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Lincoln Electric IDEALARC IM420-D User's Manual

1. OL F 6 89LL 18911 53809 HOS 0001 94 94V Vagdi NVHOVIQ ONIHIM IDEALARC DC 1000 LINCOLN E NOTES IDEALARC DC 1000 LINCOLN 8 NOTES IDEALARC DC 1000 LINCOLN 8 NOTES IDEALARC DC 1000 LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e solieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas electro dos com a pele ou roupa molhada sole se da pe a e terra e E PORTED iAH E Z7 bnfdcolntuect 27 ATUSHRELTFEL oR RRERXMUTD SMEER4XR CRA CRM NI HER ATAH 2452 Je 84 xc BSS uu 9 AXE BAZI OAR gay Quali Y pad slay ay g sit outils dan DE dus ule Y jo Keep flammable materials away Mantenga el material combustible fuer
2. SLTOA Q3193NNOO NMOHS TANVd LONI 3 dlH L HO SLIOA 08 57100 AHVWIHd O DIAGRAMS 2 JlOH1NOO AIddns H3MOd OL HOL 3009 OL 71V91419313 TVNOLLVN LOL Yad OL MOT 1 NMOHS LAdNI SDVLIOA 34 T9NIS Alddns H3MOd 3SvHd OL oe 2009 3814 7WOIH1O3 13 LNdLNO WNIWHAL H31N39 OL F 5 VEELL EEELL 1220 SOELL E6ZOL 9266 6166 53002 0001 94 IDEALARC DC 1000 LINCOLN E Jequinu epoo jueuidinbo e 104 jueuriedog eu O M si 9U JI sjieued y JO euo uo y episul LL poised s epoo 104 urejBeip 9 99 jenueuwu Aq 104 eq jou y 104 S SIUL 310 1 80061 E 0000 2000 aN o 46913 Yad STOSWAS 1V2I
3. T 5 yyyyyy in LL OL Y NY Y HOS Q3103NNOO NMOHS TANVd LONI ADVLIOA 41dIHL HO SLIOA 08 _ S109 AHVNIHd OL Qquvog od TOHLNOD 1 AlddNs 6 8 HAMOd L DIAGRAMS HANHOASNVEL NOY IS 4IVLSOWYSHL LVLSOWYSHL ASVHd OL SOHO AHVONO93S oTo 282 ots asz 3009 7IVOIHLO3 T3 TVNOLLVN zLOL Yad OL 8 ETA MOT Q3193NNOO NMOHS TANVd LAdNI ADVLIOA HO 3 19NIS ex 1 eic Lez 22 SS IMS s1109 gez Adans Le N r 3015 baie ta an 8 nt jT uz MS 7 b 886 ga de gez 1 4313W 3009 7 3813 NO 1 01 10313 TVNOLLVN JOYLNOD 7 VNINH3L HALN39
4. Faulty input contactor 1CR 2 Low line voltage Faulty 2CR relay Supply line fuse blown Contactor power circuit dead Broken power lead Wrong input voltage Secondary or choke thermostat open Open input contactor coil Faulty stop start push button switch Faulty 2CR relay Defective control board Defective start stop push button Defective 1CR interlock Ground fault between control termi nals 73 74 75 76 or 77 and nega tive output terminal Short on output terminals with 2 4 jumpered Defective control board Electrode or work lead loose or bro ken Open main transformer T1 primary or secondary circuit Output pilot relay 4CR not operating or faulty Firing circuit P C board not connect ed or is faulty If using 500 amp stud choke circuit may be open Repair or replace 2 Check input power Repair relay Replace if blown look for reason first Check pilot transformer T2 and asso ciated leads Check input voltage at contactor Check voltage against instructions Check for overheating make sure fan is operating and there is no obstruc tion to free air flow Replace faulty thermostat Replace coil Replace switch Replace relay Replace control board See P C board troubleshooting guide Check and replace if necessary Repair or replace Check 73 74 75 76 or 77 for grou
5. It can then be manually restarted by operating the start push button The power source is also protected against heavy overloads on the SCR bridge assembly through an electronic protection circuit This circuit senses an overload on the power source and opens the input contactor should the overload remain for a predeter mined time The predetermined time varies with the amount of overload the greater the overload the shorter the time The input contactor will remain open until the power source is manually started with the start push button The control board is designed with adequate protec tion so that no damage will occur if the remote control leads are shorted together or are grounded to the case The machine will automatically shut down if such faults do occur An 8 amp fuse located on the machine control panel protects the 115 volt auxiliary AC circuit 31 and 32 from overload If replacing use the same type and size fuse IDEALARC DC 1000 LINCOLN 5 E TROUBLESHOOTING xi 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 This Troubleshooting Guide is prov
6. 1 7OHLINOO 1OHINO9 GAMAN ma NOIL9310Hd LINVA HOZ HOLOVINO9 1ndNI ao Dd maces S JO OL SLOANNOO 3HOH9 SNIGT3M INSHHNO MOT SNiHId Ol 4 QV31 V SI HOZ 41 155 SY NMOHS SI Hz Gane NN TI Sova131v9 99 KINO SDVLIOA STAGON NV SHV3ddV NOLLO3NNOO SNOLLOnHISNI NO M 0S WHO OL SNOLLONYLSNI NOLLO3NNOO ATddNS LNdNI 33S M 00 WHO 0 ZH 39VL1OA LNdNI NO vH HO EH ZH OL SNOLLO3NNOO O N HIIJWOHUNdIOd WHO LH S3NIHOVW SOLVIOA ISNA MOIS di 8 14 D 3QOW SNIQTJM 5 indino NO 1N3S3Hd LON SNOLLO3NNOO 21 ANY OHLNO9 LNdINO EMS KINO S3NIHOVW 88 09 ALIHVIOd 300419373 ZMS LN3S3Hd SNOLLO3NNOO SL QNV PE H3MOd IMS SILON QN3931 19V110A Q3193NNO9 NMOHS ANSE 949 097 HO SLIOA 009 086 n uos 24 ry ole AlddNS ONIHIA OL H3MOd 108110 Savaialivo 008 N 3SVHd Od H388nNS 108110 TY B J inoo H ABVITIXNY LL OL am L 3009 1V91419313 TVNOLLVN OL SNIGNI O00000
