Page 1
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: 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 •
Page 2
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.
Page 3
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.
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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.
Page 5
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.
Page 6
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.
Page 7
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
________________________________________________________________________
Page 8
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
Page 9
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
Page 10
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
WARNING
• Do not touch electrically live
parts or electrode with skin or
wet clothing.
• Insulate yourself from work
and ground.
ELECTRIC SHOCK
can kill.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
FUMES AND
GASES can be
dangerous.
• Wear eye, ear and body protection.
ARC RAYS
can burn.
• Keep flammable material
away.
WELDING SPARKS
can cause fire or
explosion.
DUTY CYCLE
The DC-1500 is rated for 100% duty cycle at 1500 amps
and 60 volts.
SET POLARITY
Connect the electrode cable to the “Positive” or “Negative”
studs depending upon the electrode polarity desired.
Connect the work cable to the other studs.
Set the “Electrode Negative — Electrode Positive” switch
to correspond to the polarity of the electrode cable connection. This switch setting is necessary for proper operation
of the Lincoln wire feeder attached to the power source.
START THE WELDER
Press the “ On - Off ” pushbuttons to start and stop the
welder. The red pilot light near the center of the control
panel indicates when the welder is on.
SET FOR MACHINE OR REMOTE CONTROL
The output can be controlled either at the wire feeder
or the DC-1500. When the NL Option Kit is installed,
the output is controlled only from the K775 Remote
Control usually mounted at the wire feeder.
To adjust the output from the wire feeder, set the toggle switch on the front of the DC-1500 to “Output
Control Remote”. To adjust the output using the DC1500 “Output Control” rheostat, set this switch to
“Output Control at DC-1500”.
SET THE WELDER OUTPUT
With the toggle switch set to “Output Control at DC1500”, rotating the “Output Control” rheostat on the
DC-1500 from 1 to 10 increases the machine output
from minimum to maximum. The same full range control is set from the wire feeder or K775 when the toggle
switch is set to “Output Control Remote”.
Set the output as required by the welding procedures.
MODE SWITCH
The toggle switch labeled CV Innershield, CV submerged arc, VV submerged arc, is used to select the
proper welder characteristics for the process being
used.
NOTE: Some machines say ”VV” for variable voltage
while other machines use the terminology “CC” for
constant current.
The CV Innershield Mode permits the DC-1500 to produce essentially a flat output characteristic that can be
varied from approximately 20 to 60 volts. In this position the dynamic characteristics of the machine under
welding conditions provides optimum welding characteristics for Innershield welding and other open arc
processes.
The CV Submerged Arc Mode also produces an
essentially flat output characteristics that can be varied from approximately 20 to 60 volts. The dynamic
characteristics of the CV Submerged Arc Mode are
such that excellent submerged arc welding can be
obtained for most procedures that previously required
a constant current type power source.
The VV Submerged Arc Mode permits the DC-1500 to
produce a constant current output characteristic
through the range of 200A-28V to 1500A-60V with an
open circuit voltage of 45 to 98 volts. Although almost
all submerged arc welding can now be done in the CV
mode, the VV mode is available for those procedures
where VV (CC) may still be desirable.
Set-up for Various Processes
Selection of mode switch position — There are several general rules to follow in the selection of the mode
switch position.
1. Use the CV Innershield mode for all Innershield
welding.
IDEALARC®DC-1500
Page 11
B-2
OPERATION
2. Use the CV Submerged Arc mode for most submerged arc welding. However, some high speed
welding procedures may perform better on the CV
Innershield mode.
3. The VV (CC) mode is available for high current,
large puddle submerged arc procedures that cannot be done as well with the constant voltage
mode.
4. Air Carbon Arc Gouging or Cutting — For air
carbon arc gouging, the constant voltage
Innershield mode is used with the output control
set between 4 and max. depending on the application, carbon size, etc. Up to 1/2” carbons, start with
the machine control set at 4 and increase as
required for long cable lengths. With 1/2” and 5/8”
carbons, short (100’) cable lengths can lead to
occasional trip out of the protection circuit when the
carbon is shorted to the work. Cutting back the output setting will reduce the short circuit current and
minimize tripping. Longer cable lengths do an even
better job since this also reduces the short circuit
current but even more significantly permits raising
the open circuit voltage (by increasing control setting) for smoother operation. See the table below
for optimum cable size and length.
