Lincoln Electric IDEALARC IM420-D, IDEALARC DC-1000 Operator's Manual

IM420-D

IDEALARC DC-1000

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. Ho wever , your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,

most importantly, think bef ore you act and be careful.

§§99991199 -- 99992255,, 1100229933,, 1111330055,, 1111333300,, 1111333311,, 1111333322,, 1111333333,, 1111333344,, 1111668811 tthhrruu 1111668844

February, 2010

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “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.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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1.c. Do not add the fue l near an open flam e welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases i t may b e nec essar y to remov e saf ety

gu a r d s to perf o r m r equir e d m ainten a n c e. Rem o v e guards only when necessary and replace them when the ma i n t e nance requ i r i ng th e ir re moval is co mplet e . Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through a ny c onductor causes localized Electric an d Magn et ic F ie ld s (EMF ). W el di ng current creates E MF f ie ld s arou nd w el di ng cables and welding machines

2.b. EMF f ie lds m ay inte rfere w ith som e pacem akers , and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other 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:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Nev er coil the electrode l ead aro und you r body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

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

SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear d ry , hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding mu s t be perfo r med u nder electri c ally hazardo u s conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

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

3.h. Nev er simul tan eou sly t ouc h ele ctr icall y “ hot” par ts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, k ee p your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

we l ding with e lectrode s which re q uire spec i al ve n tilati on s uch as s tainles s or ha rd f a cing (see instru ctio ns on container or MSDS) or on lea d o r cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumst a nces, outd oors, a r espira tor may be r equired . Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

caus e injur y or deat h. Always use enough ventilati on, especially in confined areas, to insure breathing air is safe.

vapors

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the ma t e r i al s a f e ty d a t a shee t (MSDS) an d fo l l o w yo u r employer’s safety practices. MSDS forms are available from yo u r weld i n g di s t r ibuto r or fr om th e ma n u f actur e r .

5.f. Also see item 1.b.

Jan ‘09

iii

SAFETY

iii

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m e m b er t h a t we l d i n g s p a r ks a n d hot materials from welding can easily go through small cracks an d o pen i ngs to a d jac ent are as. Avo id wel ding ne ar hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Co n t a i ners and Piping That Have Held Haza r d o u s Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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 welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of t he w el di ng current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

the welding s pa rks fro m startin g a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Us e on ly c o m press e d ga s c y l inder s containing the correct shielding gas for the pr o c e s s used a n d p r operl y o p e ratin g re g u l a tors desi g n e d fo r th e ga s an d

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Alway s kee p cylin ders in an u prigh t posit ion s ecure ly chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Rea d a nd fol low t he ins tru ctio ns on co mpr ess ed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in a ccordance with the U.S. Nat ional Electrical Code, all local codes and the manufac turer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. U n cour t- ci rcuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’o pérations de d égraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Proté ge r l’autre p er sonnel travaillant à p roximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gout tes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

Thank You

ixix

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions. ..............................................................................................................A-2

Location ........................................................................................................................A-2

Stacking ........................................................................................................................A-2

Input Wiring ...................................................................................................................A-2

Reconnect Procedures ..........................................................................................A-3, A-4

Output Connections ......................................................................................................A-5

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Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Product Description ..............................................................................................................B-1

To Set Polarity...............................................................................................................B-2

Set-Up For Various Procedures....................................................................................B-2, B-3

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TABLE OF CONTENTS

Page

Maintenance ....................................................................................................Section D

Safety Precautions ...................................................................................................D-1

General Maintenance .........................................................................................D-1

Overload Protection ...........................................................................................D-1

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Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-7

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Connection and Wiring Diagrams..................................................................Section F

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Parts List.....................................................................................................P-146 Series

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A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – DC-1000

INPUT - THREE PHASE ONLY

Standard

Voltage

100% Duty Cycle

Input Current at Rated Output

60% Duty Cycle

A-1

50% Duty Cycle

220/380/440/50/60

380/500/50/60

100% Duty Cycle

60% Duty Cycle 50% Duty Cycle

Output Range

150A/16V-1300A/46V

INPUT

VOLTAGE /

FREQUENCY

230/460/60

575/60

415/50/60

Duty Cycle

193/96.5

77.2

193/112/96.5

112/85

102

215/108

215/124/108

124/94

113

RATED OUTPUT

Amps

1000 1140 1250

Volts at Rated Amperes

OUTPUT

Maximum Open Circuit Voltage

75V for 60 HZ models

72V for 50/60 HZ models

See the OPERATION section

information by model

RECOMMENDED INPUT WIRE AND FUSE SIZES

HERTZ

INPUT AMPERE

RATING ON

NAMEPLATE

TYPE 75°C

COPPER WIRE

IN CONDUIT

AWG(IEC-MM2) SIZES

30°C (86°F) Ambient

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG(IEC-MM2) SIZES

230/115

230/133/115

133/101

121

44 44 44

Auxiliary

for Auxiliary Power

Power

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

230 460 575

220 380 415 440 500

60 60 60

50/60 50/60 50/60 50/60 50/60

193

96.5

77.2

193 112 102

96.5 85

000 (85)

3 (27) 4 (21)

000 (85)

2 (34) 2 (34) 3 (27) 4 (21)

4 (21) 6 (14) 6 (14)

4 (21) 6 (14) 6 (14) 6 (14) 6 (14)

300 Amp 150 Amp 125 Amp

300 Amp 175 Amp 150 Amp 150 Amp 125 Amp

PHYSICAL DIMENSIONS

HEIGHT

30.75 in 781 mm

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.

WIDTH

22.25 in 567 mm

IDEALARC® DC-1000

DEPTH

39.0 in

991 mm

WEIGHT

821 lbs.

372 kg.

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

Read this entire installation section before you start installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF at the discon n e c t swit c h or fuse box before working on this equipment. Tu rn of f the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the Power Wave grounding lug (located inside the reconnect input access door) to a proper safety (Earth) ground.

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LOCATION

Even though the machine is designed to operate under a wide variety of environmental conditions, for maximum reliability and long life the machine should be located in a clean, dry place where there is free circulation of clean air in through the front and out the back of the machine. Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown of the machine.