7. LINES amp R amp H3 CONTROL TRANSFORMER LEADS INPUT TERMINALS AS SHOWN INSULATE THE UNUSED H2 amp Hi LEAD TERMINALS WITH ADEQUATE TAPE TO PROVIDE AT LEAST 600 V INSULATION CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRICAL CODE CONNECTION FOR 220 VOLTS 50 Hz 230V 60 Hz ON RECONNECT PANEL LOOSEN ALL HEX BOLTS PULL BACK MOVABLE LINKS AND ROTATE LINKS TO THEIR MEM POSITIONS POSITION EACH LINK BETWEEN THE WIRE TERMINAL AND HEX BOLT PUSH THE LINK OMPLETELY FORWARD SECURELY TIGHTEN ALL HEX BOLTS DO NOT REMOVE HEX BOLTS AT ANY TIME CONNECT 11 12 5 L3 INPUT SUPPLY LINES amp H2 CONTROL TRANSFORMER LEADS TO INPUT TERMINALS AS SHOWN INSULATE THE UNUSED H3 amp Hh LEAD TERMINALS WITH ADEQUATE TAPE TO PROVIDE AT LEAST 600 V INSULATION CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRICAL CODE LINK POSITIONS lt MOVABLE LINK POSITIONS INDICATED p BY ARROWED LINE 14358 FIGURE 3 INPUT CONNECTION DIAGRAM WARNING All Input power must be electrically disconnected before touching panel high voltage Movable Reconnect e Reconnect Input L2 Panel panel Lines Stationary Reconnect Stationary Reconnect Panel Panel 1 Mount the MERKEN reconnect panel to the 1 Mount the movable reconnect panel center set stationary reconnect panel studs In the of holes to the stationary reconnect nanel in position shown and secure firmly wi
8. S16889 8 2 90F NH Above diagram shows electrode connected positive To change N J 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 N K control box polarity connections N L Welding cables must be of proper capacity for the cur rent and duty cycle of immediate and future applica tions 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 Tape up bolted connection Connect the NA 5 control cable ground lead to the frame terminal marked 7 near the power source ter minal strip The power source must be properly ground ed If using an older automatic control cable with leads 75 76 77 Connect lead 75 to 75 on terminal strip con nect lead 76 to 74 on terminal strip connect lead 77 to 73 on terminal strip Connect the jumpers on the NA 5 voltage board as fol lows Connect RED jumper to pin S Connect WHITE jumper to pin Set the DC 1000 or DC 1500 controls as follows Set the c
9. controls dures 2 Poor electrode or work connection Repair connections 3 3CR reed switch inoperative Check reed switch voltage leads 216 to 220 Idle voltage is about 8V when welding voltage must go to zero 4 Faulty control board Replace See P C board trou bleshooting guide Poor bead shape or erratic arc on CV S 1 Improper procedures See instruction manual and proce Sub Arc dures 2 Defective 3CR reed switch Check reed switch per item c of pre vious Table above 3 Faulty control board Replace See P C board trou PE guide 4 Defective main SCR bridge Check and replace if defective Poor starting on CV I Innershield and Defective 3CR reed switch Replace CV S Sub Arc 3 Faulty control board Replace Poor arc characteristics on CV I Mode switch in CV S Sub Arc mode 1 Place mode switch CV I Innershield or other open arc processes Innershield mode 2 Defective main SCR bridge 2 Check and replace if defective Poor arc characteristics on all process 11 Defective control board Check and replace if defective See es P C board troubleshooting guide 2 Defective firing board Check and replace if defective See P C board troubleshooting guide 3 Defective main SCR bridge Check and replace if defective Poor performance including arc out 1 Insufficient output inductance Use the 500 amp output stud ages while welding at low current less than 450 am
10. i i i i N C ELECTRODE CABLE TO LN 7 CONDUCTOR BLOCK 8 2 90F ie WORK 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 N A N B N C N D N E N F Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications 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 Tape up bolted connection Connect the control cable ground lead to the frame terminal marked 77 7 near the power source terminal strip The power Source must be properly grounded Terminal strip for remote voltage control pot when used Alternative 500 amp positive terminal connection provided on DC 1000 models above code 9500 only CONNECTION OF DC 1000 TO LN 9 N F SN TO LN 9 INPUT CAB
11. IF YES IF NO POSSIBLE e D DA N CHECK GATE LEAD CHECK LIGHTS CONNECTIONS 7 8 9 TO SCR S IF ONE IF ON AND OR MORE OTHER LIGHTS ARE OUT ARE OUT MACHINE HAS OUTPUT Jumper 2 4 BUT TRIPS CHECK AC INPUT CEPINMERINTELY TO BOARD REPLACE 203 204 205 206 FIRING 207 208 POSSIBLE BOARD CHECK FOR SHORT CHECK LEADS DEFECTIVE BETWEEN ELECTRODE AND 73 74 75 76 77 FOR AUXILIARY WORK LEADS REMOVE GROUND TO WINDINGS ON MAIN EXTERNAL LEADS FROM NEGATIVE OUTPUT TRANSFORMER THE OUTPUT TERMINALS TERMINAL CHECK FOR OPEN IN LEADS 203 204 205 206 207 208 ERRATIC WELDING IF TROUBLE STILL PERSISTS CHECK LED 3 ON HECK PROCEDURE CONTROL BOARD CHECK PROCEDU CHECK MODE SWITCH FOR PROPER POSITION FOR IF LIGHT GOES ON THEN PROCESS BEING USED QUICKLY OUT WHEN START BUTTON IS PRESSED CHECK LED S 1 THRU 6 FOR EQUAL BRILLIANCY CONTROL BOARD IS DEFECTIVE AND SHOULD IF LIGHTS ARE NOT ALL APPROXIMATELY EQUALLY BE REPLACED BRIGHT REPLACE FIRING P C BOARD 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 LINCOLN F 1 DIAGRAMS F 1 CONNECTION OF DC 1000 WITH NL OPTION KIT TO LAF 3 Obsolete POWER SOURCE 67 21 4 2 31 32 ur NEGATIVE M13321 8 2