TABLE B.1
Combined Total
Electrode and
Carbon Typical
Size Current Range (Min) (Max) Lead Size
1/2” 600-1000 Amps 250’ 825’ 2 — 4/0
5/8” 800-1200 Amps 375’ 925’ 3 — 4/0
Work Lead Length
Electrode
and Work
If ever longer leads are used and the output control
is already set on max., the unit has reached its
maximum air carbon arc capability.
3/4” carbons are not recommended for use with the
DC-1500 because the high surge currents that
occur with this diameter can cause the DC-1500
fault protection circuitry to trip the machine off the
line, if the operator does not gouge in such a way
to limit the currents.
General Set-Up Procedures When Using DC-1500
and Lincoln Automatic Head NA-3
(Read the following and refer to Table B.3 in the
Operation Section.)
1. NA-3 — The NA-3 should be set for the mode
being used on the power source. If using either of
the CV modes, the NA-3 VV board switch should
be set for CV. If the power source is used in the VV
mode, then the NA-3 VV board mode switch should
be placed in the VV position.
All NA-3’s when used with the DC-1500 are capable of cold starting with the variable voltage board
mode switch in VV. Cold starting permits the wire
to be inches down to the work, automatically stop
and automatically energize the flux hopper valve.
All NA-3’s made after September 1976, are capable
of cold starting on either CV or VV settings of the
variable voltage board switch.
IDEALARC®DC-1500
B-2
2. Arc striking with DC-1500 mode switch on CV
sub-arc or CV Innershield — There are a number
of basic techniques for good arc striking that apply
to all processes and power sources. It may not be
necessary in every application to follow these
guidelines, but when striking problems do occur,
following the suggestions below should provide
trouble-free starting. These procedures apply to all
single solid wire, Innershield wire, and Twinarc 1/8”
and 3/32” solid wire.
• Except for long stickout Innershield procedures
and Tiny Twinarc 1/16” procedures, an NA-3 start
board is not needed. If a start board is not need-
ed, it should be removed from the machine, or at
least disconnected and the logic board jumper
plug replaced. Leaving it connected makes the
setup for arc striking more difficult. Also, if a crater
board is not needed, it should be removed from
the NA-3 or at least electrically disconnected and
the jumper plug replaced.
• Cut electrode to a sharp point.
• For cold starts, make certain work piece is clean
and electrode makes positive contact with plate.
• For hot starts, travel should be started before wire
contacts the work (“on the fly” starting).
• Set NA-3 open circuit voltage control to approxi-
mately the same setting as the weld setting. For
initial test welds, choose the voltage setting
based on the Table B.2. Set the inch control to 2.
These are approximate settings only until the
welding procedure has been set.
It should be noted that with the DC-1500 the OCV
required for optimum starting is lower than that
required with other type power sources.
TABLE B.2
Approximate Voltage Voltage Control Setting
22-24 2
34-36 4
46-48 6
56-60 8
• Run a test weld, setting the proper current, volt-
age and travel speed.
Page 12
B-3
OPERATION
B-3
• Once the proper welding procedure is established
and if the start is poor — wire blast-off, stub, etc.,
adjust the OCV and inch speed for optimum starting. In general, a low inch speed will provide the
best starting.
Adjust the OCV by making repeated starts and
observing the voltmeter action.
With proper adjustment of the OCV control, the
voltmeter needle will swing smoothly up to the desired arc voltage and thus provide repeatable
starts.
If the voltmeter swings above then back to the desired welding voltage, the OCV setting is too high.
This usually results in a bad start where the wire
tends to “blast-off”.
If the voltmeter needle hesitates before coming up
to the desired voltage, the OCV is set too low.
This will
• For Twinarc welding, clipping both wires to equal
lengths will be beneficial to make consistently
good starts.
3. Single Innershield Wire — Procedures and tech-
niques are the same as above, except starting is
generally better “hot” than “cold”. For electrical
stickouts above 1 3/4” an NA-3 start board is
required.
cause the electrode to stub.
• Place start board’s voltage control approximately
equal to NA-3 voltage control setting.
When set per c and d, above, the starting only
procedure will provide a current setting lower than
the NA-3 current setting and a voltage setting
nearly equal to the desired welding procedure.
• With the start board time delay set at maximum,
establish the correct arc striking procedure as described previously by changing OCV and inch
speed.
• Now increase the start board current and voltage
to bring the start current and voltage closer to the
welding procedure. The start board current and
voltage should be as close to the welding procedure as possible while still getting satisfactory
starts.