The case front incorporates a recessed control panel which protects the controls and minimizes the possibilities of accidental contact. This cover panel can be flipped open to permit access to the enclosed control section.

The individual case sides are removable for easy access for internal service or inspection.

The case rear is equipped with a removable cover plate, permitting easy access to the input panel.

The total enclosure, designed to permit outdoor operation, resists dust, salt, rain, humidity, and high and low temperature extremes.

The machine uses a 38” (965mm) long base. The low profile case facilitates installation of the machine under a workbench and stacking the machines two high to conserve floor space.

A permanent lifting eye is located at the top of the machine and is positioned so that it acts as nearly as possible through the center of gravity. This lift eye fits under the case of the second machine without interference when stacking.

STACKING

WARNING

FALLING EQUIPMENT can cause

injury.

• Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not stack more than two high.

• Do not stack the DC-1000 on top of any other machine.

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Two DC-1000’s may be stacked by observing the following safety precautions:

1. Make sure the first or bottom unit is setting on a level, well-

supported surface.

2. The units must be stacked with their fronts flush, making

sure the two holes in the base rails of the top unit are over the two pins located on top of the bottom unit.

INPUT WIRING

Be sure the voltage, phase and frequency of the input power is as specified on the welder nameplate.

Dual voltage (e.g. 230/460) models are shipped connected for the highest voltage. To change the connection, see the connection diagram pasted to the inside of the access panel in the case back.

Have a qualified electrician remove the rear access panel and connect 3 phase AC power to terminals L1, L2and L3of the

input panel in accordance with the U.S. National Electrical Code, all local codes and the wiring diagram located inside the machine.

The welder frame must be grounded. A stud marked with the symbol located inside the machine near the input panel is provided for this purpose. See the U.S. National Electrical Code for details on proper grounding methods. (See Technical Specifications)

IDEALARC® DC-1000

A-3

INSTALLATION

A-3

RECONNECT PROCEDURE

Multiple voltage machines are shipped connected to the highest input voltage listed on the machine’s rating plate. Before installing the machine, check that the Reconnect Panel in the Input Box Assembly is connected for the proper voltage.

CAUTION

Failure to follow these instructions can cause immediate failure of components within the machine.

When powering welder from a generator be sure to turn off welder first, before generator is shut down, in order to prevent damage to the welder.

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To reconnect a multiple voltage machine to a different voltage, remove input power and change the position of the reconnect board on the Reconnect Panel. Follow The Input Connection Diagram located on the inside of Case Back Input Access Door. These connection diagrams for the following codes are listed below.

1. For Single and Dual Voltage except 380/500 see

Figure 1, (S17172).

2. For 220/380/460, see Figure 2, (M14358).

3. For 380/500, see Figure 3, (S17344).

4. For Voltages not listed, see the Input Connection

Diagra m p a s ted on th e i n side of th e C a se Back Input Access Door.

FIGURE 1

IDEALARC® DC-1000

A-4

INSTALLATION

FIGURE 2

A-4

FIGURE 3

IDEALARC® DC-1000

A-5

INSTALLATION

A-5

OUTPUT CONNECTIONS

Output Studs

The output leads are connected to the output terminals. The output terminals are located on the lower case front and labeled “+” and “-”. There are 1000 amp rated “+” terminals on the right side, one 500 amp rated “+” terminal near the center and “-” terminals on the left side. They are fully recessed to minimize the possibility of accidental contact by an object or a person. Strain relief is provided by the oval holes in the base. The leads are run through these oval holes before they are connected to the output terminals.

The 1000 amp output connections provide the full rated output range of the machine. See Table1 for recommended DC-1000 cable sizes for combined lengths of electrode and work cables.

The 500 amp output connections provide enhanced lower current arc characteristics, especially for submerged arc and GMAW procedures below 450 amps.

Auxiliary Power

This machine supplies the 115 volt, AC power needed for operating wire feeding equipment. The power is available from terminals #31 and #32 on the terminal strip. An 8 amp slow blow fuse on the machine control panel protects the auxiliary power from excessive overloads. The circuit has a 1000 volt-ampere rating.

Control Cable Connection

Terminal strips with screw connections are located behind the hinged door on the front of the power source to make all the control cable connections for operating wire feeding equipment. See the appropriate connection diagram for exact instructions covering the wire feeder being used.

With the DC-1000 turned off, the control cable from the automatic wire feeding equipment is connected to the terminal strip. A strain relief box connector is provided for access into the terminal strip section. A chassis grounding screw is also provided below the terminal strip marked with the symbol for connecting the wire feeding equipment grounding wire. See the appropriate connection diagram for the exact instructions for the wire feeder being used. A spare hole is provided for an additional box connector if required.

Connecting for Air Carbon Arc:

a. Turn off all power. b. Disconnect all wire feed unit control, electrode and

work leads. c. Connect a jumper from 2-4 on terminal strip. d. Place mode switch in the CV(I) position.

With the DC-1000 connected for air carbon arc welding, the output terminals will be energized at all times.

DC-1000 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable

ELECTRODE, WORK AND #21 LEAD

Lengths up to 150 ft. (46m)

TABLE 1

at 100% Duty Cycle

IDEALARC® DC-1000

Cable SizeParallel CablesCable Length

1/0 (53mm

2/0 (67mm

3/0 (85mm

)150 ft.(46m) to 200 ft (61m)

)200 ft.(61m) to 250 ft.(76m)

B-1

OPERATION

B-1

OPERATING INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from wor k an d ground.

• Always wear dry insulating gloves.

------------------------------------------------------------------------

FUMES AND GASES can be danger-

ous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

------------------------------------------------------------------------

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed containers.

------------------------------------------------------------------------

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protection.

NOTE: All P.C. boards are protected by a moisture

resistant coating. When the welder is operated, this coating will “bake off” of certain power resistors that normally operate at high temperatures emitting some smoke and odor for a short time. These resistors and the P.C. board beneath them may become blackened. This is a normal occurrence and does not damage the component or affect the machine performance.

