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RETURN TO MAIN INDEX
SVM123-A
TM
July, 1996
IDEALARC DC 1000
For use with Machine Code Numbers: 9919
9920
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... 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 a
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth known to the State of California to cause cancer, birth defects, and other reproductive harm. defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY O
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ii ii SAFETY ELECTRIC SHOCK ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover can kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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v v RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety .....................................................................................................................................................i - iv Installation......................................................................................................................................Section A Technical Specifications ....................................................................................
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A-1 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 .....................
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A-2 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 SIZE
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A-3 A-3 INSTALLATION Read entire Installation Section before installing the IDEALARC DC-1000. STACKING HOLE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Only qualified personnel should install this machine. • Turn the input power OFF at the discon- nect switch or fuse box before installing or working on the equipment. • Do not touch electrically hot parts. STACKING PIN • Always connect the IDEALARC DC-1000 grounding terminal to a good electrical earth ground. ___________________________
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A-4 A-4 INSTALLATION FUSE AND WIRE SIZES RECONNECT PROCEDURE Protect the input circuit with the super lag fuses or Multiple voltage machines are shipped connected to delay type circuit breakers listed on the Technical the highest input voltage listed on the machine’s rating Specifications page of this manual for the machine plate. Before installing the machine, check that the being used. They are also called inverse time or ther- Reconnect Panel in the Input Box Assembly is con- mal/magnetic cir
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A-5 A-5 INSTALLATION WARNING All input power must be electrically disconnected before touching panel. ____________________________________________________ CONNECTION FOR UNDER 300 VOLTS 1. Mount the movable reconnect panel to the stationary reconnect panel studs in the position shown, and secure firmly with the nine hex nuts provided. 2. Conect L1, L2, and L3 input supply lines and H1 and H2 control transformer leads to the input side of the reconnect panel. 3. Insulate unused H3 lead terminal w
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A-6 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 termi
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A-7 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
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A-8 A-8 INSTALLATION 3. Connect electrode lead to the desired terminal OUTPUT CONNECTIONS (positive or negative) and tighten the output ter- minal nut with a wrench. See Table A.1 for recommended IDEALARC DC-1000 cable sizes for combined length of electrode and work 4. Connect the second work lead to the other out- cables. put terminal (positive if negative is attached and vice versa) following steps 2 and 3. TABLE A.1 Suggested Copper Cable Sizes - 100% Duty Cycle AUXILIARY POWER Combined Lengt
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A-9 A-9 INSTALLATION 3. If necessary, disconnect all wire feeder control CONNECTION FOR AIR/CARBON ARC cable connections from the DC-1000 terminal CUTTING OPERATION strip. WARNING 4. Remove the leads from the unit by pulling them through and out of the strain relief box connector THE OUTPUT TERMINALS ARE ENERGIZED AT (s). ALL TIMES WHEN THE IDEALARC DC-1000 IS 5. Connect a jumper wire from terminal #2 to termi- CONNECTED FOR AIR/CARBON ARC CUTTING. nal #4 on the terminal strip. ______________
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A-10 A-10 NOTES IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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B-1 B-1 OPERATION TABLE OF CONTENTS -OPERATION SECTION- OPERATION...................................................................................................................................Section B Safety Precautions..............................................................................................................................B-2 General Description ............................................................................................................................B-
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B-2 B-2 OPERATION Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. •Do not touch electrically live parts such as output terminals or internal wiring. •Insulate yourself from the work and ground. • Always wear dry insulating gloves. ____________________________________________________ FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. ________
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B-3 B-3 OPERATION OPERATIONAL FEATURES AND GENERAL DESCRIPTION CONTROLS The IDEALARC DC-1000 is an SCR-controlled, three The IDEALARC DC-1000 comes with the following phase, welding and cutting power source. It uses a standard controls: single range potentiometer to control: • DOUBLE ON/OFF PUSH BUTTON (Main Power • Submerged Arc Semi-Automatic or Automatic and 115V Auxiliary) Welding • OUTPUT CONTROL POTENTIOMETER • Open Arc Semi-Automatic or Automatic Welding • OUTPUT CONTROL SWITCH (Remote o
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B-4 B-4 OPERATION • Three circuit solid state control system provides • Enclosure designed with air intake louvers that maximum performance and circuit protection. keep dripping water from entering the unit, allow- • Low profile case provides maximum use of space. ing outdoor operation. Transformer, SCR bridge, • Convenient access to all controls. and choke have special corrosion resistant paint • Large output lead strain relief openings to prevent for added protection. terminal and cable damage
