Lincoln Electric DC 1000, SVM123-A User Manual

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TM

IDEALARC DC 1000

SVM123-A

July, 1996

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
... 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 before
you act and be careful.

For use with Machine Code Numbers: 9919

9920

View Safety Info View Safety Info View Safety Info View Safety Info

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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

SERVICE MANUAL

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. [phone]

i

SAFETY

i

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.

bleshooting and maintenance work unless the maintenance
work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated areas or vent the

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

1.a. Turn the engine off before trou-

engine exhaust fumes outdoors.

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.

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.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.

___________________________________________________

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 any conductor causes local­ized Electric and Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables and welding
machines.

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have othe health
effects which are now not known.

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete.
working near moving

___________________________________________________

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.

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Always use the greatest care when

parts.

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 togethe.
Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and
work cables. If the elecrode cable is on your right
side, the work cable should also be on your right
side.

2.d.4. Connect the work cable to the workpiece as close
as possible to the area being welded.

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

Mar ‘95

ii

SAFETY

ii

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 dry, 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
must be performed under electrically hazardous
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.

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, keep
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

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

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. Never simultaneously touch electrically “hot” parts 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.

5.b.

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.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

Mar ‘95

to

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iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
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
Containers and Piping That Have Held Hazardous
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.

6.f.

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

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

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

7.b. Always keep cylinders in an upright position securely
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. Read and follow the instructions on compressed 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 accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

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

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Mar ‘95

iv

SAFETY

iv

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.

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. Un court-circuit 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’opérations de dégraissage, 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.

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.

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. Protéger l’autre personnel travaillant à proximité au

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

4. Des gouttes 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.

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PRÉCAUTIONS DE SÛRETÉ POUR
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

v

v

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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

A-1

INSTALLATION

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

A-1

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IDEALARC DC-1000

A-2

INSTALLATION

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

A-2

Input

Voltage/Frequency

230/60

430/60

575/60

Height Width Depth Weight

30.75 in 22.25 in 38.0 in 821 Ibs
(781 mm) (567 mm) (965 mm) (372 kg)

Fuse (Super Lag)

or Breaker Size

300 193

150 96.5

125

Input Ampere Rating on

Nameplate

77

PHYSICAL DIMENSIONS

Type 75C Copper

Wire in Conduit

AWG (IEC) Sizes

000 (85mm2)

3 (26.7mm2)

6 (16mm2)

Type 75C Copper

Ground Wire in

Conduit AWG (IEC)

Sizes

4 (25mm2)

6 (16mm2)

6 (16mm2)

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IDEALARC DC-1000

A-3

Read entire Installation Section before installing
the IDEALARC DC-1000.

INSTALLATION

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel should install this
machine.

• Turn the input power OFF at the discon­nect switch or fuse box before installing or
working on the equipment.

• Do not touch electrically hot parts.

• Always connect the IDEALARC DC-1000
grounding terminal to a good electrical
earth ground.

____________________________________________________

SELECT PROPER LOCATION

A-3

STACKING HOLE

STACKING PIN

FIGURE A.1 - Stacking IDEALARC DC-1000

Machines

Place the IDEALARC DC-1000 where clean, dry air
can freely circulate in through the front intake and out
through the rear louvers. Dirt, dust, or any foreign
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
because of excessive operating temperatures.

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.

____________________________________________________

Two IDEALARC DC-1000 machines can be stacked.
Follow these guidelines when stacking:

TILTING

The IDEALARC DC-1000 must be placed on a stable,
level surface so it will not topple over.

ELECTRICAL INPUT
CONNECTIONS

Before installing the machine, check that the input
supply voltage, phase, and frequency are the same as
the machine’s voltage, phase, and frequency as spec­ified on the machine’s rating plate on the Case Front
Assembly Control Panel. Connect input power supply
by removing the rear access panel and connecting to
the three line terminals on the input panel. See Figure
A.2 for the location of the machine’s input cable entry
opening and reconnect panel assembly for dual volt­age machines.

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 bot­tom machine.

NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
Figure A.1.

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FIGURE A.2 - Input Power Supply Connection

IDEALARC DC-1000

A-4

INSTALLATION

A-4

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the

Specifications

being used. They are also called inverse time or ther­mal/magnetic circuit breakers.

DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in nui­sance tripping caused by inrush current even when
machine is not being used for welding at high output
currents.