TO SET POLARITY

Turn off the DC-1000 and connect the electrode cable to the “Positive” or “Negative” studs depending upon the electrode polarity desired. Connect the work cable to the other stud. (See “Output Connections”).

Set the “Electrode Negative-Electrode Positive” switch to correspond to the polarity of the electrode cable connection. This switch setting is necessary for proper operation of some Lincoln wire feeders and does not change the welding polarity.

Starting the Machine - The push button power “on” switch at the extreme right side of the control panel energizes and closes the three phase input contactor from a 115 volt auxiliary transformer. This in turn energizes the main power transformer.

------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

PRODUCT DESCRIPTION

The DC-1000 is an SCR-controlled three phase DC power source. It is designed with a single range potentiometer control for submerged arc or open arc automatic and semiautomatic welding. It can be used for air carbon arc cutting with carbon rods up to and including 5/8” (15.9mm) dia. The DC-1000 (below code 9500) is not recommended for stick welding or for solid wire and gas in the short arc welding mode. With the addition of the 500 amp output stud to DC1000 models above code 9500, GMAW procedures can be performed. This connectio n provides the enhanced lower current arc characteristics required for this type of welding.

The DC-1000 is provided with a three position mode switch that selects CV Innershield®, CV Submerged Arc or CC (Variable Voltage) Submerged Arc.

The unit is designed to be used with the NA-5, NA-5R and NA-3 automatics, the LT-56 and LT-7 tractors, and can also be used with the LN-7, LN-8 or LN-9 semiautomatic wire feeders.

The red light below the stop-start button indicates when the input contactor is energized.

Output Control - The output control in the center of th e contro l panel is a c o ntinuou s contro l of th e machine output. The control may be rotated from min. to max. while under load to adjust the machine output.

The machine is equipped with line voltage compensation as a standard feature. This will hold the output relatively constant except at maximum output of the machine, through a fluctuation of +/- 10% of input line voltage.

Output Control at DC-1000 or Ou tput Control Remote Switch

The toggle switch on the control panel labeled “Output Control at DC-1000” / “Output Control Remote” gives the operator the option of controlling the output at the machine control panel or at a remote station. For remote control, the toggle switch is set in the “Output Control Remote” position and controlled at the wire feed unit control or by connecting a K775 control to the appropriate terminals (as indicated on the connection diagram) on the terminal strip at the front of the machine. For control at the machine control panel, the toggle switch is set in the “Output Control at DC-1000” position.

IDEALARC® DC-1000

B-2

INSTALLATION

B-2

Remote Output Control - (Optional)

The K775 Remote Output Control consists of a control box with 28 ft. (8.4m) of four conductor cable. This connects to terminals 75, 76, 77 on the terminal strip, and the case grounding screw so marked with the symbol on the machine. These terminals are made available by opening the terminal access cover on the left side of the case front. This control will give the sa m e con t r o l as th e outp u t con t r o l on t h e machine.

Mode Switch

The toggle switch labeled C (I) Innershield, CV(S) Submerged Arc, CC (or Variable Voltage) is used to sel e ct the p r oper weld e r charac t e ristics f o r the process being used. The CC (or Variable Voltage) mode is primarily available for use with older wire feeding equipment such as the LAF-3, LT-34 and so forth. Use of this type of older equipment requires the addition of an NL Option Kit.

SET-UP FOR VARIOUS PROCEDURES

1. Selection of mode switch position - There are several general rules to follow in the selection of the mode switch position.

NOTE: Some processes and procedures may be better with the mode switch in the other CV position. If the mode switch position initially selected is not producing the desired results, then place the mode switch in the other CV position and make a test weld. Then us e the CV mode switch posit ion t hat gives the desired results.

2. NA-3 - The NA-3 should be set for the mode being used on the power source. If using either of the CV modes, the NA-3 CC board switch should be set for CV. If the power source is used in the CC mode, then the NA-3 CC board mode switch should be placed in the CC position.

All the NA-3’s when used with the DC-1000 are capable of cold starting with the constant current board mode switch in CC. Cold starting permits the wire to be inched down to the work, automatically stop, and automatically energize the flux hopper valve. All NA3’s made after September, 1976 are capable of cold starting on either CV or CC settings of the constant current board.

On the NA-3, set the open circuit voltage control to the same dial setting as the arc voltage control. If the procedure has not yet been established, a good starting point is to set the OCV to #6.

a. Use the CV(I) mode for all FCAW and GMAW

processes. The CV(I) mode is also used for air carbon arc using carbon rods up to and including 5/8” (15.9mm) dia.

Welding with NR®-151, 202, 203 and other electrodes below 20 volts, is not recommended.

b. Use the CV(S) mode for all submerged arc

welding. This applies to both low and high travel speeds.

c. The CC (Variable Voltage) mode is available

for high current large puddle submerged arc procedures that cannot be done as well with the constant voltage mode. CC mode should be used for 3/16” (4.8mm) diameter electrode and above where high current surges cause machine shutdown when starting. This occurs primarily when the slag ball is not cut from the electrode prior to starting. (Also requires a wire feeder that has a constant current mode

- i.e. NA-3S).

Run a test weld, setting the proper current, voltage and travel speed. Once the proper welding procedure is established and if the start is poor - wire blast off, stub, etc. - adjust the NA-3 OCV and inch speed controls for optimum starting. In general, a low inch speed and an OCV dial setting identical to the voltage dial setting will provide the best starting.

To further optimize starting, adjust the OCV by making repeated starts and observing the NA-3 voltmeter action. With proper adjustment of the OCV control, the voltmeter needle will swing smoothly up to the desired arc voltage and thus provide repeatable starts.

If the voltmeter swings above the set voltage and then back to the desired welding voltage, the OCV setting is too high. This usually results in a bad start where the wire tends to “blast off”.

If the voltmeter needle hesitates before coming up to the desired voltage, the OCV is set too low. This will cause the electrode to stub.

