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IDEALARC AC-1200
Single Phase Constant Current Power Source For Automatic AC Welding
For use with machines having Code Numbers 11869.
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, OPER-
ATE OR REPAIR THIS EQUIPMENT WITHOUT READING
THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
IM10119
October, 2012
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH 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 - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered 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.
____________________________________________________
1.c. Do not add the fuel nea r an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
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 that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding ma y produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding 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 “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use on ly c om pr essed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Re ad and foll ow the inst ru ctions o n c ompressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Ins tall 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
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
iv
SAFETY
iv
PRÉCAUTIONS 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 suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Thank You
vv
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!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Location ................................................................................................................A-2
Input Wiring............................................................................................................A-2
Output Connections...............................................................................................A-2
1. Wire Feeder Connections ...........................................................................A-2
Connection of AC-1200 (with NL Option) to LAF or LT34 .....................................A-3
Connection of AC-1200 to NA-4 with Switch for ʻCurrent Controlʼ.........................A-3
Connection of AC-1200 to NA-4 with rheostat for current control or LT-6.............A-3
2. Output Studs ...............................................................................................A-4
3. Auxiliary Power ...........................................................................................A-4
Duty Cycle .............................................................................................................A-4
_______________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
To set for machine or Remote Control...................................................................B-1
To set Output Current............................................................................................B-1
________________________________________________________________________
vi
Accessories .....................................................................................................Section C
Optional Kit............................................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide....................................................................................E-2,E-3
________________________________________________________________________
Wiring Diagram and Connection Diagrams .................................................Section F
________________________________________________________________________
Parts Pages............................................................................................... P-701, P-28-J
________________________________________________________________________
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS - IDEALARC®AC-1200
INPUT - SINGLE PHASE ONLY
Standard Voltage
460/60
440/50/60
415/50/60
380/50/60
Power Factor @ Rated load With P.F. Capacitors
79%(60 Hz) 76%(50 Hz)
Input Current at 100% Rated Output
Single Phase Output Scott Connection
182 209
190 219
201 232
220 255
RECOMMENDED INPUT WIRE GROUNDING CONDUCTOR AND FUSE SIZES
Input Copper Wire Size - 75˚C in Conduit Super Lag Fuses
Voltage/ Input Amps Power Input Wires Grounding Conductor Size in Amps
Hertz
1 Phase Scott 1 Phase Scott 1 Phase Scott 1 Phase Scott
Conn. Conn. Conn. Conn.
460/60 182 209 #4/0 250MCM #4 #3 300 350
440/50/60 190 219 #4/0 250MCM #4 #3 300 350
415/50/60 201 232 #4/0 300MCM #4 #3 300 350
380/50/60 220 255 250MCM 350MCM #3 #3 300 400
Duty Cycle
Height
53.50 in.
( 1358.9mm.)
RATING: IP21 ENCLOSURE
100%
RATED OUTPUT
Current Range
240/1200
Maximum Open Circuit Voltage
86-88
PHYSICAL DIMENSIONS
Width
22.30 in.
(566.4mm.)
Depth
38.00 in.
(965.2mm.)
AMPS AC
1200 @ 44 Volts
Weight
1636 lbs.
(742 kg.)
IDEALARC®AC-1200
A-2
INSTALLATION
A-2
LOCATION
Install the welder in a dry location where there is free
circulation of air in through the louvers in front and out
through the louvers in the back of the case. A location
which minimizes the amount of smoke and dirt drawn
into the machine reduces the chance of dirt accumulation that can block air passages and cause overheating.
INPUT WIRING
WARNING
• Have an electrician install
and service this equipment.
• Turn the input power off at
the fuse box before work-
ELECTRIC SHOCK
can kill.
Failure to fuse the input lines per the specifications
in this manual will constitute customer abuse and
void the warranty.
-----------------------------------------------------------------------------
Have a qualified electrician make the complete input
connection in accordance with the National Electrical
Code, all local codes and the connection diagram
located inside the machine.
ing on equipment.
• Do not touch electrically
hot parts.
The frame of the welder must be grounded, A stud marked
with the symbol located on the welder case back
hole in the back of the case is provided for this purpose.
See the National Electrical Code for details on proper
grounding methods.
OUTPUT CONNECTIONS
1. Wire Feeder Connection
Turn the input power to the welder off. Remove the
screw and lift the hinged door on the front of the control
panel to expose the terminal strips. Connect the leads of
the wire feeder input control cable to the terminal strips
exactly as specified in the appropriate connection diagram.
The AC-1200 to NA-4 connection diagrams are included
in the NA-4 Operating Manual IM-278. Attach the control
cables to the panel at the right of the terminal strip using
the clamps provided.
If connecting the AC-1200 to an older NA-4 with the toggle switch type “Current Control” (below code 7532), a K775 “Remote Control” must be purchased and installed in
accordance with the connection diagram S-15667 on page
5. The “Remote Control” cord can be lengthened to any
length by properly splicing a four conductor cord to the
standard 25ʼ cord before connecting to the AC-1200 terminal strip.