Use input and grounding wire sizes that meet local
electrical codes, or see the
page in this manual.

page of this manual for the machine

Technical Specifications

Technical

GROUND CONNECTION

Ground the frame of the machine. A ground terminal
marked with the symbol is located inside the Case
Back of the machine. Access to the rear input panel is
at the upper rear of the machine. See your local and
national electrical codes for proper grounding meth­ods.

INPUT POWER SUPPLY CONNECTIONS

A qualified electrician should connect the input power
supply leads.

1. Follow all national and local electrical codes.

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.

____________________________________________________

To reconnect a multiple voltage machine to a different
voltage, remove input power and follow the Input
Connection Diagram located on the inside of Case
Back Input Access Door. These connection diagrams
are listed below:

1. For 460 single voltage, 230/460 Dual Voltage,
220/440 Dual Voltage, 415 Single Voltage or 575
Single Voltage, refer to Figure A.3a.

2. For 380 Single Voltage Machines, refer to Figure
A.3b.

3. For 380/500 Dual Voltage Machines, refer to
Figure A.3c.

4. For 220/380/440 Triple Voltage Machines, refer to
Figure A.3d

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 recon­nect panel. See Figure A.2

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IDEALARC DC-1000

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 posi­tion shown, and secure firmly with the six hex nuts
provided. Secure the three remaining hex nuts over
the remaining three studs for future use.

2. Conect L1, L2, and L3 input supply lines and H1 and
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.

4. Connect terminal marked to ground per National
Electrical Code.

A-5

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FIGURE A.3a - Input Connection Diagram

WARNING

All input power must be electrically disconnected before touching panel.

____________________________________________________

CONNECTION FOR 380 VOLTS

1. Conect L1, L2, and L3 input supply lines and H1 and
H3 Control Transformer Leads to the Input
Terminals as shown.

2. Connect terminal marked to ground per National
Electrical Code.

FIGURE A.3b - Input Connection Diagram

IDEALARC DC-1000

A-6

INSTALLATION

WARNING

All input power must be electrically disconnected before touching panel.

____________________________________________________

CONNECTION FOR 380 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. 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 ade­quate tape to provide at least 600 volt insulation.

4. Connect terminal marked to ground per National
Electrical Code.

CONNECTION FOR 500 VOLTS

1. Mount the movable reconnect panel center set of
holes to the stationary reconnect panel in the posi­tion shown, and secure firmly with the six hex nuts
provided. Secure the three remaining hex nuts over
the remaining three studs for future use.

2. Connect L1, L2, and L3 input supply lines and H1
and H4 control transformer leads to the input side of
the reconnect panel as shown

3. Insulate unused H2 and H3 lead terminal with ade­quate tape to provide at least 600 volt insulation.

4. Connect terminal marked to ground per National
Electrical Code.

A-6

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FIGURE A.3c -Input Connection Diagram

IDEALARC DC-1000

A-7

INSTALLATION

WARNING

All input power must be electrically disconnected before touching panel.

____________________________________________________

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.

2. Connect L1, L2, and L3 input supply lines and H1
and H4 control transformer leads to input terminals
as shown.

3. Insulate unused H2 and 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 380 VOLTS 50 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.

2. Connect L1, L2, and L3 input supply lines and H1
and H3 control transformer leads to input terminals
as shown.

3. Insulate unused H2 and H4 lead terminal with ade­quate tape to provide at least 600 volt insulation.

4. Connect terminal marked to ground per National
Electrical Code.

A-7

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CONNECTION FOR 220 VOLTS 50 Hz. (230V 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.

2. Connect L1, L2, and L3 input supply lines and H1
and H2 control transformer leads to input terminals
as shown.

3. Insulate unused H3 and H4 lead terminal with ade­quate tape to provide at least 600 volt insulation.

4. Connect terminal marked to ground per National
Electrical Code.

FIGURE A.3d - Input Supply Connection Diagram

IDEALARC DC-1000

A-8

INSTALLATION

A-8

OUTPUT CONNECTIONS

See Table A.1 for recommended IDEALARC DC-1000
cable sizes for combined length of electrode and work
cables.

TABLE A.1

Suggested Copper Cable Sizes - 100% Duty Cycle

Combined Lengths of Electrodes and Work Cables

Amperes Length Cable Size

1000 0 - 250 ft. 3-3/0

(76.2m) (3 x 85.0 mm2)

CONNECT ELECTRODE AND WORK
LEADS TO OUTPUT TERMINALS

The output terminals are located on the lower case
front and labeled “+” and “-”. See Figure A.4. 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.

The 1000 amp output connections provide the full
rated output range of the machine.