IDEALARC® DC-1000

B-3

3. NA-5 - Set th e DC-10 00 mode switch to the process being used - CV(I) Innershield or CV(S) Sub Arc. Set the DC-1000 machine/remote switch in the remote position. Set the OCV 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. Adjust the OCV and inch speed as required for optimum starting. Refer to the NA-5 instruction manual for data regarding the setup of controls and modes on the NA-5.

4. LN-8 - Set the LN-8 mode switch (located on the CC board) to the CV position. Set the DC-1000 mode switch on CV(I) Innershield or CV(S) Sub Arc according to the process being used.

5. LN-7, LN-9 and other constant wire feed units Set the DC-1000 mode switch on CV(I) Innershield or CV(S) Sub Arc according to the process being used. If using an LN-9, refer to the LN-9 instruction manual for further instructions on its use. If using an LN-7, it will be necessary to use either a K775 Remote Control or operate the DC-1000 with the machine/remote switch in the machine position.

INSTALLATION

B-3

NL Option Kit (Not Required with NA-3, NA-5, LT-7 or LT-56).

The K783 NL Option Kit (for field installation) is designed to permit use of the obsolete NA-2, LAF-3, LT-3 and LT-3 section of the LT-34 tractor. It provides the necessary DC control power for the operation of the equipment and the necessary circuitry for proper inching, cold starting and arc striking. In using the NL

Option Kit, a K775 remote field control is required and is included as part of the kit. Installation instructions

are included with the NL Option Kit.

IDEALARC® DC-1000

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qual i f i ed p e rsonnel sh o u l d perform this installation.

• Turn the i n p u t power OF F a t the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

------------------------------------------------------------------------

GENERAL MAINTENANCE

1. The f an motor s have se aled bear i ngs whic h require no service.

2. In extremely dusty locations, dirt may clog the air channels causing the welder to run hot. Blow out the welder with low pressure air at regular intervals as required to eliminate excessive dirt and dust buildup on internal parts.

OVERLOAD PROTECTION

The control board is designed with adequate protection so that no damage will occur if the remote control leads are shorted together or are grounded to the case. The machine will automatically shut down if such faults do occur.

An 8-amp fuse located on the machine control panel protects the 115 volt auxiliary AC circuit (#31 and #32) from overload. If replacing, use the same type and size fuse.

The power source is thermostatically protected with two proximity thermostats against overload or insufficient cooling. One thermostat is located on the transformer secondary Negative Output Lead, and the other thermostat is located on the choke coil. The thermostats are connected in series in the machine control circuit so that if an excessive overload is applied to the machine, or the machine should receive insufficient cooling on either the main transformer, SCR bridge assembly or choke, the input contactor would open and remain open until the machine cools. It can then be manually restarted by operating the start push button.

The power source is also protected against heavy overloads on the SCR bridge assembly through an electronic protection circuit. This circuit senses an overload on the power source and opens the input contactor should the overload remain for a predetermined time. The predetermined time varies with the amount of overload; the greater the overload, the shorter the time. The input contactor will remain open until the power source is manually started with the start push button.

IDEALARC® DC-1000

E-1

TROUBLESHOOTING

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 Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column prov ides a course of ac tion for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

IDEALARC® DC-1000

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

Input contactor (1CR) chatters.

Machine input contactor does not operate.

Input contactor pulls in when start button is pressed, but immediately drops out.

1. Faulty input contactor (1CR).

2. Low line voltage.

3. Faulty 2CR relay.

1. Supply line fuse blown.

2. Contactor power circuit dead.

3. Broken power lead.

4. Wrong input voltage.

5. Secondary or choke thermostat open.

6. Open input contactor coil.

7. Faulty stop/start push button switch.

8. Faulty 2CR relay.

9. Defective control board.

1. Defective start/stop push button.

2. Defective 1CR interlock.

3. Ground fault between control terminals 73, 74, 75, 76 or 77 and negative output terminal.

4. Short on output terminals with 2-4 jumpered.

5. Defective control board.

1. Repair or replace.

2. Check input power.

3. Repair relay.

1. Replace if blown - look for reason first.

2. Check pilot transformer T2 and associated leads.

3. Check input voltage at contactor.

4. Check voltage against instructions.

5. Check for overheating; make sure fan is operating and there is no obstruction to free air flow. Replace faulty thermostat.

6. Replace coil.

7. Replace switch.

8. Replace relay.

9. Replace control board. See P.C. board troubleshooting guide.

1. Check and replace if necessary.

2. Repair or replace.

3. Check 73, 74, 75, 76 or 77 for ground to negative output circuit.

4. Remove short.

5. Replace control board. See P.C. board troubleshooting guide.

Machine input contactor operates but no output when trying to weld.

1. Electrode or work lead loose or broken.

2. Open main transformer (T1) primary or secondary circuit.

3. Output pilot relay 4CR not operating or faulty.

4. Firing circuit P.C. board not connected or is faulty.

5. If using 500 amp stud, choke circuit may be open.

1. Repair connection.

2. Repair.

3. Check relay pull-in by connecting a jumper across terminals 2 and 4 on DC-1000 terminal strip. Replace if faulty.

4. All nine light emitting diodes (LED1 thru LED9) must be lit. See P.C. board troubleshooting guide.

5. Repair.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

IDEALARC® DC-1000

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

Machine has maximum output but not control.

Machine has minimum output and no control.

Machine does not have maximum output.

Machine has output but trips off immediately when wire feed unit start button is pressed.

1. Output control switch (SW3) in wrong position.

2. Output control switch faulty.

3. Open in feedback circuitry.

4. Faulty control or firing circuit P.C. boards.

5. Output control potentiometer circuit open (Lead 75).

1. Terminals 73, 74, 75, 76 or 77 grounded to positive output.

1. One input fuse blown.

2. One phase of main transformer open.

3. Faulty control or firing circuit P.C. boards.

4. Output control potentiometer defective.

5. Output control potentiometer leads open - 76, 77, 226, 236, 237, 238.

1. Check position of switch.

2. Check switch and replace if faulty.

3. Check wiring and control and firing circuit P.C. board wiring harness plugs.

4. All light emitting diodes must be lit, except LED4 on the control/fault board. See P.C. board troubleshooting guide.

5. Check and replace potentiometer if faulty. Check wiring of Lead #75.

1. Check 73, 74, 75, 76 or 77 for ground to positive output circuit.

1. Check and replace if blown after checking for reason for blown fuse.

2. Check for open and repair.

3. All light emitting diodes must be lit on both P.C. boards, except LED4 on control/fault board. See P.C. board troubleshooting guide.

