Lincoln Electric Idealarc DC-1500 Service Manual Download Page 1

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Constant Voltage and Constant Current DC Arc Welding Power

Source, 3 Phase Rectifier Type

For use with machines having Code Numbers 8294 and above.

SVM202-A

July, 2010

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.

SERVICE MANUAL

IDEALARC

DC-1500

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

RETURN TO MAIN MENU

Summary of Contents for Idealarc DC-1500

Page 1: ...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 SERVICE MANUAL IDEALARC DC 1500 Sales and...

Page 2: ...THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANS...

Page 3: ...pen arc welding Headshield and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers fro...

Page 4: ...near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Sa...

Page 5: ...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 chaussur...

Page 6: ...ance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic scree...

Page 7: ...ld be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adja...

Page 8: ...ARC DC 1500 Page Safety i vi Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagra...

Page 9: ...A 1 A 1 IDEALARC DC 1500 Installation A 1 Technical Specifications A 2 Safety Precautions A 3 Location A 3 Input Wiring Output Connection A 3 Ratings A 4 Return to Master TOC Return to Master TOC Ret...

Page 10: ...Current Contstant Voltage Current Range 200 1500 Amps 200 1500 Amps Maximum Open Circuit Voltage 98 VDC Auxiliary Power 115 VAC 8 Amps RATED OUTPUT Input Voltage Frequency 460 60 380 440 50 60 Type 75...

Page 11: ...arity as required by the welding procedures Connect the work cables to the other set of studs Tighten the nuts with a wrench b Auxiliary Power This machine supplies the 1000 volt amperes of 115 volt A...

Page 12: ...rminal strip f Connecting for Air Carbon Arc To use the DC 1500 for air carbon arc or other appli cations disconnect all wire feeder welding cables and control leads and connect a jumper between 2 and...

Page 13: ...RATION SECTION B 1 B 1 IDEALARC DC 1500 Operation B 1 Duty Cycle Polarity Starting B 2 Set up B 3 B 5 Connecting to Wire Feeders B 6 B 7 Return to Master TOC Return to Master TOC Return to Master TOC...

Page 14: ...the On Off pushbuttons to start and stop the welder The red pilot light near the center of the control panel in dicates when the welder is on OPERATING INSTRUCTIONS WARNING ELECTRIC SHOCK can kill Do...

Page 15: ...for most submerged arc welding However some high speed welding pro cedures may perform better on the CV Innershield mode 3 The VV CC mode is available for high current large puddle submerged arc proc...

Page 16: ...blast off If the voltmeter needle hesitates before coming up to the desired voltage the OCV is set too low This will cause the electrode to stub h For Twinarc welding clipping both wires to equal len...

Page 17: ...1 Install the NA 5 per the information in the NA 5 operating manual IM 305 Connect the NA 5 to the DC 1500 as described on the connection diagram 2 Place the DC 1500 mode switch in the proper position...

Page 18: ...al strip 5 Feed the K775 control cable through the clamp on the front of the NL option box and connect the leads to ter minals 75 76 and 77 per connection diagram 6 Replace the cover This completes th...

Page 19: ...oltage but it will improve starting particularly at low currents Adjust the control for optimum starting NOTE The Hot Start Control does not affect the start ing method of the LAF 3 i e cold start hot...

Page 20: ...OTES B 8 B 8 IDEALARC DC 1500 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 TO...

Page 21: ...E OF CONTENTS ACCESSORIES SECTION C 1 C 1 IDEALARC DC 1500 Accessories C 1 Connection of Machine to Wire Feeders C 2 C 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 22: ...d N H For proper operation the electrode cable must be snugged under the clamp bar on the left side of the NA 5 control box S16889 7 6 84G Connection of DC 1500 With NL Option Kit K783 to LAF 3 Obsole...

Page 23: ...present on earlier DC 1500 S15534 2 26 82B Connection of DC 1500 With NL Option Kit K783 to LT 3 or LT 34 Obsolete N A On codes above 8234 extend lead 67 and connect it to the electrode cable going t...

Page 24: ...OTES C 4 C 4 IDEALARC DC 1500 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 TO...

Page 25: ...DEALARC DC 1500 Maintenance D 1 Safety Precautions D 2 Routine Maintenance D 2 General Maintenance D 2 D 3 Overload Protection D 2 D 3 Major Component Location D 4 Return to Master TOC Return to Maste...