12. N C Tape up bolted connection N D Alternative 500 amp positive terminal connection provided ELECTRODE CABLE TO WIRE FEED UNIT on DC 1000 models above code 9500 only Above diagram shows electrode connected positive To change p WORK 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 IDEALARC DC 1000 LINCOLN F 2 DIAGRAMS F 2 CONNECTION OF DC 1000 WITH NL OPTION KIT TO LT 3 or LT 34 Obsolete 35 VOLT CONTROL EXCITER 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 DC LT 3 REMOTE DC CONTROL BOLT amp TAPE 7 CONNECTIONS X D E SPARE UP SPARE LEADS NOT USED 5 atrazag 4455 58 61 ELECTRODE CABLE AUTOMATIC EQUIPMENT N C Terminals 73 amp 74 not present on earlier DC 1500 s N D Alternative 500 amp positive terminal connection provided on DC 1000 models above code 9500 only This diagram shows the electrode connect ed positive To change polarity turn power Source
13. be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 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 Also see item 1 b Jan 09 SAFETY gt 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 Remember that welding sparks and hot 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 WELDING and CUTTING 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 fo
14. eyu wes ra o cen k Tuc b k GU Hu SES tros ane a CU P 146 Series A 1 INSTALLATION A TECHNICAL SPECIFICATIONS DC 1000 INPUT THREE PHASE ONLY Standard Input Current at Rated Output Voltage 100 Duty Cycle 60 Duty Cycle 50 Duty Cycle 230 460 60 193 96 5 215 108 230 115 575 60 77 2 86 92 220 380 440 50 60 193 112 96 5 215 124 108 230 133 115 380 500 50 60 112 85 124 94 133 101 415 50 60 102 113 RATED OUTPUT Duty Cycle S Volts at Rated Amperes 10096 Duty Cycle 6096 Duty Cycle 5096 Duty Cycle OUTPUT Output Range Maximum Open Circuit Voltage Auxiliary Power 75V for 60 HZ models See the OPERATION section 150A 16V 1300A 46V ANSE 72 for 50 60 HZ models for Auxiliary Power information by model RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT INPUT AMPERE VOLTAGE RATING ON SUPER LAG FREQUENCY NAMEPLATE OR BREAKER HEIGHT WEIGHT 30 75 in 25 i 0 i 821 Ibs 781mm 372 kg 1Also 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 IDEALARC DC 1000 LINCOLN 5 we 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 disconnect switch or fuse box before working on this equipment Turn o
15. grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction
16. 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 connec tion diagram on the terminal strip at the front of the machine For control at the machine control panel the toggle switch is set in the Output Control at DC 1000 position IDEALARC DC 1000 LINCOLN 5 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 77 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 same control as the output control on the machine Mode Switch The toggle switch labeled C 1 Innershield CV S Submerged Arc CC or Variable Voltage is used to select the proper welder characteristics for 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 a Use the CV I mode fo
17. off reverse the electrode and work leads at the power source and position the NL OPTION __ CONNECT THE RED LEAD TO TERMINAL 22 K 775 REMOTE CONTROL gt MOUNTED AT TRACTOR TO LT 3 TRACTOR CONTROL BOX M13322 8 2 90F Contactor drop out delay switch on the NL Option Kit must be in the position The 4 0 cables shown will handle up to 1000 amps at 8096 duty cycle For higher currents or duty cycle add additional cables to the power source output studs 1000 s switch on the power source and NL Option Kit to the proper polarity Also reverse the leads on the back of the ammeter and volt meter in the LT 3 control box CONNECTION OF DC 1000 OR DC 1500 to NA 3 LT 5 or LT 7 Connect the control cable ground lead to the frame terminal marked rh near the power source terminal strip The power source must be properly grounded TO AUTOMATIC CONTROL BOX POWER SOURCE Fa T CONTROL CABLE EE A p Tps Li ii 1 RETTA o in If using an older control cable Connect lead 75 to 75 on termi nal strip connect lead 76 to 76 on terminal strip connect lead 77 to 77 on terminal strip N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications gt 00 GND N B Extend lead 21 using 14 or larger insulated wire physically 31 suitable for the installation An 516586
18. ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER id TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aid
19. pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas XJOA2 5 t tRQRUALTEX OARE IJ BOR RE ERE EVE Ro ezido sel HAE zia cals l l jlgall lin Jad Y cal gil Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURAN A DO EMPREGADOR J OVESR J lt BEZ LTRHOR MEITS gt TF SU ER XE JR JE t A9 DIR FE ER f li A SR RETARD Bd 0 SEA HU HA ZIYA ore BHC a lal galg a al gly oig qul gal agi ouais il LINCOLN 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
20. 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 WEB SITE at www lincolnelectric com Choose Quick Links and then 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 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 mino