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

1. Set the ON/OFF PUSH BUTTON to OFF.

2. Insert the electrode lead through the oval opening
in the lower shelf of the front case, closest to the
desired polarity (positive or negative). Pull through
enough cable to reach the output terminals.

3. Connect electrode lead to the desired terminal
(positive or negative) and tighten the output ter­minal nut with a wrench.

4. Connect the second work lead to the other out­put terminal (positive if negative is attached and
vice versa) following steps 2 and 3.

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 volt­ampere rating.

CONNECTION FOR SEMI-AUTOMATIC
OR AUTOMATIC WIRE FEEDER
CONTROL

With the DC-1000 turned off, the control cable from
the semi-automatic or 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 plugged hole is provided
in case an additional box connector is required.

NOTE: See the
ual for specific instructions on connecting the follow­ing semi-automatic and automatic wire feeders:

• LN-7

ACCESSORIES

Section of this man-

FIGURE A-4 - Output Terminals

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• LN-8

• LN-9

• NA-3

• NA-5

•LT-7

• LT-56

IDEALARC DC-1000

Semi-Automatic Wire Feeders

}

}Automatic Wire Feeders

Tractors

}

A-9

INSTALLATION

A-9

CONNECTION FOR AIR/CARBON ARC
CUTTING OPERATION

WARNING

THE OUTPUT TERMINALS ARE ENERGIZED AT
ALL TIMES WHEN THE IDEALARC DC-1000 IS
CONNECTED FOR AIR/CARBON ARC CUTTING.

____________________________________________________

1. Set ON/OFF PUSH BUTTON to OFF.

2. Locate and open the access door on the Front
Case Assembly.

3. If necessary, disconnect all wire feeder control
cable connections from the DC-1000 terminal
strip.

4. Remove the leads from the unit by pulling them
through and out of the strain relief box connector
(s).

5. Connect a jumper wire from terminal #2 to termi­nal #4 on the terminal strip.

6. Set the Welding Mode Switch to the CV(I) position
for air/carbon arc cutting.

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IDEALARC DC-1000

A-10

NOTES

A-10

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IDEALARC DC-1000

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

B-1

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IDEALARC DC-1000

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.

____________________________________________________

B-2

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 equip­ment. Observe all safety information throughout this
manual.

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IDEALARC DC-1000

B-3

OPERATION

B-3

GENERAL DESCRIPTION

The IDEALARC DC-1000 is an SCR-controlled, three
phase, welding and cutting power source. It uses a
single range potentiometer to control:

• Submerged Arc Semi-Automatic or Automatic
Welding

• Open Arc Semi-Automatic or Automatic Welding

• Air/Carbon Arc Cutting (Carbon Rod Sizes up to
5/8” [15.9 mm ] Diameter)

• With the addition of the 500 ampere output termi­nal on models code 9500 and above, GMAW pro­cedures can be performed.

The IDEALARC DC-1000 has a three-position
Welding Mode Switch to enable the user to operate in
one of three modes:

• Constant Voltage (CV) Innershield®

• Constant Voltage (CV) Submerged Arc

• Variable Voltage (VV) - Constant Current (CC)
Submerged Arc

The IDEALARC DC-1000 can be easily connected to
wire feeding equipment, including:

• Semi-automatic wire feeders LN-7, LN-8, and
LN-9

• Automatic wire feeders NA-3 and NA-5

• Tractors LT-56 and LT-7

RECOMMENDED PROCESSES AND
EQUIPMENT

The IDEALARC DC-1000 is recommended for the fol­lowing welding or cutting processes within its output
capacity of 140 amps to 1250 amps (625 amps at 500
amp output stud) in the Constant Voltage mode, and
140 amps to 1250 amps in the Variable Voltage
(Constant Current) mode:

• Submerged Arc Semi-Automatic or Automatic
Welding

• Open Arc Semi-Automatic or Automatic Welding

• Air/Carbon Arc Cutting (Carbon Rod Sizes up to
5/8” [15.9 mm] Diameter)

OPERA TIONAL FEATURES AND
CONTROLS

The IDEALARC DC-1000 comes with the following
standard controls:

• DOUBLE ON/OFF PUSH BUTTON (Main Power
and 115V Auxiliary)

• OUTPUT CONTROL POTENTIOMETER

• OUTPUT CONTROL SWITCH (Remote or
Machine Control)

• WELDING MODE SWITCH

• CONTROL CIRCUIT POLARITY SWITCH

• POWER SOURCE PILOT LIGHT

• DC AMMETER (OPTIONAL)

• DC VOLTMETER (OPTIONAL)

DESIGN FEATURES AND
ADVANTAGES

The following list of design features will help you
understand the machine’s total capabilities and how
you can take advantage of them to get maximum use
of your machine.