Page 26: ...pplied Always wear a face shield and long sleeves when servicing See additional warning information throughout this Operator s Manual WARNING ROUTINE MAINTENANCE 1 Every 6 months or so the machine sho...

Page 27: ...button to start the welder An 8 amp slow blow fuse located on the front of the machine protects the 115 volt auxiliary AC circuit 31 and 32 from overload If replacing use the same type and size fuse G...

Page 28: ...T OF WELDER MAIN TRANSFORMER T5 INTER PHASE REACTOR FIRING BOARD RELAY AREA CONTROL BOARD TERMINAL FEEDER STRIP AREA CONTROL PANEL SHUNT POSITIVE OUTPUT STUD FRONT OF WELDER SCR BANK RIGHT TOP FAN INP...

Page 29: ...ACTOR MAIN TRANSFORMER NEGATIVE TERMINALS POSITIVE TERMINALS LATCHING RESISTOR D1 6CR PILOT RELAY SHUNT 6CR PILOT RELAY F E E D B A C K F E E D B A C K MODE SWITCH OUTPUT CONTROL FIRING BOARD CONTROL...

Page 30: ...hree 115 VAC phase angle trans formers are located in the base area left rear These transformers provide power and timing to the Firing Board NOTE Unshaded areas of Block Logic Diagram are the subject...

Page 31: ...p ply gate pulses to the SCR Bridge Closing of the Pilot Relay a dry closure of leads 2 and 4 also brings the Latching Resistor into the machine output circuit The Latching Resistor provides a pre loa...

Page 32: ...usions If the 73 74 75 76 or 77 leads come in contact with either of the machine s output cables the DC 1500 will only operate at a minimum output or the input contactor will open FIRING BOARD CONTROL...

Page 33: ...tate The amount of time spent in the ON state is con trolled by the Gate An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since...

Page 34: ...OTES E 6 E 6 IDEALARC DC 1500 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 TO...

Page 35: ...uxiliary Transformer T1 Voltage Test F 13 Main Transformer T5 Voltage Test F 17 Control Transformer T2 T3 T4 Voltage Test F 21 Firing Board Test F 25 Control Board Test F 31 Static SCR Test F 37 Activ...

Page 36: ...mponents in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are descri...

Page 37: ...paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t r...

Page 38: ...ary Transformer T1 may be faulty Perform the Auxiliary Transformer Test T1 3 The primary or secondary ther mostats may be open Check or replace Also check the associated wiring See wiring diagram 4 Th...

Page 39: ...terminals 3 If the problem persists after performing steps 1 and 2 the problem is in the DC 1500 1 The 5CR interlock relay may be faulty Replace if neces sary some older codes will not have 5CR An int...

Page 40: ...Check 8 AMP fuse in the front panel Replace if blown 4 Check for loose or faulty weld cable connections 1 Check operation of output pilot relay 6CR There should be 115 VAC present on leads 31 and 4 at...

Page 41: ...from the output control potentiometer R1 to the control board plug 12 pin 7 See wiring dia gram 4 Perform Firing Board Test 5 Perform Control Board Test 6 Perform SCR Output Bridge Test Machine has mi...

Page 42: ...nes at the DC 1500 Make sure input voltages match machine rating and reconnect panel 2 Put output control switch SW4 in OUTPUT CON TROL AT DC 1500 position If problem is solved then check remote contr...

Page 43: ...to the negative out put cable or there is a short on the welding output termi nals 2 If the machine still shuts off when all control and welding cables are removed then the problem is internal to the...

Page 44: ...some open circuit voltage is present over 3 VDC after performing Step 1 then the problem is within the DC 1500 1 Check for an internal short between leads 2 and 4 See wiring diagram 2 The Pilot Relay...

Page 45: ...eck 7CR on Code 8146 8293 2 Perform the Firing Board Test 3 Perform the SCR Output Bridge Test 4 The control board may be faulty Replace Poor arc characteristics in all processes 1 Check for the corre...

Page 46: ...TES F 12 F 12 IDEALARC DC 1500 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 T...

Page 47: ...ctric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltage is being a applied to the pr...