21. remote voltage A sensing work lead is available for this purpose Connect it 21 directly to the work piece keeping it electrically separate from i 1 i 1 i i i 1 amp i N C i i 1 l 1 i 1 the welding work lead circuit and connection For nience this extended 21 lead should be taped to the weld r NEGATIVE n ing work lead ep G RE 7 Tape up bolted connection Mi ELECTRODE CABLE TO AUTOMATIGHEQUNEMENST N D Terminals 73 amp 74 not present on earlier DC 1500 N E Alternative 500 amp positive terminal connection provided on DC 1000 models above code 9500 only p WORK 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 IDEALARC DC 1000 LINCOLN ES DIAGRAMS F 3 CONNECTION OF DC 1000 to NA 5 N A N B ar TO NAS INPUT CABLE PLUG CONTROL CABLE N F i B i N D i i 32 i 31 i 2 i j 4 i a i 1 2 i i NEGATIVE POSITIVE 1 i o i i i E N B amp N C N D BOLT TO CABLES FROM NA 5 WIRE CONTACT ASSEMBLY joue TO WORK X N G N C amp N H
22. terminals Ly Lo and La of 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 LINCOLN 5 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 con nected 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 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 con nection diagrams for the following codes are listed below 1 For Single and Dual Voltage except 380 500 see Figure 1 517172 2 For 220 380 460 see Figure 2 M14358 3 For 380 500 s
23. the reconnect panel as shown Insulate unused H2 lead terminal with adequate tape to provide at least 600 volt insulation Connect terminal marked to ground per National Electrical Code 5 17172 IDEALARC DC 1000 LINCOLN 5 B INSTALLATION Bt FIGURE 2 Y INPUT SUPPLY CONNECTION DIAGRAM p WARNING ALL INPUT POWER MUST BE ELECTRICALLY DISCONNECTED BEFORE TOUCHING PANEL NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR HIGHEST VOLTAGE CONNECT ON FOR 440 VOLTS 50 Hz 460V 60 Hz N RECONNECT LOOSEN ALL HEX BOLTS PULL BACK MOVABLE LINKS AND ROTATE LINKS TO THEIR NEM POSITIONS POSITION EACH LINK BETWEEN THE WIRE TERMINAL AND HEX BOLT PUSH THE LINK COMPLETELY FORWARD SECURELY TIGHTEN ALL HEX BOLTS DO NOT REMOVE HEX BOLTS AT ANY TIME CONNECT LI L2 amp L3 INPUT SUPPLY LINES amp HI amp Hh CONTROL TRANSFORMER LEADS TO INPUT TERMINALS AS SHOWN INSULATE THE UNUSED H2 amp LEAD TERMINALS WITH ADEQUATE TO PROVIDE AT LEAST 600 V INSULATION CONNECT TERMINAL MARKED 0 GROUND PER NATIONAL ELECTRICAL CODE 5 LINK POSITIONS CONNECTION FOR 380 VOLTS 50 Hz 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 SECURELY TIGHTEN ALL HEX BOLTS DO NOT REMOVE HEX BOLTS AT ANY TIME CONNECT L1 L2 5 L3 INPUT SUPPLY
24. they fail Also see item 1 c 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 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 7 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from t
25. 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 weld ing the output terminals will be energized at all times TABLE 1 DC 1000 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable at 100 Duty Cycle ELECTRODE WORK AND 21 LEAD Cable Length Parallel Cables Cable Size Lengths up to 150 ft 46m 150 ft 46m to 200 ft 61m 200 ft 61m to 250 ft 76m 1 0 53mm IDEALARC DC 1000 LINCOLN 8 B OPERATION B 1 OPERATING INSTRUCTIONS A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be danger 3 ous Keep your head out of fumes X AR Use ventilation or exhaust to remove fumes from breathing zone A WELDING SPARKS can cause fire or TX X explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection 12 See additional warning information front of this operator s manual PRODUCT DESCRIPTION The D
26. 90F 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 equip ment N B On DC 1500 units below code 8234 this is 67 and the LAF 3 67 lead can be connected either to the 467 termi nal 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 ELECTRODE CABLE TO AUTOMATIC EQUIPMENT CONNECT THE RED LEAD TO 7 TERMINAL 22 N 35 VOLT CONTROL EXCITER K775 REMOTE CONTROL TT 9 WOUNTED AT LAF 3 64 2110 21323 TO LAF 3 CONTROL N D Alternative 500 amp positive terminal connection provided on DC 1000 models above code 9500 only This diagram shows the electrode connect ed 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 volt meter in the LAF 3 control box Contactor drop out delay switch on the NL Option Kit must be in the position RS TAPE UP LEADS NOTUSED 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 mak
27. C 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 DC 1000 models above code 9500 GMAW procedures can be performed This connection 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 NOTE 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 Negati
28. H10313 A D i 7 LO Tlld 1NdINO xog avg xog xog HOLIMS 0334 Q31VALLOV LNIJYYNO 14l1 OHINOO OHINOO L 2 e sr 1p er vr 9r quvoa 40 LN3NOdWOO WOH4 NOILO31OHd LINVS HOC ALIAVO HOLO3NNOO HOLOV INOO HOL 4 29 Ha WHOJSNVUL NOLVIOS L 4 6 HANHOISNVEL TOHLNOO ZL 995 HANHOASNVUL HAMOd NIV N LL MOS M 00 WHO 0 WHO MOL iH i ISNA MOTS dNV8 14 T 25 ON 9 YMS 108110 OHINO9 109170 EMS 0001 ll it ALINV10d 2004193713 ZMS H3MOd LNdNI LMS Ole SIZ ON3931 o Jg 1 l 1NnHS LNdLNO ji TE Od 11N9419 v 99 gr ONIHI4 912 S DASE GL 59 STAGOW TIY LON TN Fc 7 34 9 l9 A INO SANIHOVIN o div 008 31dIHL ANY NO SH V3ddV NOLLO3NNOO 24 SNOILONYLSNI NOLLO3NNOO AlddNS 1 33S NO tH HO EH ZH OL SNOLLO3NNOO O N S3NIHOVIN 39V L10A NO 1N3S3Hd LON SNOLLO3NNOO 21 LL OL SALON e TN OS DON 99056 Nes