Be sure the voltage, phase and frequency of the input
power
is as specified on the welder nameplate.
For most installations, connect the AC-1200 to single
phase power or to one phase of a three phase line.
Unbalanced line conditions can be easily avoided by
properly balancing the AC-1200 with other machinery
on the lines.
When installing two or four Scott connected AC-1200
machines for AC-AC tandem arc welding, three phase
input power must be used. The terminals for connections to provide an output phase angle less than or
greater than the usual 90º phase angle are included
on the input panel.
The AC-1200 does not have an input contactor.
Therefore, include an external starter or disconnect
switch when planning the input circuit.
Remove the right side panel of the AC-1200 and bring the
input power lines through the hole in the back of the case.
See the table below for reccomended sizing of input leads
and overcurrent protection.
If connecting the AC-1200 to an LAF-4 or the AC controls of the LT-34 tractor, the AC-1200 must be ordered
with the required “–NL” optional circuit installed. This kit
includes the K-775 “Remote Control”. Connect in accordance with diagram S-15666 on page 5.
To connect the AC-1200 to any other wire feeder, write to
the factory for instructions giving complete nameplate information for the specific equipment.
When connection to the terminal strips are completed,
close the door and replace the screw.
IDEALARC®AC-1200
A-3
INSTALLATION
A-3
Connection of AC-1200 (with NL Option) S-15666
to LAF-4 or LT-34 4-18-75
Connection of AC-1200 to NA-4 S-15667
with Switch for ‘Current Control’ 4-18-75
Connection of AC-1200 to
NA-4 with rheostat for current control or LT-6.
IDEALARC®AC-1200
S-15602
6-22-84H
A-4
2. Output Studs
Connect the work cables to the “To Work” stud on
the front of the AC-1200. Connect the electrode
cables to the “Min”, “Med” or “Max” studs for the
output desired. Actual current ranges for each stud
are indicated on the nameplate above each stud.
Recommended cable sizes are listed below. Both
the “To Work” and “Max” studs have two terminals
to simplify connection of recommended cables in
parallel. Tighten the nuts with a wrench.
Select cables required for combined work and electrode cable lengths up to 150ʼ from the following
table:
Duty
Cycle One 4/0 Two 4/0 Three 4/0 Four 4/0
100% 500 930 1150 1350
80%* 560 1040 1290 1510
* Based on 10 minute cycle.
Maximum Allowable Current for Copper Welding Cable
Cables in accessory kit recommended below have
terminals as required to comply with applicable
U.L. standards for safety.
INSTALLATION
A-4
150ʼ combined length electrode and work cables.
3. Auxiliary Power
920 volt-amperes of 115 volt AC power are available from #31 and #32 on the AC-1200 terminal
strip.
DUTY CYCLE
The AC-1200 is rated for 100% duty cycle at 1200
amps and 44 volts.
IDEALARC®AC-1200
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
Read and understand this entire section before operating the machine.
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating
gloves.
FUMES AND GASES
can be dangerous.
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
Output Control 1 Single Phase
Remote Control Setting
Local Control Settin
Input Power Type U1 Rated Input Voltage
Submerged Arc Welding U2Rated Welding Voltage
Transformer Type X Rated Duty Cycle
Fuse I1Rated Input Current
High Voltage Indicator I2Rated Welding Current
3
Uo
Three Phase
Rated No-Load Voltage
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS
can cause fire or
explosion
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
Observe additional Safety Guidelines detailed
throughout this manual.
High Temperature Indicator
Rated Frequency
TO SET FOR LOCAL OR REMOTE
CONTROL
The output can be controlled either from the AC1200, the wire feeder or other remote locations.
To adjust the current from the wire feeder or other
remote locations, set the toggle switch on the front of
the AC-1200 to “ “. To adjust the output current
from the AC-1200, set this switch to “ “.
T0 SET THE OUTPUT CURRENT
Start the AC-1200 using the line disconnect switch or
breaker installed with the input wiring. The yellow pilot
light on the front panel indicates when the welder is
on.
Adjust the output current from minimum to maximum
within the range set by the output stud connections
using either the “ “ rheostat on the AC-1200 (toggle switch set on “ “) or the wire feeder or other
remote rheostat (toggle switch set on “ “).
IDEALARC®AC-1200
C-1
OPTIONAL KIT: Remote control K775.
ACCESSORIES
C-1
IDEALARC®AC-1200
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Have qualified personnel do the
maintenance and troubleshooting
work.
• Turn the input power OFF at the disconnect
switch or fuse box before working on this
equipment.
• Do not touch electrically live parts or electrode
with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
See additional warning information
throughout this operatorʼs manual.
------------------------------------------------------------
D-1
1. Every three months, blow out the machine with
compressed air. More frequent cleaning may be
necessary in areas with chemical or metallic particles and large quantities of dust.
2. The fan motors have sealed bearings which require
no service.
IDEALARC®AC-1200
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
CAUTION
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.
IDEALARC®AC-1200
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE
CAUSE
E-2
RECOMMENDED
COURSE OF ACTION
Welder will not start.