• Excellent arc characteristics for optimum constant
voltage submerged arc and Innershield® welding
performance.

• A control circuit designed to provide good starting
for a large variety of processes and procedures.

• Output Control Potentiometer that provides easy
single range continuous control.

• Output Control Switch that provides simple switch­ing from local to remote control.

• Red neon pilot light to confirm that the Input
Contactor is energized.

• Auxiliary power source to provide 115-volt AC
power (1000 VA) to wire feeding equipment.

• Multi-functional terminal strip for easy connection
of wire feeding control cables and switching
between CV Innershield® and CV Submerged Arc
welding when using the Dual Process or Dual
Procedure Kits.

• Recessed output terminals to help prevent any
person or object from accidentally coming into
contact with the output current. These terminals
are prominently labeled positive and negative for
easy identification.

• Thermostatically protected power source.

• Electronic protection circuit to protect power
source against overloads.

• Input line voltage compensation to provide an
essentially constant output.

• SCR electronically controlled welder output pro­vides extra long life, especially for highly repetitive
welding applications.

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IDEALARC DC-1000

B-4

OPERATION

B-4

• Three circuit solid state control system provides
maximum performance and circuit protection.

• Low profile case provides maximum use of space.

• Convenient access to all controls.

• Large output lead strain relief openings to prevent
terminal and cable damage.

• Easily removed case side, even when stacked.

• Enclosure designed with air intake louvers that
keep dripping water from entering the unit, allow­ing outdoor operation. Transformer, SCR bridge,
and choke have special corrosion resistant paint
for added protection.

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

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IDEALARC DC-1000

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.

B-5

FIGURE B.1 - Control Panel Keys

1. ON/OFF PUSH BUTTON: This push button turns

the machine ON or OFF

2. OUTPUT CONTROL POTENTIOMETER: This
control provides tapered, continuous control of the
machine output. The control can be rotated from
minimum to maximum while machine is under
load to adjust the machine output.

3. WELDING MODE SWITCH: This toggle switch is
used to select the proper welder performance
characteristics for the process being used. There
are three modes: CV (Constant Voltage)
Innershield®, CV (Constant Voltage) Submerged
Arc, and VV (Variable Voltage) CC (Constant
Current) Submerged Arc.

4. OUTPUT CONTROL SWITCH: This toggle switch
is used to switch between “Output Control at DC­1000” for local control of machine output and
“Output Control Remote” for remote control of
machine output.

5. CONTROL CIRCUIT POLARITY SWITCH: This
toggle switch is used to set power source voltage
sensing polarity to match the polarity to which the
electrode is connected to the machine. This pro­vides the correct polarity at the terminal strip for
correct operation of the automatic wire feeding
equipment powered by the auxiliary power from
the power source.

6. POWER SOURCE PILOT LIGHT: The red neon
light glows when the power source input contactor
is energized.

7. VOLTMETER: An optional voltmeter is available.

8. AMMETER: An optional ammeter is available.

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IDEALARC - DC 1000

B-6

OPERATION

B-6

OPERATING STEPS

The following procedures are for using the IDEALARC
DC-1000 in the local control mode of operation. For
remote control of the machine, see the Remote
Control of Machine Operation section.

Before operating the machine, make sure you have all
materials needed to complete the job. Be sure you are
familiar with, and have taken all possible safety pre­cautions before starting work. It is important that you
follow these operating steps each time you use the
machine.

1. Turn on the main AC power supply to the
machine.

2. Set the CONTROL CIRCUIT POLARITY SWITCH
to the appropriate position.

- Set toggle to “Electrode Negative” position if the

electrode is connected to the negative (-) output
terminal.

- Set toggle to “Electrode Positive” position if the

electrode is connected to the positive (+) output
terminal.

3. Set the WELDING MODE SWITCH to welding
process being used.

- CV Innershield®

- CV Submerged Arc

- VV (CC)

WELDING PROCEDURE
RECOMMENDATIONS

Select Welding Mode Switch position based on type of
welding to be done.

1 Innershield® Welding/Other Open Arc Processes:

Use the CV Innershield® mode.