Page 48: ...the Auxiliary Transformer T1 on the left lower right rear of machine See Figure F 1 4 Locate the Auxiliary Transformer above prima ry leads H1 H3 etc at the reconnect area T1 See wiring diagram NOTE U...

Page 49: ...es will have a 5 Amp slow blow fuse on the reconnect area for the primary connection to T1 fuse may be blown 8 With the input power disconnected check for meg ohms of resistance to case ground of weld...

Page 50: ...TES F 16 F 16 IDEALARC DC 1500 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 T...

Page 51: ...ct the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltages are being...

Page 52: ...ge is not present for any or all of the three phases the con tactor may be faulty 6 Carefully test with an AC voltmeter for approx imately 70 0 Volts on the six main transformer secondary leads Check...

Page 53: ...F 4 SCR s MAIN TRANSFORMER T5 VOLTAGE TEST continued TROUBLESHOOTING AND REPAIR F 19 F 19 IDEALARC DC 1500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Retur...

Page 54: ...TES F 20 F 20 IDEALARC DC 1500 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 T...

Page 55: ...ce Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltages are being a applied to the primary win...

Page 56: ...k for the correct secondary voltages at the TS1 terminal strip See Table F 5 See Wiring Diagram 8 If any of the secondary voltages are missing or incorrect check for loose or faulty connections See Wi...

Page 57: ...FIGURE F 5 TERMINAL STRIP CONTROL TRANSFORMERS T2 T3 T4 VOLTAGE TEST PROCEDURE continued TROUBLESHOOTING AND REPAIR F 23 F 23 IDEALARC DC 1500 Return to Section TOC Return to Section TOC Return to Sec...

Page 58: ...TES F 24 F 24 IDEALARC DC 1500 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 T...

Page 59: ...ctrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test determines whether or not the Firing Board is receiving the correct voltages and gate signals The...

Page 60: ...ion 6 Connect a jumper wire from terminal 2 to ter minal 4 on the terminal strip These can be accessed through the Front Panel Assembly door See Figure F 6 7 Locate LEDs 1 thru 6 Each LED should glow...

Page 61: ...being supplied to the Firing Board from leads 205 and 206 connected to the phase angle winding on the T3 Control Transformer LED 8 is OFF or is DIMMER than other LED s The proper AC voltage may not b...

Page 62: ...Test 11 Locate and test for 6 to 15 VDC between leads 231 and 214 on the Firing Board in the CV mode When the output control potentiometer R1 is rotated the DC voltage between leads 231 and 214 should...

Page 63: ...ontacts can be heard or felt on cover opening and closing If the Output Pilot Relay 6CR does not close when energized check for loose or faulty wiring See Wiring Diagram 16 Replace the Firing Board if...

Page 64: ...TES F 30 F 30 IDEALARC DC 1500 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 T...

Page 65: ...rs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the Control Boa...

Page 66: ...put Control At DC 1500 Panel position and the Welding Mode Switch SW5 in a CV position LED 2 should change in brightness as the Output Control Potentiometer is rotated As the open circuit voltage is i...

Page 67: ...uity zero ohms from lead 255 to 256 on the 12 pin molex plug If open T7 control board transformer may be defective See Figure F 11 c Check for 115 VAC at TS1 terminal strip leads 31 to 202 32 if prese...

Page 68: ...m Remove main supply power to the DC 1500 2 Test for continuity zero ohms from the posi tive output stud to lead 210 at 9 pin molex plug on the Control Board See wiring diagram and Figure F 11 3 Test...

Page 69: ...also the remote control circuitry See wiring diagram 2 If the above procedures do not reveal the prob lem then the Control board may be faulty Replace IF LED 5 Control Signal does not light and varie...

Page 70: ...TES F 36 F 36 IDEALARC DC 1500 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 T...

Page 71: ...ontact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The Static SCR Test is a quick check to determine if a...

Page 72: ...L1 L3 L5 L6 L4 L2 12 PIN 9 PIN G1587 1 FIGURE F 13 FIRING BOARD STATIC SCR TEST PROCEDURE continued PROCEDURE 1 Remove main supply power to the DC 1500 2 Remove all Molex plugs from the firing board...

Page 73: ...the meter leads and check from cathode to anode of SCR 1 R x 1000 SCALE a If a low resistance is indicated in either direction disconnect the associated snubber board mounted on SCR inside mounting c...