29. LE PLUG CONTROL CABLE POWER SOURCE 173 74 75 76 Z oc w gt NEGATIVE POSITIVE N B amp N C ELECTRODE CABLE TO WIRE FEED UNIT 517185 8 2 90 TO WORK 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 B N C N D N E N F N G N H Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications 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 con nection 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 Tape up bolted connection Connect the LN 9 control cable ground lead to the frame terminal marked gt near the power source terminal strip The power Source must be p
30. RETURN TO MAIN MENU rere IDEALARC DC 1000 2010 ith hi having Code Numbers een 89919 9925 10293 11305 11330 11331 11332 11333 11334 11681 thru 11684 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful HK atate e RS SERRE P LL LL LL L GSI 2 ET OPERATOR S MANUAL uem e A C n ISO 9001 Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 Copyright O Lincoln Global Inc LINCOLN 5 ELECTRIC 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 4 Diesel engine exhaust some of its constituents The engine exhaust from this product contains are known to the State of California to ca
31. a del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos o CEU EA e 18 tJ 5 PA i ects 248 AIX nig Ole ALI al sU ala e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e B eA ei 119 A HZA dil s due Lily aday cl gal ga 5 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 ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from br
32. ake 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 bro ken 3 LEDS indicates power is being applied to fault pro tection pilot relay 2CR to turn on the input contac tor 4 LED4 indicates when overcurrent protection circuit is being activated 5 LEDS 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 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 1 Lights 7 8 and 9 indicate AC power being sup plied to the P C boards from T1 auxiliary winding If a light is not lit turn the machine off and unplug P5 from J5 on the firing P C board Turn the machine on and check the following voltages Light That Was Off Check AC Voltage Between Pins of Plug P5 Voltage Should Be Approx P5Pins2 amp 4 75 VAC Wires 203 204 P5 Pins 7 amp 3 75 VAC Wires 205 206 P5 Pins 9 amp 8 75 VAC Wires 207 208 If approximately 75 VAC 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 boa
33. allation 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 HEE IJ 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 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 connec tion diagram pasted to the inside of the access panel in the case back Have a qualified electrician remove the rear access panel and connect phase AC power to
34. ause the electrode to stub IDEALARC DC 1000 LINCOLN 5 ET INSTALLATION 3 NA 5 Set the DC 1000 mode switch to the process being used 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 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 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 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 fo
35. e d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 IX IX for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in o
36. e 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 NA 3 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 pro cedure has not yet been established a good starting point is to set the OCV to 6 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 con trols 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 c
37. e 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 CONNECTION OF DC 1000 TO LN 8 POWER SOURCE Ped cu um TP AUT ETET 1178 74 75 7e 77 CONTROL gt gt LN 8 INPUT CABLE PLUG Connect the control cable ground lead to the frame terminal marked 77 7 near the power source terminal strip The power Source must be properly grounded P POSITIVE S17176 8 2 90F If using an older control cable Connect lead 75 to 75 on ter minal strip connect lead 76 to 76 on terminal strip connect lead 77 to 77 on terminal strip 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 physi cally suitable for the installation An S16586 remote 31 voltage sensing work lead is available for this purpose 2 Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connec tion For convenience this extended 21 lead should be taped to the welding work lead
38. eathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria etai ADP53AmtRE EOCUC METE Ze OF OR Ez s JL Ek HEEL SR ER TR S e SWA e s amp xiossH 247 8 HS THARA MESHA us iua lui e bia gs 4 92 e All gaal lt Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas ALTTLAM R UAUNUP DORI YF e HEMMER SHA AHS tue Ab all Qi il Sl Juill dall e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez
39. ee Figure 3 517344 4 For Voltages not listed see the Input Connection Diagram pasted on the inside of the Case Back Input Access Door FIGURE 1 WARNING NOTE Dual voltage machines are shi UM N FOR UNDER 300 VOLTS HI Movable Reconnect Panel Stationary Reconnect Panel p He 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 LI L2 6 L3 input supply lines amp H and H2 control transformer leads to the input side of the reconnect panel 3 Insulate unused lead terminal with ade quate tape to provide at least 600 volt insulation Tape l Connect terminal marked to ground National Electrical code INPUT CONNECTION DIAGRAM All input power must be electrically disconnected before touching panel input f 12 Lines high voltage CONNECTION FOR OVER 300 VOLTS Hi Movable Reconnect Panel LI Stationary Reconnect Panel Hount 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 re maining hex nuts over the remaining three studs for future use Connect 11 12 amp L3 input supply lines amp amp H3 control transformer leads to the input side of
40. ey are connected to the output termi nals The 1000 amp output connections provide the full rated output range of the machine See Tablet 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 sub merged 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 appropri ate 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 pro vided for access into the terminal strip section A chassis grounding screw is also provided below the terminal strip marked with the symbol or connect ing the wire feeding equipment grounding wire See the appropriate connection diagram for the exact instructions for the
41. ff 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 e 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 cir culation 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 possi bilities 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 inst
42. for grounded 73 74 75 76 17 Check and clean all connections Check table in instruction manual Check procedures for recommended settings Check and replace if defective Check and replace if necessary 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 LINCOLN 5 ES TROUBLESHOOTING ES Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Output control not functioning on remote 1 Output control switch in wrong posi 41 Place switch in Output Control tion Remote 2 Faulty output control switch 2 Check and replace if found faulty 3 Faulty remote control potentiometer 3 Check and replace if found faulty Voltage from 75 to 77 should be 3 to 5V 4 Leads or connections open in control 4 Check all leads and connections circuit internal or remote for continuity repair if necessary 5 Faulty firing or control circuit P C All light emitting diodes must be lit on board both P C boards except LED4 on control fault board See P C board troubleshooting guide Poor starting on CV S Sub Arc 1 Improper procedures or setting of See instruction manual and proce
43. he 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 E SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une
44. ided 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 SYMP TOMS 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 provides a course of action 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 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 LINCOLN 5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Input contactor 1CR chatters Machine input contactor does not oper ate Input contactor pulls in when start button is pressed but immediately drops out Machine input contactor operates but no output when trying to weld
45. 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock 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 standards 4 b Use sui
46. lowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 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 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 N 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disc
47. nd to negative output circuit Remove short Replace control board See P C board troubleshooting guide Repair connection Repair Check relay pull in by connecting a jumper across terminals 2 and 4 on DC 1000 terminal strip Replace if faulty All nine light emitting diodes LED1 thru LED9 must be lit See P C board troubleshooting guide 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 LINCOLN 5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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 Variable or sluggish welding arc Machine will not shut off Output control not functioning on the 1 machine position Output control switch faulty Open in feedback circuitry Faulty control or firing circuit P C boards Output control potentiometer circuit open Lead 75 Terminals 73 74 75 76 or 77 grounded to positive output One input fuse blown One phase of main transformer open Faulty control or firing circuit P C board
48. onnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 5 Exposure to EMF fields in welding may have other health effects which are now not known 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 Never coil the electrode lead around your 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source 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 dry hole free gloves to insulate hands 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