2. Submerged Arc Welding: Use the CV Submerged
Arc mode. If performing high speed welding,
switch between the CV Submerged Arc and the
CV Innershield® mode and use the mode that
produces the best welding results. High Current,
Large Puddle Submerged Arc Welding: Use the
VV (CC) mode.

3. When the IDEALARC DC-1000 is used for
Air/Carbon Arc cutting, use the CV (I) mode and
initially set the OUTPUT CONTROL POTEN­TIOMETER to “9”. Based on the size of the car­bon being used, turn the potentiometer to a lower
setting as required to obtain the best results. You
can use carbon rods up to 5/8” (15.9 mm) in diam­eter. The welder protection circuit protects the
machine from extremely high short circuiting puls­es.

SEMI-AUTOMATIC AND
AUTOMATIC WIRE FEEDING WITH
IDEALARC DC-1000 AND WIRE
FEEDERS

4. Push the ON/OFF PUSH BUTTON to the ON
position.

- The red neon light glows.

- The fan starts.

5. Set Output Control Potentiometer to desired volt­age or current.

6. Make the weld (NOTE: Terminal #2 and #4 must
be connected together to energize the machine
output).

REMOTE CONTROL OF MACHINE
OPERATION

The toggle switch on the control panel labeled “Output
Control at DC-1000” - “Output Control Remote” gives
the operator the option of controlling the machine out­put from a remote location. If in the Remote position, a
wire feeder with remote control capabilities or a
remote control device such as a K775, must be con­nected to terminals #75, #76, and #77 to operate.
Refer to
information.

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Accessories

NA-3 AUTOMATIC WIRE FEEDER

1. Set the DC-1000 Output Control Switch to
Remote.

NOTE: Later model NA-3 automatic wire feeders are
capable of cold starts when the NA-3 Mode switch is
in the CV or VV (CC) mode position. Some earlier
models are capable of cold starting only in the VV
(CC) mode position. Cold starting enables you to
inch the wire down to the work, automatically stop,
and automatically energize the flux hopper valve.

2. Set the DC-1000 welding mode switch for the
desired process: CV Submerged Arc, CV
Innershield® mode or VV (CC) mode.

3. Set the NA-3 mode Switch Position to either CV or
VV (CC) to match the DC-1000 mode selected in
step 2.

4. Refer to the NA-3 operators manual for instruc­tions on how to use the NA-3 in conjunction with
the DC-1000.

Section for wire feeder remote

5. Follow the following guidelines for good arc strik­ing detailed below for each welding mode.

IDEALARC DC-1000

B-7

OPERATION

B-7

GOOD ARC STRIKING GUIDELINES FOR THE
NA-3 WITH THE IDEALARC DC-1000 IN THE CV
INNERSHIELD®, CV SUBMERGED ARC OR VV
(CC) WELDING MODES.

Following are some basic arc striking techniques that
apply to all wire feed processes. Using these proce­dures should provide trouble-free starting. These pro­cedures apply to single, solid wires and Innershield®
wires.

1. Cut the electrode to a sharp point.

2. Set the NA-3 Open Circuit Voltage Control to the
same dial setting as the Arc Voltage Control. If
this is a new welding procedure, a good starting
point is to set the Open Circuit Voltage Control to
#6.

NOTE: The open circuit voltage of the IDEALARC
DC-1000 varies from approximately 25 volts to 75
volts in the CV Innershield or CV Submerged Arc
modes. The open circuit voltage is constant in the
VV (CC) mode.

3. Run a test weld. Set proper current, voltage, and
travel speed.

a. For the best starting performance, the

NA-3 Open Circuit Voltage Control and
Voltage Control setting should be the
same. Set the Inch Speed Control for the
slowest inch speed possible.

b. To adjust the Open Circuit Voltage Control

to get the best starting performance, make
repeated starts observing the NA-3 volt­meter.

When the voltmeter pointer swings smoothly up to the
desired arc voltage, without undershooting or over­shooting the desired arc voltage, the Open Circuit
Voltage Control is set properly.

If the voltmeter pointer overshoots the desired voltage
and then returns back to the desired voltage, the
Open Circuit Voltage Control is set too high. This can
result in a bad start where the wire tends to “Blast off.”

If the voltmeter pointer hesitates before coming up to
the desired voltage, the Open Circuit Voltage Control
is set too low. This can cause the electrode to stub.

4. Start and make the weld.

a. Cold starts. For cold starts, be sure the

work piece is clean and the electrode
makes positive contact with the work
piece.

b. Hot “On the Fly” starts. For hot starts, trav-

el should begin before the wire contacts

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the work piece.