• Now decrease the start time as low as possible
for optimum starts.
7. Arc striking with the DC-1500 mode switch in VV.
• NA-3 — The NA-3 variable voltage board mode
switch should be set to the VV position.
• Set OCV control at 6.5 to 7.0.
• Other techniques recommended in the previous
sections for good arc striking apply here also.
4. Twinarc Innershield — Procedures and tech-
niques are the same as above, except starting is
generally better “hot than “cold”. Use of an NA-3
start board improves starting.
5. Twinarc Submerged Arc 1/16” — Procedures
and techniques are the same as above, except starting is best when using CV Innershield and the NA-3
start board.
6. Use of the NA-3 Start Board — For those
processes above that recommend use of the NA-3
start board, the following method should be used to
set up the procedure.
• Set start time at 0 and start current and voltage at
mid-range. Start the weld and set the proper current and voltage for the welding procedure.
• Turn the start board timer to maximum.
• Set start board current 1 to 1 1/2” dial numbers
below NA-3 front control settings.
IDEALARC®DC-1500
Page 13
B-4
OPERATION
B-4
General Set-Up Procedures When Using DC-1500 and
Lincoln Automatic Head NA-5
(See Table B.3)
1. Install the NA-5 per the information in the NA-5 operating manual (IM-305). Connect the NA-5 to the DC1500 as described on the connection diagram.
2. Place the DC-1500 mode switch in the proper position
according to the process and procedure to be used.
3. Place the machine/remote switch in remote.
4. Connect the work lead to the work or a suitable piece
of scrap. Clip the end of the electrode to a sharp
point.
5. Preset the Start (if used), Weld and Crater (if used)
Controls to the wire speed and voltage specified in
the procedure.
6. Make several test welds, readjusting the starting and
stopping controls in the following order:
• Set the Arc Striking Wire Speed and Volts Controls
for optimum arc striking.
For initial test welds, set the NA-5 arc striking
wire speed control to 1/2 the weld wire feed
speed and the arc striking voltage control 4
volts above the weld voltage.
• If striking is still not satisfactory, see the NA-5
operating manual for information on the feed
motor acceleration.
• If installed, adjust the “Start Controls” to set the
welding procedures for the time set on the timer
to provide the bead size, penetration, or other
factor as needed for the application. If not used,
this board should be disconnected and the
jumper plug replaced.
• If installed, adjust the “Crater Controls” to set
the welding procedures for the set time after the
stop button is pressed to provide the bead size
or fill the crater as needed for the application. If
not used, this board should be disconnected
and the jumper plug replaced.
• Set the “Burnback Time” to provide the stopping
characteristics needed.
TABLE B.3
RECOMMENDED SET-UP PROCEDURES FOR NA-3/DC-1500, NA-5/DC-1500
INNERSHIELD SUBMERGED ARC
Single Single
Innershield Innershield High Current
Equipment and Stickout Stickout Twinarc Single Tiny Twin Very Large
Control Settings under 1 3/4” over 1 3/4” Innershield Solid Wire
Tiny Twin 1/16”
Wire Feed Type NA-3S NA-3S NA-3S
Control or NA-5 or NA-5 or NA-5 NA-3S NA-5 NA-3S NA-5 NA-3S NA-5 NA-3S NA-5
NA-3N NA-3N NA-3N
NA-3S VV Board
Mode Switch
NA-3 Inch Speed
Dial Setting
(5)
NA-5 Arc Striking —
Wire Speed
NA-3 OCV Control
NA-5 Arc Striking
Volts Control
NA-3 Start Board
CV — CV — CV — CV — CV — CV — VV —
2—2—2—2— 2—2— 2—
(5)
(5)
(4)
(6)
—
(4) (4) (4) (4) (4) (4) (4)
(4)
—
(6)
—
—
(4)
—
(6)
—
(4)
(6)
—
—
(6)
—— — — — — —
(2)
— Req’d
(2)
— Req’d
(2)
—
(2)
—
(2)
DC-1500 Output
Control Switch — Remote Remote Remote Remote Remote Remote Remote
Machine or Remote
DC-1500
Mode
Switch
DC-1500 Output
Control
CV CV CV CV Submerged CV CV Submerged
Innershield Innershield Innershield Arc
(3)
Innershield Arc
Inoperative Inoperative Inoperative Inoperative Inoperative Inoperative Inoperative
(1)
Over 1/16” Puddle
(4)
—
—
—
(4)
(6)
— 6.5 - 7.0 —
(2)
—
(3)
—
(2)
NA-3S NA-5
CC CVS
(4)
—
(1)
Starting is best with “hot” starting. Start button is pressed with wire above the work.
