFERENCE CIRCUIT
CW "N"
15 332 332
1/2W T.S.3
47.5
D12 C30 -10V
L 8556
R111
-10V
1N4004 74 .047
D24 C29 "N" 47.5 100V
1N4004 .047
-6.2V R136
100V
R27
2.21K 74 J1
73 8
J2 73
R112 R142 7
OUTPUT TRIM CIRCUIT
75.0 75.0 D35
1N4004
-6.2V
-6.2V
FRANCE CANADA AUSTRALIA
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. IDEALARC DC1000
Firing PC Board (G1486-5 and above) Schematic
Output Snubber (M14312) Schematic
S 19699
NEG
1
(-)
M14312-1
C7 TP7
.05
GND
320V
OUTPUT SNUBBER
600V 160J
NEG
FRANCE
TP8
WELDER
C8
C7
TP7
OUTPUT
POS
TO FRAME
STUDS
CANADA
C8 TP8
.05 320V
600V 160J
AUSTRALIA
(+) POS
1
CAPICITORS = MFD/VOLTS
A.N.S.I. ELECTRICAL SYMBOLS PER E1537
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS
DIAGRAM, MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS
HAVING A COMMON CODE.

UNLESS OTHERWISE SPECIFIED TOLERANCE Ch'ge.Sht.No. EQUIP.

ON HOLES SIZES PER E-2056 THE LINCOLN ELECTRIC CO. TYPE
DC-1000
2-19-93G
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2 CLEVELAND, OHIO U.S.A. OUTPUT SNUBBER SCHEMATIC
SUBJECT
ON ALL ANGLES IS + .5 OF A DEGREE
SCALE NONE
MATERIAL TOLERANCE ("t") TO AGREE SHT.
WITH PUBLISHED STANDARDS DR. MCW DATE 4-10-90 CHK. J.J. SUP'S'D'G. NO. S 19699

Svm123a DC1000

Uploaded by

Copyright:

Available Formats

Svm123a DC1000

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Svm123a DC1000

Uploaded by

Copyright:

Available Formats

RETURN TO MAIN INDEX

IDEALARC DC 1000 July, 1996

For use with Machine Code Numbers: 9919

Safety Depends on You

increased by proper installation

... and thoughtful operation on

1.g. To prevent accidentally starting gasoline engines while turn-

____________________________________________________ ELECTRIC AND MAGNETIC

it to cool before refueling to prevent spilled fuel

2.d. All welders should use the following procedures in order to

2.d.4. Connect the work cable to the workpiece as close

2.d.5. Do not work next to welding power source.

the following equipment: hazardous to health. Avoid breathing these

3.g. Never dip the electrode in water for cooling. products.

5.e. Also see item 1.b.

5. Toujours porter des lunettes de sécurité dans la zone de

2. Dans le cas de travail au dessus du niveau du sol, se pro-

seront effectués par un électricien qualifié.

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Electrical Diagrams .......................................................................................................................Section G

Connection for Wire Feeder Control ...............................................A-8

TECHNICAL SPECIFICATIONS – IDEALARC DC - 1000

Constant Voltage 140 to 625 Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES

Type 75C Copper Type 75C Copper

230/60 300 193 000 (85mm2) 4 (25mm2)

430/60 150 96.5 3 (26.7mm2) 6 (16mm2)

575/60 125 77 6 (16mm2) 6 (16mm2)

the IDEALARC DC-1000.

SELECT PROPER LOCATION Machines

Place the IDEALARC DC-1000 where clean, dry air TILTING

is equipped with a heavy accessory such

the three line terminals on the input panel. See Figure

Two IDEALARC DC-1000 machines can be stacked.

the two holes in the base rails of the second

FUSE AND WIRE SIZES RECONNECT PROCEDURE

Connection Diagram located on the inside of Case

on the inside of the machine.

All input power must be electrically disconnected before touching panel.

CONNECTION FOR UNDER 300 VOLTS

CONNECTION FOR OVER 300 VOLTS

FIGURE A.3a - Input Connection Diagram

CONNECTION FOR 380 VOLTS

FIGURE A.3b - Input Connection Diagram

CONNECTION FOR 380 VOLTS

CONNECTION FOR 500 VOLTS

FIGURE A.3c -Input Connection Diagram

CONNECTION FOR 440 VOLTS 50 Hz (460V, 60 Hz.)

CONNECTION FOR 380 VOLTS 50 Hz.

CONNECTION FOR 220 VOLTS 50 Hz. (230V 60 Hz.)

FIGURE A.3d - Input Supply Connection Diagram

(positive or negative) and tighten the output ter-

Suggested Copper Cable Sizes - 100% Duty Cycle AUXILIARY POWER

NOTE: See the ACCESSORIES Section of this man-

FIGURE A-4 - Output Terminals

CONNECTION FOR AIR/CARBON ARC

CUTTING OPERATION cable connections from the DC-1000 terminal

operating your machine.

FUMES AND GASES