ARC STRIKING WITH IDEALARC DC-1000 AND
THE NA-3 START BOARD

When electrical strikeouts exceed 1 3/4” (44.4 mm) an
NA-3 Start Board may be required to improve arc
striking. When the NA-3 Start Board is used to
improve arc striking, use the following procedures:

1. Set start time at 0.

2. Set NA-3 start current and start voltage at mid
range.

3. Set the NA-3 output current and voltage to the
proper settings for the welding procedure to be
used.

4. Turn the Start Board Timer to maximum.

5. Set Start Board current and voltage control.

a. Set the Start Board current control to 1-

1/2 dial numbers below that set on the
NA-3 current control.

b. Set the Start Board voltage control equal

with the NA-3 voltage control setting

NOTE: These Start Board current and voltage set­tings result in a start-up current that is lower than
the NA-3 current setting and approximately equal
with the NA-3 voltage setting for the desired weld­ing procedure.

6. Establish the correct arc striking procedure with
the NA-3 Start Board timer set at maximum.

a. For the best starting performance, the

NA-3 Open Circuit Voltage Control and
Voltage Control setting should be the
same. Set the Inch Speed Control for the
slowest inch speed possible.

b. To adjust the Open Circuit Voltage Control

to get the best starting performance, make
repeated starts observing the NA-3 volt­meter.

When the voltmeter pointer swings smoothly up to the
desired arc voltage, without undershooting or over­shooting the desired arc voltage, the Open Circuit
Voltage Control is set properly.

If the voltmeter pointer overshoots the desired voltage
and then returns back to the desired voltage, the
Open Circuit Voltage Control is set too high. This can
result in a bad start where the wire tends to “Blast off.”

If the voltmeter pointer hesitates before coming up to
the desired voltage, the Open Circuit Voltage Control
is set too low. This can cause the electrode to stub.

IDEALARC DC-1000

B-8

OPERATION

B-8

c. Set NA-3 Start Board current and voltage

as close to the welding procedure current
and voltage as possible.

NOTE: The Start Board current and volt­age should be as close as possible to the
welding procedure current and voltage,
while still getting satisfactory starts.

d. Set the start time to as low a time as possi-

ble while still getting satisfactory starts.

7. Start and make the weld.

IDEALARC DC-1000 POWER SOURCE
SETTING WHEN CONNECTED TO NA-5
AUTOMATIC WIRE FEEDER

When using the IDEALARC DC-1000 with the NA-5
automatic wire feeder, set the controls on the IDE­ALARC DC-1000 as follows for the best performance:

1. Turn OFF main AC input power supply to the IDE­ALARC DC-1000.

2. Connect the electrode cables to terminal
polarity to be used.

3. Set the CONTROL CIRCUIT POLARITY SWITCH
to the same polarity as the electrode cable con­nection.

4. Set the OUTPUT CONTROL SWITCH to
REMOTE.

5. Set the IDEALARC DC-1000 WELDING MODE
SWITCH to the position that matches the welding
process being used.

a. For submerged arc welding, set WELDING

MODE SWITCH TO CV SUBMERGED
ARC position.

b. For all open arc welding processes set

WELDING MODE SWITCH TO CV
INNERSHIELD® position.

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.

LN-8 SEMI-AUTOMATIC WIRE FEEDER

To use the LN-8 Semi-Automatic Wire Feeder with
IDEALARC DC-1000

1. Set the IDEALARC DC-1000 WELDING MODE
SWITCH to either CV Innershield® mode or CV
Submerged Arc mode depending on the welding
process being used.

2. Set the IDEALARC DC-1000 OUTPUT CONTROL
SWITCH to the REMOTE position.

3. Set the LN-8 Welding Mode Switch to the CV
position. The LN-8 Welding Mode Switch is locat­ed on the variable voltage VV (CC) board.

4. Refer to the LN-8 Operator’s Manual for instruc­tions on how to use the LN-8.

LN-7 AND LN-9 SEMI-AUTOMATIC WIRE
FEEDERS OR OTHER CONSTANT WIRE
FEEDERS

To use the LN-7, LN-9, or other constant wire feed
speed semi-automatic wire feeders with IDEALARC
DC-1000

1. Set the IDEALARC DC-1000 WELDING MODE
SWITCH to either CV Innershield® mode or CV
Submerged Arc mode depending on the welding
process being used.

NOTE: These semi-automatic wire feeders cannot be
used in the VV (CC) mode.

