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TABLE OF CONTENTS - ACCESSORIES SECTION

C-1

IDEALARC® DC-1500

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Connection of Machine to Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2/C-3

Содержание Idealarc DC-1500

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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