(2)
If an Na-3 start board is called for, refer to (General Set-Up Procedures When Using DC-1500 and Lincoln Automatic Head NA-3
in this Operation Section) for details on how to set the controls. If an NA-3 start board is not required, it should be electrically discon-
nected and the jumper plug replaced.
(3)
Some high speed welding procedures may perform better on the CV Innershield mode. Merely change the switch between CV Innershield
and CV Submerged arc position and select the best welding.
(4)
The NA-5 arc striking wire speed should initially be set at 1/2 the welding wire feed speed, and the NA-5 arc striking volts control 4
volts above the welding voltage. These controls can be adjusted as required for optimum arc striking.
(5)
Exact dial setting depends on cable size and length, carbon size, etc.
(6)
Set the OCV control to the same dial setting as the NA-3 voltage control. For initial test welds, choose the setting on Table B.1 in this
Operation Section.
IDEALARC®DC-1500
Page 14
B-5
OPERATION
NL Option Kit
(Not Required With NA-3, NA-5, LT-7 or LT-56)
The K783 NL option kit (for field installation) is
designed to permit use of the NA-2, LAF-3, LT-3 and
the LT-3 section of the LT-34 tractor with DC-1500’s
assigned code 7687 and above. It provides the necessary DC control power for the operation of the equipment and the necessary circuitry for proper inching,
cold starting and arc striking. In using the NL option
kit a K775 remote field control is required and is
included as part of the option kit. (See Item 5 in the
Installation Section)
The NL option kit consists of a sheet metal box, 12.5”
long, 11.5” deep and 5.7” high. This box mounts on
top of the DC-1500 and the following controls are
located on the front of the box:
1. Inch speed control — used for LT tractor only.
2. Hot start control — used to obtain optimum arc
striking.
3. Polarity switch — changes polarity of control circuit to correspond with electrode polarity.
4. Contactor dropout delay switch — switches in or
out a slight contactor drop out delay to prevent
sticking of the wire in the crater at the end of welding.
The terminal strip for connection to the automatic
equipment is located under the front cover. All necessary control leads for connection to the DC-1500 are
wired into the NL kit for easy connection to the DC1500 terminal strip.
WARNING
Before proceeding with any installation, be certain
the DC-1500 is turned off.
-------------------------------------------------------------
1. Mount the NL option box to the top of the DC-1500
with the screws used to fasten the roof and sides.
2. Remove the cover of the NL option for access to
the terminal strip.
B-5
3. Feed the control cable from the automatic wire
feed control unit through the grommet on the front
of the NL box. Connect the control leads per the
appropriate Connection Diagram Section at the
back of this manual. Secure the cables to the case
with the clamps and screws provided.
4. Using the same diagram, connect the leads from
the option kit to the DC-1500 terminal strip.
5. Feed the K775 control cable through the clamp on
the front of the NL option box and connect the
leads to terminals 75,76, and 77 per connection
diagram.
6. Replace the cover. This completes the installation.
NOTE: An NL Option was factory installed inside
DC-1500’s built to codes 7562-NL, 7636-NL and
7676-NL. The instructions for the K783 apply except
as follows:
1. The factory installed NL Option does not have a
separate “POS — NEG” switch.
2. The factory installed NL Option does not have an
“Inch Speed” control.
3. It cannot be used with LT-3 or LT-34 wire feeders.
4. The fuse protecting the 115 volt DC circuit is a 2
amp fuse located on the NL Option panel inside the
welder.
Operation When Connected to the NA-2
1. Set the “POS — NEG” switch (on both NL Option &
DC-1500) to correspond to the polarity of the electrode cable connection.
2. Set the mode switch on the front of the DC-15000
to “Constant Voltage — Innershield” or “Constant
Voltage — Sumerged Arc”.
3. Set the toggle switch on the front of the DC-1500 to
“Output Control Remote”.
4. Set the output as required for the procedures using
the K775 Remote Output Control shipped with the
NL Option.
5. Set the NA-2 inch speed to a speed lower than
welding feed speed for good starting using the control on the NA-2. The NL Option “Inch Speed” control is not in the circuit.