4. Check and replace if faulty.

5. Repair.

Variable or sluggish welding arc.

Machine will not shut off.

Output control not functioning on the

(1)

machine

(1)

If connected to an LN-9 or NA-5, disconnect leads 73, 74, 75 before troubleshooting.

1. Machine has either an internal or external short circuit on the output.

2. Faulty control P.C. board.

3. Terminals 73, 74, 75, 76, 77 grounded to negative output terminal.

1. Poor work or electrode connection.

2. Welding leads too small.

3. Welding current or voltage too low.

4. Defective main SCR bridge.

1. Input contactor contacts frozen.

2. Faulty 2CR relay.

1. Check internally and externally for any shorts and remove or repair.

2. Replace control board. See P.C. board troubleshooting guide.

3. Check for grounded 73, 74, 75, 76,

77.

1. Check and clean all connections.

2. Check table in instruction manual.

3. Check procedures for recommended settings.

4. Check and replace if defective.

1. Check and replace if necessary.

2. Check and replace if necessary.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

IDEALARC® DC-1000

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-4

Output control not functioning on remote control.

Poor starting on CV(S) Sub-Arc.

Poor bead shape or erratic arc on CV(S) Sub-Arc.

1. Output control switch in wrong position.

2. Faulty output control switch.

3. Faulty remote control potentiometer.

4. Leads or connections open in control circuit.

5. Faulty firing or control circuit P.C. board.

1. Improper procedures or setting of controls.

2. Poor electrode or work connection.

3 3CR reed switch inoperative.

4 Faulty control board.

1. Improper procedures.

2. Defective 3CR reed switch.

3. Faulty control board.

4. Defective main SCR bridge.

1. Place switch in “Output Control Remote”.

2. Check and replace if found faulty.

3. Check and replace if found faulty. (Voltage from 75 to 77 should be 3 to 5V).

4. Check all leads and connections, internal or remote, for continuity; repair if necessary.

5. All light emitting diodes must be lit on both P.C. boards, except LED4 on control/fault board. See P.C. board troubleshooting guide.

1. See instruction manual and procedures.

2. Repair connections.

3. Check reed switch voltage leads 216 to 220. Idle voltage is about 8V; when welding, voltage must go to zero.

4. Replace. See P.C. board troubleshooting guide.

1. See instruction manual and procedures.

2. Check reed switch per item c. of previous Table above.

3. Replace. See P.C. board troubleshooting guide.

4. Check and replace if defective.

Poor starting on CV(I) Innershield and CV(S) Sub-Arc.

Poor arc characteristics on CV(I) Innershield or other open arc processes.

Poor arc characteristics on all processes.

Poor performance (including arc outages) while welding at low current (less than 450 amps) when connected to 1000 amp “+” output studs.

Machine frequently shuts off while using the 500 amp “+” output stud.

1. Defective 3CR reed switch.

2. Faulty control board.

1. Mode switch in CV(S) Sub-Arc mode.

2. Defective main SCR bridge.

1. Defective control board.

2. Defective firing board.

3. Defective main SCR bridge.

1. Insufficient output inductance.

1. Effective current demand well over 500 amperes.

1. Replace.

2. Replace.

1. Place mode switch in CV(I) Innershield mode.

2. Check and replace if defective.

1. Check and replace if defective. See P.C. board troubleshooting guide.

2. Check and replace if defective. See P.C. board troubleshooting guide.

3. Check and replace if defective.

1. Use the 500 amp “+” output stud.

1. Use the 1000 amp “+” output studs.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

IDEALARC® DC-1000

E-5

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

P.C. BOARD TROUBLESHOOTING GUIDE

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box before working on equipment.

• Do not touch electrically hot parts.

---------------------------------------------------------------------

Machine settings for P.C. board troubleshooting. Disconnect all leads to the wire feeder and jumper terminals #2 and #4 on DC-1000. Output Control at DC-

1000. Mode switch in the CV(I) position.

CON TROL/FAULT PR OTE CTI ON P.C. BOARD

1. LED1 indicates AC input voltage is present at pins 255-256. If not lit, check the voltage across the secondary winding of the control transformer, T2. The voltage should be approximately 115 volts. If not, the problem is in the power supply and not the P.C. board.

E-5

1. Lights 7, 8, and 9 indicate AC power being supplied to the P.C. boards from T1 auxiliary winding. If a light is not lit, turn the machine off and unplug P5 from J5 on the firing P.C. board. Turn the machine on and check the following voltages:

Light That Check AC Voltage Voltage Should

Was Off Between Pins of Be Approx.

Plug P5

7 P5 Pins 2 & 4 75 VAC

(Wires 203, 204)

8 P5 Pins 7 & 3 75 VAC

(Wires 205, 206)

9 P5 Pins 9 & 8 75 VAC

(Wires 207, 208)

• If appr oxima tely 75 VA C is present, turn the machine off, plug P5 back into firing board. Turn the machine back on and check to see if the light or lights are on. If the light or lights are not on replace the firing P.C. board.

• If the 75 VAC was not present, then check the wiring.

2. LED2 indicates welder output voltage is being supplied to the control circuit. If not lit, check to make certain lead 222 from pin 2 of the 15-pin control circuit P.C. board connector is connected to the power source negative output lead and is not broken.

3. LED3 indicates power is being applied to fault protection pilot relay 2CR to turn on the input contactor.

4. LED4 indicates when overcurrent protection circuit is being activated.

5. LED5 indicates a control signal is being supplied to the firing circuit. As the output control is varied, LED5 should change brilliancy from bright at low output to dim at high output.

FIRING CIRCUIT P.C. BOARD

All nine light emitting diodes must be lit when the power source is turned on and the wire feed arc start button is pressed or a jumper is connected between 2 and 4.