Welder will not weld (Contactors
operating properly)
Welder will not weld (Contactors not
operating).
1. Supply line fuse blown.
2. Open supply line lead.
3. Wrong supply line voltage.
1. Electrode or ground cable loose or
broken.
1. Thermostat on coil tripped. Welder
overheated (Fan motors operating). light is on.
2. Thermal protection in auxiliary
transformer, T2, has opened. (Fan
motors not running)
3. Circuit across #2 and #4 not working properly.
1. Replace fuse.
2. Look for possible cause and
repair.
3. Repair.
voltage.
1. Tighten connection or repair broken cable.
1. Check operation of fans and make
sure there is no obstruction to air
flow. Do not operate in excess of
welder rating.
First check 8 Amp fuse and replace if
necessary. I
possible areas of misadjustment
have been checked and the problem persists, Contact your local
Lincoln Authorized Field
Service Facility.
Provide nameplate specified
f all recommended
Welder welds at min. only no control.
4. Wire feeder control power; No
voltage across #31 and #32.
1. Remote control switch in wrong
position.
2. Control rheostat open.
3. Control circuit open.
4. Open saturable reactor control coil
or connection.
5. Welder control circuit dead: No
voltage across Control Board
Transformer X1-X2.
1. Switch to “ “ for welder rheostat control and to “ ” for control through accessory.
I
f all recommended possible
areas of misadjustment have
been checked and the problem
persists, Contact your local
Lincoln Authorized Field
Service Facility.
CAUTION
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.
IDEALARC®AC-1200
E-3
TROUBLESHOOTING
E-3
PROBLEMS
(SYMPTOMS)
Welder welds at max. only no control.
Contacts chatter.
POSSIBLE
CAUSE
Diodes or SCRʼs on heat sink
assemblies shorted.
Shorted or grounded current controll
rheostat.
Output By-Pass Capacitors open or
disconnected.
Free wheeling diode open or disconnected.
P.C. board components failed.
1. Low supply line voltage. Check
with Power Company.
Faulty contactor.
RECOMMENDED
COURSE OF ACTION
I
f all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
CAUTION
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.
IDEALARC®AC-1200
F-1
DIAGRAMS
F-1
IDEALARC®AC-1200
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 code number.
F-2
DIAGRAMS
AC-1200 SCOTT CONNECTION DIAGRAM
F-2
IDEALARC®AC-1200
F-3
DIAGRAMS
AC-1200 SCOTT CONNECTION DIAGRAM
TWO PARALLEL MACHINES SCOTT CONNECTED TO TWO OTHER PARALLEL MACHINES
FOR DESIRED PHASE ANGLE, INTERCONNECT MACHINES (AS SHOWN BELOW).
BOTH PHASE ANGLES MUST BE THE SAME.
TO GROUND PER NATIONAL
CB
A
ELECTRIC CODE.
F-3
N.B.
4/O CABLE
N.B.
WORK
ELECTRODE
ELECTRODE
WORK
4/O CABLES
N.C.
TEASER TRANSFORMER
TRAIL ARC
L2
L2
P1
L1
P1
L1
MAIN TRANSFORMER
LEAD ARC
CBA
L2
100
90
80
L1
4/O CABLES
N.C.
L2
100
90
80
L1
TO GROUND PER NATIONAL
ELECTRIC CODE.
WORK
N.B.
ELECTRODE
4/O CABLE
N.B.
ELECTRODE
WORK
3 PHASE SUPPLY LINE (N.A.)
NOTES:
N.A. TO OBTAIN NORMAL PHASE SEQUENCE AT THE WELDING ARCS, THE INPUT LINE PHASE SEQUENCE SHOULD BE A-C-B.
N.B. ELECTRODE CABLES OF PARALLELED MACHINES SHOULD BE CONNECTED TO THE SAME RANGE TAP.
N.C. NUMBER OF 4/O CABLES CONNECTED: 1 ON MIN. TAP; 2 PARALLEL ON MED. TAP; 3 PARALLEL ON MAX. TAP.
A.01
M10033-1
IDEALARC®AC-1200
F-4
DIAGRAMS
AC-1200 AND PARALLELED DC-1000’s
F-4
IDEALARC®AC-1200
F-5
DIAGRAMS
AC-1200 AND DC-1500’s
F-5
IDEALARC®AC-1200
WARNING
Spanish
AVISO DE
PRECAUCION
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
Aislese del trabajo y de la tierra.
Keep flammable materials away.
Mantenga el material combustible
fuera del área de trabajo.
Wear eye, ear and body protection.
Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
Isole-se da peça e terra.
Gardez à l’écart de tout matériel
inflammable.
Entfernen Sie brennbarres Material!
Mantenha inflamáveis bem guarda-
dos.
Protégez vos yeux, vos oreilles et
votre corps.
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
Turn power off before servicing.
Do not operate with panel open or
guards off.
WARNING
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
Débranchez le courant avant l’entre-
tien.
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
Não toque as partes elétricas nuas.
No operar con panel abierto o
guardas quitadas.
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• 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
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