Page 74: ...TES F 40 F 40 IDEALARC DC 1500 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 T...

Page 75: ...irs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The Active SCR Test will determine if the...

Page 76: ...8 9 1 2 4 3 5 6 7 8 9 10 11 12 9 PIN MOLEX 12 PIN MOLEX L1 L3 L5 L4 L2 G1530 1 1 2 4 3 5 6 7 8 9 1 2 4 3 5 6 7 8 9 10 11 12 9 PIN MOLEX 12 PIN MOLEX FIGURE F 15 CONTROL BOARD L7 L8 L9 L1 L3 L5 L6 L4...

Page 77: ...CR HEATSINK LOCATION S ACTIVE SCR TEST PROCEDURE continued 3 Perform test procedure as follows Refer to Figure F 17 Repeat test for all six SCRs NOTE DO NOT DISASSEMBLE THE HEAT SINKS THIS TYPE OF SCR...

Page 78: ...less than 4 5 volts A Connect SCR into the test circuit as shown A lead to anode C lead to cathode and G lead to the gate See Wiring Diagram B Close switch SW1 switch SW2 should open voltmeter should...

Page 79: ...terminals probe to positive terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT C...

Page 80: ...e to positive terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHI...

Page 81: ...e to positive terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE INNERSHI...

Page 82: ...Scope probes connected at machine ouput terminals probe to positive terminal probe to negative terminal SCOPE SETTINGS Volts Div 10 V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TYPICA...

Page 83: ...achine output terminals probe to positive terminal probe to negative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal ABNORMAL OPEN CIRCUIT VOLTAGE WAVE...

Page 84: ...TES F 50 F 50 IDEALARC DC 1500 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 T...

Page 85: ...safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the...

Page 86: ...ting bracket and remove contactor INSTALLATION 1 Mount contactor to bracket with 3 self tapping screws 2 Connect H1 H2 H3 leads to bottom of CR1 3 Connect the input supply leads 4 Connect 2 211 leads...

Page 87: ...ervice Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the SCR ou...

Page 88: ...om the bottom aluminum lead on rectifier 6 17 Disconnect leads 211 and 247 from the bot tom thermostat on rectifier 6 18 Disconnect the top aluminum lead on rectifier 6 Disconnect the bottom aluminum...

Page 89: ...MBLY SCR OUTPUT BRIDGE REPLACEMENT continued TROUBLESHOOTING AND REPAIR F 55 F 55 IDEALARC DC 1500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Mas...

Page 90: ...the removed rectifier and mount to a new 5 rectifier Connect the red lead on top and the white lead on the bottom of the terminal strip 2 Apply E1868 Joint Compound on the heat sink surfaces 2 places...

Page 91: ...ar of the unit 20 Connect the bottom aluminum secondary lead to the bottom heat sink of rectifier 6 Connect the top aluminum secondary lead to the top heat sink of rectifier 6 21 Tighten all rectifier...

Page 92: ...elay 41 Mount the top fiber air baffle to the two rear rec tifier brackets 42 Blow out the unit 43 Re test units per instructions provided TROUBLESHOOTING AND REPAIR F 58 F 58 IDEALARC DC 1500 Return...

Page 93: ...val of any mechanical part that could affect the machine s elec trical characteristics or if any electrical components are repaired or replaced INPUT IDLE AMPS AND WATTS Input Volts Phase Hertz Maximu...

Page 94: ...2 G 4 PC Board Assembly Firing Circuit PC Board G1587 1 G 5 PC Board Assembly Snubber PC Boards L6980 1 L6981 1 G 6 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or mu...

Page 95: ...3 SNUBBER P C BD 1 216 FRONT R ELECTRODE POLARITY F1 W 8A SLOW BLOW FUSE 248 253 30 300W 239 D1 R1 246 G2 215 229 32 31 224 230 75 10K POT 238 237 SW2 SW4 21 SHUNT CONTROL POWER TRANS 32 N B 204 206 2...

Page 96: ...3 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return...

Page 97: ...OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC PROPRIETARY CONFIDENTIAL t MAT...

Page 98: ...TROLLED MANUFACTURER No THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS W...

Page 99: ...IETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC PROPRIETARY...

Page 100: ...THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LIN...

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