2. Lights 1 through 6 indicate gate signals are being supplied to the main power SCR’s 1 through 6 respectively. If light 5 on the control circuit and lights 7 through 9 on the firing circuit are lit and lights 1 through 6 are not lit, check lead 231 between the firing circuit and the control circuit that it is not broken and is connected to each Molex connector. If the lead shows continuity and lights 1 through 6 are not lit, replace the firing circuit P.C. board. If any one of the lights 1 through 6 is not lit and lights 7 through 9 are lit, replace the firing circuit P.C. board.

CAUTION

IDEALARC® DC-1000

E-6

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

PRO CED URE F OR RE PLA CIN G P.C . BOARDS

When P.C. board is to be replaced, the following procedure must be followed:

1. Visually inspect P.C. board in question. Are any of the components damaged? Is a conductor on the back side of the board damaged? All P.C. boards are protected by a moisture resistant coating. When the welder is operated, this coating will “bake off” of certain power resistors that normally ope r ate at h igh tempe ratures e m itting so me smoke and odor for a short time. These resistors and the P.C. board beneath them may become blackened. This is a normal occurrence and does not damage the component or affect the machine performance.

a. If there is no damage to the P.C. board, insert

a new one and see if this remedies the problem. If the problem is remedied, replace the old P.C. board and see if the problem still exists with the old P.C. board.

E-6

1) If the problem is no longer present with the old board, check the P.C. board harness plug and P.C. board plug for corrosion, contamination, or oversize.

2) Check leads in the harness for loose connections.

b. If there is damage to the P.C. board, refer to

the Troubleshooting Guide

CAUTION

IDEALARC® DC-1000

E-7

TROUBLESHOOTING

OUTLINE FOR DC-1000 TROUBLESHOOTING GUIDE

If troubleshooting guide indicates a possible P.C. board problem, the following guide can be used to locate the problem.

NO WELDER OUTPUT (INPUT CONTACTOR “ON”. 2 AND 4 CLOSED)

CHECK CONTROL BOARD

E-7

LED5

IF OFF

CHECK LED1

IF OFF IF ON

CHECK AC REPLACE

INPUT TO CONTROL

CONTROL BOARD

BOARD -

POSSIBLE

DEFECTIVE

T2 TRANSFORMER

MACHINE HAS OUTPUT

(Jumper 2-4) BUT TRIPS

OFF IMMEDIATELY

CHECK FOR SHORT CHECK LEADS

BETWEEN ELECTRODE AND 73, 74, 75, 76, 77 FOR

WORK LEADS, REMOVE GROUND TO

EXTERNAL LEADS FROM NEGATIVE OUTPUT

THE OUTPUT TERMINALS TERMINAL

CHECK GATE LEAD CHECK LIGHTS

CHECK FIRING BOARD

IF YES IF NO

CONNECTIONS 7,8,9

TO SCR’S

IF ON

LED’S

ALL

NINE LIGHTS

SHOULD

BE ON

IF ONE IF ON AND

OR MORE OTHER LIGHTS

ARE OUT ARE OUT

CHECK AC INPUT

TO BOARD, REPLACE

203-204, 205-206 FIRING

207-208 -- POSSIBLE BOARD

DEFECTIVE

AUXILIARY

WINDINGS ON MAIN

TRANSFORMER

CHECK FOR OPEN

IN LEADS 203, 204

205, 206, 207, 208

IF TROUBLE STILL PERSISTS,

CHECK LED 3 ON

CONTROL BOARD

IF LIGHT GOES ON, THEN

QUICKLY OUT WHEN START

BUTTON IS PRESSED,

CONTROL BOARD IS

DEFECTIVE AND SHOULD

BE REPLACED

ERRATIC WELDING

CHECK PROCEDURE

CHECK MODE SWITCH FOR PROPER POSITION FOR

PROCESS BEING USED

CHECK LED’S 1 THRU 6 FOR EQUAL BRILLIANCY

IF LIGHTS ARE NOT ALL APPROXIMATELY EQUALLY

BRIGHT, REPLACE FIRING P.C. BOARD

CAUTION

IDEALARC® DC-1000

F-1

21 4



574



672142

132

75 76

N.C.

POWER SOURCE

.B.

N.A.

NEGATIVE

POSITIVE

N.D.

TO WORK

ELECTRODE CABLE TO A

UTOMATIC EQUIPMENT

35 VOLT CONTROL EXCITER

421

45 29

TAPE UP LEADS NOT USED

K775 REMOTE CONTROL M

OUNTED AT LAF-3

O LAF-3

CONTROL BOX

CONNECT THE RED LEAD TO T

ERMINAL 22

L OPTION

G N D

OWER SOURCE

NEGAT IVE

POSITIVE

N.A.

ELECTR ODE CA BL E TO

TO WORK

}

TO LN-8 IN PUT

CABLE PLUG

CONTROL CABLE

32 31

}

WIRE FEED UNIT

N.D.

N.B. &

N.C.

M13321 8-2-90F

DIAGRAMS

CONNECTION OF DC-1000 WITH NL OPTION KIT TO LAF-3 (Obsolete)

F-1

N.A. On all DC-1000 and DC-1500 units

with codes above 8234 extend lead 67 and connect it to the electrode cable going to the automatic equipment.

N.B. On DC-1500 units below code 8234

this is 67 and the LAF-3 #67 lead can be connected either to the #67 terminal or the electrode cable terminal as shown. Terminal 82 not present on later D.C. 1500’s and all DC-1000’s.

N.C. Terminals 73 and 74 not present on

earlier DC-1500’s.

CONNECTION OF DC-1000 TO LN-8

S17176 8-2-90F

N.D. Alternative 500 amp positive terminal

connection provided on DC-1000 models above code 9500 only.

This diagram shows the electrode connected positive. To change polarity, turn power source off, reverse the electrode and work leads at the power source and position the switch on the power source and NL Option Kit to the proper polarity. Also reverse the leads on the back of the ammeter and voltmeter in the LAF-3 control box.

