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Lincoln Electric IM420-D manual

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Table of contents for the manual

  • Page 1

    • 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 • World's Leader in Welding and Cutting Products • OPER A T OR’S MANU AL IM420-D February, 2010 Safety Depends on You Lincoln arc welding and cutting equipment i[...]

  • Page 2

    FOR ENGINE pow ered equipment. 1.a. 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 areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

  • Page 3

    ARC R A Y S can bur n. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b . Use suitable clothing made from durable flame-resistant material to protect your skin and tha[...]

  • Page 4

    FOR ELECTRIC ALL Y pow ered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electri[...]

  • Page 5

    PRÉC A UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’élec[...]

  • Page 6

    ix ix Thank Y ou for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. [...]

  • Page 7

    x x T ABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions . ...........................[...]

  • Page 8

    A -1 INS T ALLA TION IDEALARC® DC-1000 A -1 60% Duty Cycle 215/108 86 215/124/108 124/94 113 TECHNICAL SPECIFICA TIONS – DC-1000 Volts at Rated Amperes 44 44 44 Auxiliary Power See the OPERATION section for Auxiliary Power information by model Amps 1000 1140 1250 Maximum Open Circuit Voltage 75V for 60 HZ models 72V for 50/60 HZ models Duty Cycl[...]

  • Page 9

    A-2 INS T ALLA TION IDEALARC® DC-1000 A-2 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. ST ACKING Two DC-1000’s may be stacked by observing the following[...]

  • Page 10

    A-3 INS T ALLA TION IDEALARC® DC-1000 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. Failure to follow these instructions can ca[...]

  • Page 11

    A-4 INS T ALLA TION IDEALARC® DC-1000 A-4 FIGURE 2 FIGURE 3[...]

  • Page 12

    A-5 INS T ALLA TION IDEALARC® DC-1000 A-5 OUTPUT 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 “-” te[...]

  • Page 13

    B-1 OPER A TION IDEALARC® DC-1000 B-1 PRODUCT DESCRIPTION The DC-1000 is an SCR-contr olled 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 [...]

  • Page 14

    B-2 INS T ALLA TION IDEALARC® DC-1000 B-2 Remote Output Control - (Optional) The K775 Remote Output Control consists of a control box with 28 ft. (8.4m) of four conductor cable. This connects to terminals 75, 76, 77 on the terminal strip, and the case grounding screw so marked with the symbol on the machine. These terminals are made available by o[...]

  • Page 15

    B-3 INS T ALLA TION IDEALARC® DC-1000 B-3 3. N A - 5 - Set the DC-1000 mode switch to the proc ess bein g us ed - CV (I) Inner shie ld or C V(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 [...]

  • Page 16

    D-1 MAINTENANCE D-1 The control board is designed with adequate protec- tion so that no damage will occur if the remote control l ea d s a r e s h o r te d to g e th e r o r ar e g r o u nd e d t o th e 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 au[...]

  • Page 17

    E-1 TR OUBLESHOO TING E-1 IDEALARC® DC-1000 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. C A UTION This Troubleshooting Guide is provided to help you locate and [...]

  • Page 18

    E-2 TR OUBLESHOO TING E-2 IDEALARC® DC-1000 Observe all Safety Guidelines detailed throughout this manual 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. C A UTION [...]

  • Page 19

    E-3 TR OUBLESHOO TING E-3 IDEALARC® DC-1000 Observe all Safety Guidelines detailed throughout this manual 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. C A UTION [...]

  • Page 20

    E-4 TR OUBLESHOO TING E-4 IDEALARC® DC-1000 Observe all Safety Guidelines detailed throughout this manual 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. C A UTION [...]

  • Page 21

    E-5 TR OUBLESHOO TING E-5 IDEALARC® DC-1000 Observe all Safety Guidelines detailed throughout this manual 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. C A UTION [...]

  • Page 22

    E-6 TR OUBLESHOO TING E-6 IDEALARC® DC-1000 Observe all Safety Guidelines detailed throughout this manual 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. C A UTION [...]

  • Page 23

    E-7 TR OUBLESHOO TING E-7 IDEALARC® DC-1000 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. C A UTION MACHINE HAS OUTPUT (Jumper 2-4) BUT TRIPS OFF IMMEDIATELY CHEC[...]

  • Page 24

    F-1 DIA GR AMS F-1 IDEALARC® DC-1000 CONNECTION OF DC-1000 WITH NL OPTION KIT TO LAF-3 (Obsolete) 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[...]

  • Page 25

    F-2 DIA GR AMS F-2 IDEALARC® DC-1000 CONNECTION OF DC-1000 WITH NL OPTI ON KIT TO L T -3 or L T -34 (Obsolete) N.A. On all DC-1000 and DC-1500’s above Code 8234 extend lead 67 and connect it to the electrode cable going to the automatic equipment. N.B. On DC-1500 units below code 8234 this is #67 and the LT-3 or LT-34 #67 lead can be connected e[...]

  • Page 26

    F-3 DIA GR AMS F-3 IDEALARC® DC-1000 CONNECTION OF DC-1000 to NA-5 N.A. Welding cables must be of proper capacity for the cur- rent and duty cycle of immediate and future applica- tions. N.B. Extend lead 21 using #14 or larger insulated wire phys- ically suitable for the installation. An S16586-[ ] remote voltage sensing work lead is available for[...]

  • Page 27

    F-4 DIA GR AMS F-4 IDEALARC® DC-1000 CONNECTION OF DC-1000 TO LN-7 CONNECTION OF DC-1000 TO LN-9 N.A. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications. N.B. Extend lead 21 using #14 or larger insulated wire physically suit- able for the installation. An S16586-[ ] remote voltage sensing [...]

  • Page 28

    F-5 DIA GR AMS F-5 IDEALARC® DC-1000 DC-1000 WIRING DIAGRAM FOR CODES 9919 - 9925, 10293, 1 1305, 1 1330, 1 1331, 1 1332, 1 1333, 1 1334 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If[...]

  • Page 29

    F-6 DIA GR AMS F-6 IDEALARC® DC-1000 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment cod[...]

  • Page 30

    NO TES IDEALARC® DC-1000[...]

  • Page 31

    NO TES IDEALARC® DC-1000[...]

  • Page 32

    NO TES IDEALARC® DC-1000[...]

  • Page 33

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INS TR UCTION FOR THIS EQUIPMENT AND THE CONSUMABLES T O BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABRIC [...]

  • Page 34

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A AS INS TR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E AS P ARTES DE USO , E SIGA AS PRÁTIC AS DE SE GURANÇA DO EMPRE GADOR. • Kee p yo ur h ead out of f umes . • Use ven tila tion or exha us[...]

  • Page 35

    • 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 • World's Leader in Welding and Cutting Products •[...]