49. ontrol 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 For proper operation the electrode cable must be snugged under the clamp bar on the left side of the NA 5 control box 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 Alternative 500 amp positive terminal connection pro vided on DC 1000 models above code 9500 only Alternate submerged arc mode available for improved arc stability in high current large puddle slow travel procedures by making special connections on both DC 1500 and NA 5 On DC 1500 Control Board G1530 2 and superseding remove red and blue jumpers from 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 proce dures on DC 1500 without control board jumpers DC 1500 with control board jumpers on FR pins or DC 1000 IDEALARC DC 1000 LINCOLN F 4 DIAGRAMS F 4 CONNECTION OF DC 1000 TO LN 7 TO LN 7 INPUT CABLE PLUG POWER SOURCE LN 7 CONTROL CABLE i N E ii i if i 21 4 32 Ud i i J j i i i j 32 i i i 31 i i 2 i i i 4 i i a i i i i 24
50. ps when connected to 1000 um amp output studs Machine frequently shuts off while using Effective current demand well over Use the 1000 amp output studs the 500 amp output stud 500 amperes A CAUTION CAUTION If for any reason you do not understand the test ACT EE 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 LINCOLN 5 E 5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual P C BOARD TROUBLESHOOTING GUIDE WARNING TN e 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 ter minals 2 and 4 on DC 1000 Output Control at DC 1000 Mode switch in the CV I position CONTROL FAULT PROTECTION P C BOARD 1 LED 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 2 LED2 indicates welder output voltage is being sup plied to the control circuit If not lit check to m
51. r all FCAW 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 recommend ed 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 NOTE Some processes and procedures may be bet ter with the mode switch in the other CV position If the mode switch position initially selected is not pro ducing the desired results then place the mode switch in the other CV position and make a test weld Then use the CV mode switch position that 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 capa bl
52. r personal injury damage to this equipment TABLE OF CONTENTS Page MSHA AMON Section A Technical Specifications Ran nin ana cenit d n z k da e bU eet Adie A 1 Safety PI CAUTIONSE UR m A 2 Ter lle M A 2 SLACKING PR l eee di her RE V HEKER bO BE VA BER A 2 Ins esie A 2 Reconnect Piro Ged U say d als dll lek Mase ne N L Kilk neza ne ccu A 3 A 4 O tp t Connections rrr dd A 5 eC me Section B Safety Precautions i eee Etes ice acutae aod B 1 Product D Scription DER B 1 POSET POAN EE Ir B 2 Set Up For Various Procedures eene B 2 B 3 SRE Section D I D 1 General MainternariCe iiie terii i et c ba E n EE EFE LER c kO c n Bn k EW N D 1 Overload Protection sisi D 1 Troubleshooting eo ruuccee nr recu ee ern nennen kenn nnn a kek kun n kaka kaka kx ania acd Section E Safety Precauti ns iiie iure Eae eid endl neers E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guides recorded eta ct cer cd E 2 thru E 7 Connection and Wiring Diagrams ses Section F Parts L1St oen da b ka x la wane kuc
53. r proper inching cold starting and arc striking n 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 LINCOLN De MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING e ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts GENERAL MAINTENANCE 1 The fan motors have sealed bearings which require no service 2 n extremely dusty locations dirt may clog the air channels causing the welder to run hot Blow out the welder with low pressure air at regular inter vals as required to eliminate excessive dirt and dust buildup on internal parts OVERLOAD PROTECTION The power source is thermostatically protected with two proximity thermostats against overload or insuffi cient cooling One thermostat is located on the trans former secondary Negative Output Lead and the other thermostat is located on the choke coil The thermostats are connected in series in the machine control circuit so that if an excessive overload is applied to the machine or the machine should receive insufficient cooling on either the main transformer SCR bridge assembly or choke the input contactor would open and remain open until the machine cools
54. r the equipment being used 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 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 though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until
55. rd If the 75 VAC was not present then check the wiring 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 cir cuit P C board If any one of the lights 1 through 6 is not lit and lights 7 through 9 are lit replace the firing circuit P C board 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 LINCOLN 5 ES TROUBLESHOOTING ED Observe all Safety Guidelines detailed throughout this manual PROCEDURE FOR REPLACING P C BOARDS When P C board is to be replaced the following pro cedure 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 operate at high temperatures emit
56. roperly grounded 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 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 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 Alternative 500 amp positive terminal connection provided on DC 1000 models above code 9500 only IDEALARC DC 1000 LINCOLN LO Jequinu su e 10 91AJ9S O 914A 2 si eux sjeued y Jo euo uo y LL paysed si epoo e 104 urejBeip ou jJenueui siu seuluoeui 104 jou jUO 104 S SIUL 310 80061 NI LON AN z 8 5 El cooo ooo 18919 SIOSNAS 1VOIH103 13 4 o o o o U3AO2 m Old LNdLNO ava xog xo ES vr or 1014 114 Yor HOLIMS Q33H Q31VALLOV LNSYHND
57. s Output control potentiometer defec tive Output control potentiometer leads open 76 77 226 236 237 238 Machine has either an internal or external short circuit on the output Faulty control P C board Terminals 73 74 75 76 77 ground ed to negative output terminal Poor work or electrode connection Welding leads too small Welding current or voltage too low Defective main SCR bridge Input contactor contacts frozen Faulty 2CR relay If connected to an LN 9 or NA 5 disconnect leads 73 74 75 before troubleshooting Check position of switch Check switch and replace if faulty Check wiring and control and firing circuit P C board wiring harness plugs All light emitting diodes must be lit except LED4 on the control fault board See P C board troubleshoot ing guide Check and replace potentiometer if faulty Check wiring of Lead 75 Check 73 74 75 76 or 77 for ground to positive output circuit Check and replace if blown after checking for reason for blown fuse Check for open and repair All light emitting diodes must be lit on both P C boards except LED4 control fault board See P C board troubleshooting guide Check and replace if faulty Repair Check internally and externally for any shorts and remove or repair Replace control board See P C board troubleshooting guide Check
58. table clothing made from durable flame resistant LINCOLN 5 material to protect your skin and that of your helpers from the arc rays 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 lt 4 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to
59. th the the position shown and secure firmly with the nine hex nuts provided six hex nuts provided Secure the three maining hex nuts over the remaining three stud for future use 2 Connect 11 L2 amp L3 input supply lines 5 H4 control transformer leads to the input side 3 Insulate unused and lead terminals with ade of the reconnect panel as shown quate tape to provide at least 600 volt insulation 2 Connect 11 L2 amp L3 input supply lines amp H and H2 control transformer leads to the input side of the reconnect panel tape to provide at least 600 volt insulation 4 Connect terminai marked to ground per Connect termina marked to ground per National Eiectrical code Nationa Electrical Code T ye Insulate unused H2 and lead terminals with adequate i S 11344 IDEALARC DC 1000 LINCOLN Ass INSTALLATION A 5 QUTPUT CONNECTIONS Output Studs The output leads are connected to the output termi nals 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 termi nals on the left side They are fully recessed to mini mize 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 th
60. ting 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 a If there is no damage to the P C board insert a new one and see if this remedies the prob lem If the problem is remedied replace the old P C board and see if the problem still exists with the old P C board 1 Ifthe 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 con nections b If there is damage to the P C board refer to the Troubleshooting Guide 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 LINCOLN E 7 TROUBLESHOOTING E 7 OUTLINE FOR DC 1000 TROUBLESHOOTING GUIDE If troubleshooting guide indicates a possible 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 LED5 IF OFF IF ON CHECK LED1 CHECK FIRING BOARD LED S IF OFF IF ON ALL NINE LIGHTS CHECK AC REPLACE SHOULD INPUT TO CONTROL BE ON CONTROL BOARD BOARD
61. ur posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer 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 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
62. use can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 h To avoid scalding do not remove the N FOR ENGINE L du remove th powered equipment A i A 7 pressure cap when the engine is Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated 23 areas or vent the engine exhaust fumes K h outdoors ELECTRIC AND SR MAGNETIC FIELDS may be dangerous 2 a Electric current f
63. ve 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 ener gizes the main power transformer The red light below the stop start button indicates when the input contactor is energized Output Control The output control in the center of the control panel is a continuous control of the 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 compensa tion as a standard feature This will hold the output rel atively constant except at maximum output of the machine through a fluctuation of 10 of input line voltage Output Control at DC 1000 or Output 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

Lincoln Electric IDEALARC IM420-D User's Manual

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