Contactor drop out delay switch on the NL Option Kit must be in the “On” position.

Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source must be properly grounded.

*If using an older control cable: Connect lead #75 to #75 on terminal strip, connect lead #76 to #76 on terminal strip, connect lead #77 to #77 on terminal strip.

N.A. Welding cables must be of proper capacity for the current

N.B. Extend lead 21 using #14 or larger insulated wire physi-

IDEALARC® DC-1000

N.C. Tape up bolted connection.

N.D. Alternative 500 amp positive terminal connection provided

The 4/0 cables shown will handle up to 1000 amps at 80% duty cycle. For higher currents or duty cycle add additional cables to the power source output studs.

For best arc striking when connected to an LAF-3 make the following change inside the LAF-3 control unit. Remove the blue jumper lead connected between #1 on the coil of the main relay and #7 on the coil of the transfer relay. (The main relay is the upper right relay when facing the left end of the control box. The transfer relay is just to the left of the main relay.)

and duty cycle of immediate and future applications.

cally suitable for the installation. An S16586-[ ] remote voltage sensing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead.

on DC-1000 models above code 9500 only.

F-2

O WORK

LT-3 REMOTE D

C CONTROL

ELECTRODE CABLE TO

AUTOMATIC EQUIPMENT

.D.

NEGATIVE

POSITIVE

.A.

N.B.

POWER SOURCE

N.C.

74 75

67 21 4

31 32

76 77

5 VOLT CONTROL

XCITER

75 7

GND

75 76

BOLT & TAPE

7 CONNECTIONS

1 42

4458

SPARE

APE UP SPARE LEADS (NOT USED)

2132

42 434458

NL OPTION

CONNECT THE RED LEAD TO

TERMINAL 22

-775 REMOTE CONTROL

OUNTED AT TRACTOR

O LT-3 TRACTOR

CONTROL BOX

G N D

POWER SOURCE

NEGAT IVE

POSITIVE

N.A.

ELECTRO DE CAB LE TO

TO WORK

}

CONTROL CABLE

32 31

}

N.B. &

N.C.

TO AUTOMATIC

CONTROL BOX

N.D.

N.E.

AUTOMATIC EQUIPMENT

}

DIAGRAMS

CONNECTION OF DC-1000 WITH NL OPTION KIT TO LT-3 or LT-34 (Obsolete)

M13322 8-2-90F

F-2

N.A. On all DC-1000 and DC-1500’s

above Code 8234 extend lead 67 and connect it to the electrode cable going to the automatic equipment.

N.B. On DC-1500 units below code 8234

this is #67 and the LT-3 or LT-34 #67 lead can be connected either to the #67 or the electrode cable terminal as shown. Terminal 82 not present on later D.C. 1500’s and all DC1000’s.

CONNECTION OF DC-1000 OR DC-1500 to NA-3, LT-5 or LT-7

S15534 8-2-90F

Above diagram shows electrode connected positive. To change polarity, turn power source off, reverse the electrode and work leads at the power source and position the switch on power source to proper polarity. Also reverse the leads on the back of the ammeter and voltmeter in the automatic control box.

N.C. Terminals 73 & 74 not present on

N.D. Alternative 500 amp positive terminal

earlier DC-1500’s.

connection provided on DC-1000 models above code 9500 only.

Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source must be properly grounded.

*If using an older control cable: Connect lead #75 to #75 on terminal strip, connect lead #76 to #76 on terminal strip, connect lead #77 to #77 on terminal strip.

N.A. Welding cables must be of proper capacity for the current

and duty cycle of immediate and future applications.

N.B. Extend lead 21 using #14 or larger insulated wire physically

suitable for the installation. An S16586-[ ] remote voltage sensing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead.

N.C. Tape up bolted connection.

N.D. Terminals 73 & 74 not present on earlier DC-1500.

N.E. Alternative 500 amp positive terminal connection provided

on DC-1000 models above code 9500 only.

IDEALARC® DC-1000

Contactor drop out delay switch on the NL Option Kit must be in the “On” position.

The 4/0 cables shown will handle up to 1000 amps at 80% duty cycle. For higher currents or duty cycle add additional cables to the power source output studs.

F-3

G N D

NEG

TIVE

POSITIVE

N.A.

BLE

}

TO NA-5 IN

PUT

ABL

PLU

N.K.

CONTACT ASSEMBLY

ROM

NA-5 W

N.B.

N.C.

BOLT TO CAB

LES

.D.

CONNECT TO WORK

.C. & N.H

DIAGRAMS

CONNECTION OF DC-1000 to NA-5

N.A. Welding cables must be of proper capacity for the cur-

rent and duty cycle of immediate and future applications.

N.B. Extend lead 21 using #14 or larger insulated wire phys-

ically suitable for the installation. An S16586-[ ] remote voltage sensing work lead is available for this purpose. Connect it directly to the work piece keeping it separate from the welding work cable connection to work piece. For convenience, this extended #21 lead should be taped along the welding work cable.

N.C. Tape up bolted connection.

N.D. Connect the NA-5 control cable ground lead to the

frame terminal marked near the power source terminal strip. The power source must be properly grounded.

N.E. If using an older automatic control cable with leads 75,

76, 77: Connect lead 75 to #75 on terminal strip, connect lead #76 to #74 on terminal strip, connect lead #77 to #73 on terminal strip.

N.F. Connect the jumpers on the NA-5 voltage board as fol-

lows: Connect RED jumper to pin “S”, Connect WHITE jumper to pin “B”.

F-3

S16889 8-2-90F

Above diagram shows electrode connected positive. To change polarity turn power off, reverse the electrode and work leads at the power source, position the positive - negative switch on the power source to correspond to the polarity of the electrode cable connection. Refer to NA-5 operating manual for required NA-5 control box polarity connections.

N.G. Set the DC-1000 or DC-1500 controls as follows: Set

the control switch to “Output Control Remote”. For Submerged Arc Processes set the switch to “C.V. Submerged Arc”. For Open Arc Processes, set the mode switch to “C.V. Innershield”.

