Lincoln Electric IM318 User Manual

Constant Voltage and Constant Current DC Arc Welding

Power Source, 3 Phase Rectifier Type

®

RETURN TO MAIN MENU

IDEALARC DC-1500

For use with machines having Code Numbers 8294 and above.

For codes below 8294 see IM280.

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.

IM318-C

November, 2011

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] 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 near 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 may 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 only compressed 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. Read and follow the instructions on compressed 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. 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
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.

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.

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.

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.

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.

PRÉCAUTIONS DE SÛRETÉ POUR
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 customerʼs 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 vi

Installation .......................................................................................................Section A

Location .................................................................................................................A-1

Input Wire ..............................................................................................................A-1

Output Connection ..........................................................................................A-1,A-2

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1

Duty Cycle .............................................................................................................B-1

Set Polarity .............................................................................................................B-1

Start the Welder ....................................................................................................B-1

Set for Machine or Remote Control.......................................................................B-1

Set the Welder Output...........................................................................................B-1

Mode Switch..........................................................................................................B-1

Set-up for Various Processes ........................................................................B-1, B-2

General Set-Up Procedures When Using DC-1500 and Lincoln Automatic Head NA-3
General Set-Up Procedures When Using DC-1500 and Lincoln Automatic Head NA-5

Recommended Set-Up Procedures for NA-3/DC-1500, NA-5/DC-1500 ...............B-4

NL-Option Kit, Operation When Connected to the NA-2.......................................B-5

Operation When Connected to the LAF-3 and the K783 NL Option Kit ...............B-6

Operation When Connected to the LT-3 or LT-34 ................................................B-6

Overload Protection ..............................................................................................B-6

_______________________________________________________________________

TABLE OF CONTENTS

Page

.......B-2, B-3

..............B-4

Maintenance ....................................................................................................Section D

Safety Precaution ..................................................................................................D-1

General Maintenance ............................................................................................D-1

Overload Protection...............................................................................................D-1

________________________________________________________________________

Section E ..............................................................................................Troubleshooting

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-4

P.C. Board Troubleshooting Guide ................................................................E-3, E-4

________________________________________________________________________

Wiring Diagram, Connection Diagrams and Dimension Print .......................Section F

________________________________________________________________________

Parts List ........................................................................................P-118, P-84-J Series

________________________________________________________________________

A-1

INSTALLATION

A-1

WARNING

• Do not lift this machine using lift
bale if it is equipped with a
heavy accessory such as a trailer
or gas cylinder.

• Lift only with equipment of

FALLING

EQUIPMENT can

cause injury.

adequate lifting capacity.

• Be sure machine is stable when
lifting.

LOCATION

Install the welder in a dry location where there is free cir-cula­tion of air in through the louvers in the 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.

Based on National Electrical Code For 60 Hertz,

3 Phase Welders at 100% Duty Cycle

NOTE: The standard machines are designed to oper-

ate on 460 volt-60 Hertz, 440 volt-50 Hertz and 380
volt-50 Hertz input power systems. However, to use
the machines on 380 volt-50 Hertz power, reconnect
the transformer input leads in accordance with the
connection diagram pasted to the inside of the lower
right side case panel.

OUTPUT CONNECTION

(Turn Power Source Off)

1. Output Studs

The “Positive” and “Negative” output studs are
located on the front panel. Two of each are provid­ed to simplify connecting multiple electrode or
work cables as suggested in the table below.

Connect the electrode cables to the “Positive”
studs for electrode positive (DC+) polarity or to
the “Negative” stud for electrode negative (DC-)
polarity as required by the welding procedures.
Connect the work cables to the other set of studs.
Tighten the nuts with a wrench.

• Turn the input power off at the
fuse box before working on
equipment.

ELECTRIC SHOCK

can kill.

• Do not touch electrically hot
parts.

Failure to fuse the input lines per the specifications
in this manual will constitute customer abuse and
void the warranty.

-----------------------------------------------------------------------

Be sure the voltage, phase and frequency of the input power is
as specified on the welder nameplate.

Have a qualified electrician remove the lower right side case
panel and connect 3 phase AC power to terminals L

of the input contactor in accordance with the Na-tional

L

3

Electrical Code, all local codes and the wiring diagram located
inside the machine.

The frame of the welder must be grounded. A stud marked
with the symbol located on the fan shroud is provided for
this purpose. See the U.S. National Electrical Code for
details on proper grounding methods.

, L2and

1

Recommended Input Wire, Grounding Wire and

Fuse Sizes

Copper Wire Size

Type 75° In Conduit

Input Amps 3 Input Grounding Super Lag Fuse
Volts Input Wires Conductor Size in Amps

460 184 000 3 300

Suggested Copper Cable Sizes — 80% Duty Cycle

Below 1000 amps Two 4/0
1000 to 1200 amps Three 4/0
1200 to 1500 amps Four 4/0

Up to

200’

2. Auxiliary Power

This machine supplies the 1000 volt-amperes of
115 volt, AC power needed for the automatic wire
feeders. The power is available from terminals
#31 and #32 on the terminal strip.

3. “NL Option” (K783)

Installation of an NL option is required when con­necting a DC-1500 to LAF-3, NA-2, LT-3 or LT-34
wire feeding systems. See the section on page 9
entitled “NL Option Kit” for full information.

4. Wire Feeder Connection — Without NL Option

Turn 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
strip exactly as spec-ified in the appropriate con­nection diagram included in the wire feeder
Operating Manual. Attach the control cable to the
panel at the right of the terminal strip using the
clamp attached to the control cable. Close the
door and replace the screw.

To connect the DC-1500 to wire feeders not cov­ered in available connection diagrams, write to
the factory for instructions giving complete name­plate information for the DC-1500 and wire feed­er.

IDEALARC®DC-1500

A-2

5. Optional Remote Control (K775)

This control is included as part of the “NL Option”.
Connect it to the “NL Option” box per instructions
shipped with the option. (Not required with the NA­3, NA-5, LT-7 or LT-56.)

It can be purchased separately when the DC-1500
is used for other applications.

To install, turn the power off. Remove the screw
and lift the hinged door on the front of the control
panel to expose the terminal strips. Connect the
numbered leads to the appropriate terminals — 75
to 75, etc — on the terminal strip and the green
lead to the stud marked with the symbol .
Attach the control cord to the panel at the right of
the terminal strip using a suitable clamp. Close the
door and replace the screw. The Re-mote Control
cord can be lengthened to any length by properly
splicing an appropriate four conductor rubber-cov­ered cable to the standard 25’ cord before connect­ing to the DC-1500 terminal strip.

6. 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 #4 on the terminal strip on the front
of the DC-1500. With the #2 to #4 jumper connect­ed, the output studs are en-ergized whenever the
machine is on.

INSTALLATION

A-2

WARNING

If the electrode leads to the wire are not discon­nected per instructions, the wire feeder nozzle or gun
and electrode will be electrically “hot”.

---------------------------------------------------------------

7. DC-1500 Paralleling Kit

A kit for field installation only, (order K1900-1) is
avail-able for paralleling two DC-1500’s for currents
up to 3000 amperes, 100% duty cycle. Complete
installation instructions are shipped with the kit.

8.

Connecting for High Frequency Starting

As shipped, these welders can be used with a high
frequency unit for improved automatic welding start­ing characteristics.

RATINGS

IP21 enclosure
Main Transformer insulation class 155° (F)

IDEALARC®DC-1500