2. Set the IDEALARC DC-1000 OUTPUT CONTROL
SWITCH.

a. LN-7: Use either an optional K775 Remote

Control Box Assembly or set the IDE­ALARC DC-1000 OUTPUT CONTROL
SWITCH in the Local position.

b. LN-9: Refer to the LN-9 Operator’s Manual

for instructions on how to use the LN-9.

7. Refer to NA-5 Operator’s Manual for instructions
on how to use the NA-5.

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IDEALARC DC-1000

C-1

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

C-1

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IDEALARC DC-1000

C-2

ACCESSORIES

C-2

OPTIONS/ACCESSORIES

• Remote Control Box Assembly (K775)

• LN-7

• LN-8 }Semi-Automatic Wire Feeders

• LN-9

• NA-3

• NA-5

• LT-7 and LT-56 Tractors

METERS

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 con­nects to terminals #75, #76, #77 on the terminal strip,
and the case grounding screw marked with the sym­bol 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.

}

Automatic Wire Feeders

CONNECTING THE NA-3 OR LT-7 TO
IDEALARC DC-1000

1. Disconnect main AC input power to the IDE­ALARC DC-1000.

2. Set IDEALARC DC-1000 ON/OFF PUSH BUT­TON to OFF.

3. Connect the wire feeder control cable leads to the
IDEALARC DC-1000 terminal strip as shown in
Figure C.1.

CONNECTIONS FOR SEMI-AUTO­MATIC 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.

3. Insert control cable through the strain relief box
connector and pull enough cable through to reach
the terminal strip.

4. Connect the automatic wire feeder control cable to
the terminal strip. See corresponding connection
diagram in this section of the manual, or the
instructions included with the wire feeder.

5. Connect the wire feeder grounding wire to the
chassis ground screw marked with the symbol .

NOTE: The IDEALARC DC-1000 Auxiliary Power
Circuit (at #31 and #32 on the terminal strip) supplies
115-volt AC power to the wire feeding equipment. The
circuit has a 1000 volt ampere rating. An 8-amp slow
blow fuse on the machine’s control panel protects the
auxiliary power supply from excessive overloads or
short circuits.

FIGURE C.1 - NA-3 or LT-7 Wire Feeder
Connection to the IDEALARC DC-1000

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

CAUTION

The IDEALARC DC-1000 must be properly grounded.

____________________________________________________

5. Extend wire feeder control cable lead #21 so it
can be connected directly to the work piece.

a. Make a bolted connection using AWG #14

or larger insulated wire.

b. Tape the bolted connection with insulating

tape.

NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.

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c. Keep the #21 lead electrically separate

from the work cable circuit and connection.

IDEALARC DC-1000

C-3

ACCESSORIES

C-3

d. Tape the #21 lead to work cable for ease

of use.

6. Connect the welding cables as shown in Figure
C.1.

NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.

NOTE: The connection diagram shown in Figure C.1
shows the electrode connected for positive polarity.
To 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 NEGA­TIVE.

e. Reverse the leads at the back of the

ammeter and voltmeter on the wire feeder
automatic control box.

CONNECTING THE NA-5 TO THE
IDEALARC DC-1000

5. Extend wire feeder control cable lead #21 so it
can be connected directly to the work piece.

a. Make a bolted connection using AWG #14

or larger insulated wire.

b. Tape the bolted connection with insulating

tape.

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.

d. Tape the #21 lead to work cable for ease

of use.

6. Connect NA-5 wire feeder control jumpers on the
Voltage Control Board. See NA-5 Operator’s
Manual.

a. Connect red jumper on Voltage Control

Board to pin “S.”

b. Connect white jumper on Voltage Control

Board to pin “B.”

7. Connect the welding cables as shown in Figure
C.2.

NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.

NOTE: For optimum performance, use the NA-5 with
IDEALARC DC-1000 codes

1. Disconnect main AC input power to the IDE­ALARC DC-1000.

2. Set the IDEALARC DC-1000 ON/OFF PUSH
BUTTON to OFF.

3. Connect the wire feeder control cable leads to the
IDEALARC DC-1000 terminal strip as shown in
Figure C.2.

NOTE: If using a K215 control cable, connect con­trol cable leads #75 to #75 on the terminal strip,
#76 to #74 on the terminal strip, and #77 to #73
on the terminal strip.

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

8288

and above.

CAUTION

The IDEALARC DC-1000 must be properly grounded.

____________________________________________________

FIGURE C.2 - NA-5 Wire Feeder Connection to

the IDEALARC DC-1000

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IDEALARC DC-1000

C-4

NOTE: The connection diagram shown in Figure C.2
shows the electrode connected for positive polarity.
To change polarity:

a. Set the IDEALARC DC-1000 ON/OFF

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 NEGA­TIVE.

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.

ACCESSORIES

CONNECTING THE LN-8 TO THE
IDEALARC DC-1000

1. Set the ON/OFF PUSH BUTTON to the OFF pos­tion.

2. Disconnect AC input power to the IDEALARC DC-

1000.

3. Connect the wire feeder control cable leads to the
DC-1000 terminal strip. See Figure C.3.

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

CAUTION

C-4

FIGURE C.3 - LN-8 Wire Feeder Connection

to the IDEALARC DC-1000

6. Connect lead #75(A) to #75 on the terminal strip.

7. Connect lead #76(B) to #76 on the terminal strip.

8. Connect lead #77(C) to #77 on the terminal strip.

9. Connect the welding cables as shown in Figure
C.3.

NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.

10. Set the DC-1000 output control switch to the
”Output Control Remote” position.

The IDEALARC DC-1000 must be properly grounded.

____________________________________________________

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

b. Tape the bolted connection with insulating

NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.

c. Keep the #21 lead electrically separate

d. Tape the #21 lead to the work cable for

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or larger insulated wire.

tape.

from the work cable circuit and connection.

ease of use.

IDEALARC DC-1000

NOTE: The connection diagram shown in figure C-3
shows electrode connected positive. 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 NEGA­TIVE.

e. Refer to LN-8 operator’s manual for proper

control box polarity connections.

C-5

ACCESSORIES

CONNECTING THE LN-9 WIRE FEEDER
TO THE IDEALARC DC-1000

1. Set the ON/OFF PUSH BUTTON to the OFF pos­tion.

2. Disconnect AC input power to the IDEALARC DC-

1000.

3. Connect the wire feeder control cable leads to the
DC-1000 terminal strip. See Figure C.4.

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

CAUTION

The IDEALARC DC-1000 must be properly grounded.

____________________________________________________

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

or larger insulated wire.

b. Tape the bolted connection with insulating

tape.

NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.

c. Keep the #21 lead elecrically separate

from the work cable circuit and connection.

d. Tape the #21 lead to the work cable for

ease of use.

6. Connect lead #75(A) to #75 on the terminal strip.

7. Connect lead #76(B) to #74 on the terminal strip.

8. Connect lead #77(C) to #73 on the terminal strip.

9. Connect the welding cables as shown in Figure
C.4.

Note: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.

C-5

FIGURE C.4 - LN-9 Wire Feeder Connection

to the IDEALARC DC-1000

11. Set the DC-1000 output control switch to the
”Output Control Remote” position.

NOTE: The connection diagram shown in figure C-4
shows electrode connected for positive polarity. 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. Position the positive-negative switch on

the power source to correspond to the
polarity of the electrode cable connection.

e. Refer to LN-9 operating manual for

required polarity connections.

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”.

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IDEALARC DC-1000

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.

2. Disconnect main AC input power to the IDE­ALARC DC-1000.

3 Connect the wire feeder control cable leads to the

IDEALARC DC-1000 terminal strip as shown in
Figure C.5.

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

CAUTION

The IDEALARC DC-1000 must be properly grounded.

____________________________________________________

5. PERFORM THIS STEP ONLY IF THE LN-7 IS
EQUIPPED WITH A METER KIT.

C-6

Extend wire feeder control cable lead #21 so it can be
connected directly to the work piece.

a. Make a bolted connection using AWG #14

or larger insulated wire.

b. Tape the bolted connection with insulating

tape.

NOTE: If the work cable length is less than 25 feet
and the connections to the work piece are secure,
then wire feeder control cable lead #21 can be con­nected directly to the DC-1000 terminal strip.

NOTE: An S-16586-X remote voltage sensing work
lead is available for this purpose.

b. Keep the #21 lead electrically separate

from the work cable circuit and connection.

c. Tape the #21 lead to work cable for ease

of use.

6. Connect the welding cables as shown in Figure
C.5.

FIGURE C.5 - LN-7 Wire Feeder Connection to

the IDEALARC DC-1000

NOTE: Welding cables must be of proper capacity for
the current and duty cycle for immediate and future
applications.

NOTE: The connection diagram shown in Figure C.5
shows the electrode connected for positive polarity.
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

POLARITY SWITCH to NEGATIVE.

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IDEALARC DC-1000