N.H. For proper operation, the electrode cable must be

snugged under the clamp bar on the left side of the NA5 control box.

N.J. Terminals #73 and #74 were not present on DC-1500

machines below code 8294. These earlier code machines are not suitable for use with the NA-5.

N.K. Alternative 500 amp positive terminal connection pro-

vided on DC-1000 models above code 9500 only.

N.L. Alternate submerged arc mode available for improved

arc stability in high current, large puddle, slow travel procedures by making special connections on both DC1500 and NA-5.

On DC-1500 Control Board (G1530-2 and superseding) remove red and blue jumpers from “FR” pins and reconnect to corresponding “SR” pins.

On NA-5 Voltage Board (G1556-1 and superseding) white jumper must be connected to pin “D”.

NA-5 pin “D” connection may also be used for some procedures on DC-1500 without control board jumpers, DC-1500 with control board jumpers on “FR” pins or DC-1000.

IDEALARC® DC-1000

F-4

N D

POWER SOURCE

LN-7 CONTROL CABLE

TO LN-7 INPUT

CABLE PLUG

NEGATIVE

OSITIVE

N.B. & N.C.

N.D.

N.F.

N.A.

ELECTRODE CABLE TO

LN-7 CONDUCTOR BLOCK

TO WORK

}

N.E.

G N

POWER SOURCE

CABLE PLUG

NEGAT IVE

POSITIVE

N.B. & N.C.

N.D.

N.A.

ELECTR ODE CA BLE T O

}

TO LN-9 INPUT

N.F.

N.H.

WIRE FEED UNIT

CONNECT TO WORK

}

N.E.

CONTROL CABLE

DIAGRAMS

CONNECTION OF DC-1000 TO LN-7

N.A. Welding cables must be of proper capacity for the current and

duty cycle of immediate and future applications.

N.B. Extend lead 21 using #14 or larger insulated wire physically suit-

able for the installation. An S16586-[ ] remote voltage sensing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead. (This extended #21 lead connection replaces the need to employ the remote work lead accessory on LN-7 meter kits which have a direct work lead jack. An LN-7 not equipped with a meter kit does not require lead 21 to be extended.)

N.C. Tape up bolted connection.

N.D. Connect the control cable ground lead to the frame terminal

marked near the power source terminal strip. The power source must be properly grounded.

F-4

S17177 8-2-90F

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power source and position the switch on power source to proper polarity.

CONNECTION OF DC-1000 TO LN-9

S17185 8-2-90F

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the power source, position the positive-negative switch on the power source to correspond to the polarity of the electrode cable connection. Refer to LN-9 operating manual for required polarity connections.

N.E. Terminal strip for remote voltage control pot. when used.

N.F. Alternative 500 amp positive terminal connection provided on

DC-1000 models above code 9500 only.

N.A. Welding cables must be of proper capacity for the current and

duty cycle of immediate and future applications.

N.B. Extend lead 21 using #14 or larger insulated wire physically suit-

able for the installation. An S16586-[ ] remote voltage sensing work lead is available for this purpose. Connect it directly to the work piece keeping it separate from the welding work cable connection to work piece. For convenience, this extended #21 lead should be taped along the welding work cable. (This extended #21 lead connection replaces the need to employ the remote work lead accessory on LN-9’s which have a direct work lead jack.)

N.C. Tape up bolted connection.

N.D. Connect the LN-9 control cable ground lead to the frame terminal

marked near the power source terminal strip. The power source must be properly grounded.

N.E. If using an older automatic control cable with leads 75, 76, 77;

Connect lead 75 to #75 on terminal strip, connect lead #76 to #74 on terminal strip, connect lead #77 to #73 on terminal strip.

N.F. The LN-9 voltage control jumpers must be connected as follows

(Refer to LN-9 operating manual): White jumper on voltage board to pin “S”. Blue jumper on voltage board (later units only) or on start board (earlier units). To pin “B”.

N.G. Set the DC-1000 controls as follows: Set the control switch to

“Output Control Remote”. For Submerged Arc Processes, set the mode switch to “C.V. Innershield”.

N.H. Alternative 500 amp positive terminal connection provided on

DC-1000 models above code 9500 only.

IDEALARC® DC-1000

F-5

DC-1000 WIRING DIAGRAM FOR CODES 9919 - 9925, 10293, 11305, 11330, 11331, 11332, 11333, 11334

DIAGRAMS

F-5

IDEALARC® DC-1000

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-6

DIAGRAMS

F-6

IDEALARC® DC-1000

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

NOTES

IDEALARC® DC-1000

NOTES

IDEALARC® DC-1000

NOTES

IDEALARC® DC-1000

WARNING

Spanish

AVISO DE

PRECAUCION

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground.

• No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

• Aislese del trabajo y de la tierra.

• Keep flammable materials away.

• Mantenga el material combustible

fuera del área de trabajo.

• Wear eye, ear and body protection.

• Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

• Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

• Isolez-vous du travail et de la terre.

• Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

• Isolieren Sie sich von den

Elektroden und dem Erdboden!

• Não toque partes elétricas e electro-

dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Gardez à l’écart de tout matériel

inflammable.

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-

dos.

• Protégez vos yeux, vos oreilles et

votre corps.

• Tragen Sie Augen-, Ohren- und Kör-

perschutz!

• Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

• Turn power off before servicing.

• Do not operate with panel open or

guards off.

WARNING

• Los humos fuera de la zona de res-

piración.

• Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

• Gardez la tête à l’écart des fumées.

• Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

• Vermeiden Sie das Einatmen von

Schweibrauch!

• Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

• Mantenha seu rosto da fumaça.

• Use ventilação e exhaustão para

remover fumo da zona respiratória.

• Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

• Débranchez le courant avant l’entre-

tien.

• Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

•

Não opere com as tampas removidas.

•

Desligue a corrente antes de fazer serviço.

•

Não toque as partes elétricas nuas.

• No operar con panel abierto o

guardas quitadas.

• N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

• Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

• Mantenha-se afastado das partes

moventes.

• Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric IDEALARC IM420-D, IDEALARC DC-1000 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual