Lincoln Electric SVM123-A Electric Shock can Kill, Select Proper Location, Stacking, Tilting

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A-3

INSTALLATION

A-3

 

 

 

 

Read entire Installation Section before installing

 

 

 

 

 

 

the IDEALARC DC-1000.

STACKING HOLE

SAFETY PRECAUTIONS

 

 

 

 

 

 

 

 

 

WARNING

 

 

 

ELECTRIC SHOCK CAN KILL.

 

 

 

 

• Only qualified personnel should install this

 

 

 

 

machine.

 

 

 

 

• Turn the input power OFF at the discon-

 

 

 

 

nect switch or fuse box before installing or

 

 

 

 

working on the equipment.

STACKING PIN

 

 

• Do not touch electrically hot parts.

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

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SELECT PROPER LOCATION

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.

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Two IDEALARC DC-1000 machines can be stacked.

Follow these guidelines when stacking:

1.Select a firm, level surface capable of supporting the total weight of two machines (1642 pounds/744 kilograms).

2.Set the bottom machine in place.

3.Stack the second machine on top of it by aligning the two holes in the base rails of the second machine with the two pins on top front of the bot- tom machine.

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

FIGURE A.1 - Stacking IDEALARC DC-1000

Machines

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 spec- ified 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 volt- age machines.

FIGURE A.2 - Input Power Supply Connection

IDEALARC DC-1000

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Contents Idealarc Electric and Magnetic Fields SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Output Technical Specifications Idealarc DCSelect Proper Location Electric Shock can KillElectrical Input Connections StackingFuse and Wire Sizes Reconnect ProcedureInput Power Supply Connections Ground ConnectionFigure A.3a Input Connection Diagram Figure A.3c -Input Connection Diagram Figure A.3d Input Supply Connection Diagram Output Connections Cutting Operation Connection for AIR/CARBON ARCIdealarc DC-1000 Operation Electric Shock can kill Safety InstructionsDesign Features Advantages Operational Features and ControlsGeneral Description Recommended Processes and EquipmentWelding Capability Return to Section Controls and SettingsWelding Procedure Recommendations Remote Control of Machine OperationNA-3 Automatic Wire Feeder ARC Striking with Idealarc DC-1000 and the NA-3 Start Board Remote LN-8 SEMI-AUTOMATIC Wire FeederTable of Contents AccessoriesConnecting the NA-3 or LT-7 to OPTIONS/ACCESSORIESIdealarc DC-1000 Remote Output Control OptionalFigure C.2 NA-5 Wire Feeder Connection to Idealarc DC-1000 Connecting the NA-5 to the Idealarc DC-1000Connecting the LN-8 to the Idealarc DC-1000 Connecting the LN-9 Wire Feeder to the Idealarc DC-1000 Connecting the LN-7 Wire Feeder to the Idealarc DC-1000 Maintenance Routine and Periodic Maintenance Safety Precautions Electric Shock Can KillFigure D.1 Major Component Locations Idealarc DC-1000 Theory of Operation TOR, and Main Transformer Input Line VOLTAGE, ContacCONTROL, and Feedback Output RectificationCircuits Contactor HOLD-IN Protection DevicesFigure E.5 SCR Operation SCR OperationIdealarc DC-1000 Troubleshooting & Repair Locate Problem Symptom HOW to USE Troubleshooting GuideBoard can be damaged by static electricity PC Board Troubleshooting ProceduresControl Transformer Test Return Return to Master TOC Return Return to Section TOC Perform SCR Output Bridge Troubleshooting & Repair Function Problems Perform Firing Board Test Perform Control Board Test SCR Output Troubleshooting & Repair Control Transformer T2 Voltage Test Test DescriptionFigure F.1 Control Transformer Lead Location Test ProcedureFigure F.2 Control Transformer X1 and X2 Test Points Main Transformer T1 Voltage Test Test Description Figure F.4 Main Secondary Lead Test Points From Expected VAC Firing Board Test Test Procedure for Normal Firing Board Operation Figure F.7 Terminal Strip Jumper Wire Connections Figure F.8 Output Pilot Relay 4CR Location Then Table F.1 LED 7, 8 and 9 Check ListControl Board Test Figure F.9 Control Board LED and Pin Locations Test Procedure for Normal Control Board OperationIf LED 1 does not light, when the start switch is on Possible Problems Pertaining to the Control BoardFigure F.11 LED 2 Open Circuit Voltage Test Points If LED 4 lights Static SCR Test Figure F.12 Test ProcedureFigure F.13 SCR Heat Sink Assembly Test Points Static SCR Test Active SCR Test Active SCR Test Figure F.16 Heat Sink Assembly Test Points Battery Test Scope Settings Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Input Contactor 1CR Cleaning AND/OR Replacement Figure F.18 Input Contactor Cover Removal Cleaning ProcedureRemoval Contactor ReplacementInstallation SCR Output Bridge Replacement Figure F.22 Preparation For SCR Output Bridge Removal SCR Output Bridge RemovalFigure F.23 SCR Output Bridge Removal Removal of Individual SCR Heat Sink Assemblies SCR Output Bridge Installation SCR Heat Sink InstallationTOC Removal and Reassembly of Lift Bail Figure F.25 Lift Bail Removal Removal of Lift BailReassembly of Lift Bail Main Transformer Removal and Installation Figure F.26 Main Transformer Disassembly Main Transformer Disassembly and AssemblyCoil Removal Replacement Main Transformer DisassemblyTransformer Reassembly Transformer InstallationIdealarc DC-1000 Open Circuit Voltages Input Idle Amps and WattsIdealarc DC-1000 Electrical Diagrams Idealarc DC-1000 Wiring Diagram Codes 9919 Operating Schematic Control PC Board G1585 Layout Firing PC Board G1486-5 and above Layout Control PC Board G1585 Schematic Firing PC Board G1486-5 and above Schematic Output Snubber M14312 Schematic
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