6. Set the “Hot Start Control” on the NL Option to 4.
7. Set the “Contactor Drop-Out Delay” switch to “Off”.
Refer to the NA-2 Operating Manual for instructions for setting the contactor drop-out delay and
crater fill-ing features built into the NA-2 circuit.
IDEALARC®DC-1500
Page 15
B-6
OPERATION
B-6
Operation When Connected to the LAF-3
and the K783 NL Option Kit
For proper arc striking and welding when using the
LAF-3 with the DC-1500 and K783 NL Option Kit, follow the instructions below (Turn the input power off at
the fuse box before working inside the machine.):
1. Connect the DC-1500 NL option, and LAF-3 per
the Connection Diagram M13321 in the Diagram
Section.
2. Remove the cover from the LAF-3 control box.
3. Remove the blue jumper lead connected between
#1 on the coil of the main relay and #7 on the coil
of the transfer relay. (The main relay is the upper
right relay when facing the left end of the control
box. The transfer relay is just to the left of the main
relay.)
4. Replace the LAF-3 control cover.
5. Set the “POS — NEG” switch (on both the NL
Option and the DC-1500) to correspond to the
polarity of the electrode cable connection.
6. Set the mode switch on the front of the DC-1500 to
“Variable Voltage”.
7. Set the toggle switch on the front of the DC-1500 to
“Output Control Remote”.
8. Set the DC-1500 welding current as required by
the procedures using the K775 Remote Output
Control shipped with the NL Option.
9. Set the LAF-3 “Inch Speed” control near minimum
so the electrode touches the work lightly before
starting the arc. The NL Option “Inch Speed” control is not in the circuit.
10. Set the “Hot Start Control” on the NL Option at
#2. This setting does not change the open circuit voltage, but it will improve starting, particularly at low currents. Adjust the control for optimum starting.
NOTE: The “Hot Start Control” does not affect the
starting method of the LAF-3, i.e., “cold” start, “hot”
start, etc. See IM198-B, Sec. 2.4.9.
11. Set the NL Option “Contactor Drop-Out Delay”
switch to “On”. This circuit delays opening of
the output contactor for a fixed length of time
after wire feeding stops to prevent sticking.
Overload Protection
The NL Option kit includes two fuses on the front
panel. The upper fuse (2 amp slow blow) protects the
inching circuit when the option is used with LT-3 and
LT-34 wire feeders. The lower fuse (2.8 amp slow
blow) protects the 115 volt DC circuit (#1 and #2). If
replacing either fuse use the same size and type.
Operation When Connected to the LT-3 or
LT-34
Follow the same instructions as above except in Step
1, connect per M13322. Omit Steps 2, 3 and 4. Set
the “Inch Speed” control on the NL Option as low as
possible so the electrode touches the work piece lightly before starting the arc.
IDEALARC®DC-1500
Page 16
D-1
MAINTENANCE
WARNING
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
D-1
ELECTRIC SHOCK
• Do not touch electrically hot parts.
can kill.
GENERAL MAINTENANCE
1. The fan motors have sealed bearings which require
no service.
2. In extremely dusty locations, dirt may clog the air
channels causing the welder to run hot. Blow out
the welder with low pressure air at regular intervals. Also blow dirt out of the NL Option box.
OVERLOAD PROTECTION
The DC-1500 has built-in protective thermostats. If the
rectifier or transformer reaches the maximum safe
operating temperature because of frequent overload or
high room temperature plus overload, the contactor
drops out stopping the welder. The thermostat automatically reset when the temperature reaches a safe
operating level. Press the “On” button to start the
welder.
The power rectifiers are also protected by a special
solid state circuit. With the occurrence of a short circuit or excessively high overloads, the input contactor
opens. When the overload is removed, press the “On”
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.
IDEALARC®DC-1500
Page 17
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.
Note: To locate the “Firing Circuit” and “Control/Fault Protection Circuit” P.C. boards, remove the upper case
panel on the left side of the machine. The names are printed on the boards.
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®DC-1500
Page 18
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE
CAUSE
E-2
RECOMMENDED
COURSE OF ACTION
Input contactor (CR1) chatters.
Machine input contactor does not
operate.
Machine input contactor operates
but no output when trying to weld.
1. Faulty input contactor (1CR).
2. Low line voltage.
3. Faulty pilot relay (2CR).
1. Supply line fuse blown.
2. Contactor power circuit dead.
3. Broken power lead.
4. Wrong input voltage.
5. Primary or power SCR thermostats open.
6. Open input contactor coil.
7. Faulty on-off switch.
8. Faulty pilot relay (2CR).
1. Electrode or work lead loose or
broken.
2. Open main transformer (T5) primary or secondary circuit.
3. “Firing Circuit” P.C. board not
connected or is faulty.
4. Output pilot relay (6CR) not operating or faulty.
1. Repair or replace.
2. Check with power company.
3. Replace relay.
1. Replace if blown. Look for reason first.
2. Check pilot transformer T1 and
associated leads and 5 amp fuse.
3. Check input voltage at contactor.
4. Check voltage against nameplate.
5. Check for overheating. Make
sure both fans are operating and
there is no obstruction to free air
flow. Faulty thermostats —
replace.
6. Replace coil.
7. Replace switch.
8. Replace relay.
1. Repair connection.
2. Repair.
3. All nine light emitting diodes (L1
thru L9) must be lit. (See “P.C.
Board Troubleshooting Guide”.)
4. Check relay by connecting a
jumper across terminals 2 and 4
on DC-1500 terminal strip.
Replace if faulty.
Machine has maximum output but no
control.
1. “Output Control” switch (SW4) in
wrong position.
2. “Output Control” switch faulty.
3. Open in feed back circuitry.
4. Faulty “Control/Fault Protection”
or “Firing Circuit” P.C. boards.
5. Output control potentiometer
open (lead no. 75).
1. Check position of switch.
2. Check switch and replace if
faulty.
3. Check wiring and control and
“Firing Circuit” P.C. board wiring
harness plugs.
4. All light emitting diodes must be
lit, except L4 on “Control/Fault
Protection” board. (See “P.C.
Board Troubleshooting Guide.”)
5. Check and replace if faulty.
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®DC-1500
Page 19
E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE
CAUSE
E-3
RECOMMENDED
COURSE OF ACTION
Machine does not have maximum
output.
Machine has output but trips off
immediately.
1. One input fuse blown.
2. One phase of main transformer
open.
3. Faulty “Control/Fault Protection”
or “Firing Circuit” P.C. boards.
4. Output control potentiometer
defective.
5. Output control potentiometer
leads open 226, 237, 236, 73, 74,
76, 77.
1. Machine has either an internal or
external short circuit on the output.
2. Faulty “Control/Fault Protection”
P.C. board.
3. Machine output voltage applied to
control leads.
1. Check and replace if blown after
checking for reason for blown
fuse.
2. Check for open and repair.
3. All light emitting diodes must be lit
on both P.C. boards, except L4
on “Control/Fault Protection”
board.(See “P.C. Board
Troubleshooting Guide.”)
4. Check and replace if faulty.
5. Check and repair broken leads.
1. Check internally and externally for
any shorts and remove or repair.
2. If no short circuits, LED L4 must
be lit (See “P.C. Board
Troubleshooting Guide”).
3. Check control cable or wire feeder for shorted or grounded control
leads.
Variable or sluggish welding arc.
Machine will not shut off.
1. Poor work or electrode connection.
2. Welding Cables too small.
3. Welding current or voltage too
low.
1. Input contacts frozen.
2. Pilot relay contacts stuck closed.
1. Check and clean all connections.
2. Check Suggested Copper Cable
Sizes in the table of the Instalation
Section.
3. Check procedures for recommended settings.
1. Check for approximately .13 inch
over travel of contacts.
2. Check and replace if necessary.
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®DC-1500
Page 20
E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE
CAUSE
E-4
RECOMMENDED
COURSE OF ACTION
Output control not functioning on the
machine.
Output control not functioning on the
machine.
1. “Output Control” switch in the
wrong position.
2. Faulty output control switch.
3. Faulty “Output Control” rheostat.
4. Leads or connections open in
“Control Circuit”.
5. Faulty “Firing Circuit” or
“Control/Fault Protection” P.C.
board.
1. “Output Control” switch in the
wrong position.
2. Faulty output control switch.
3. Faulty remote control rheostat.
4. Leads or connections open in
“Control Circuit”
5. Faulty “Firing” or “Control/Fault
Protection” P.C. board.
1. Place switch in “Output Control at
DC-1500”.
2. Check and replace if found faulty.
3. Check and replace if found faulty.
4. Check lead continuity and connections for an open and repair if necessary.
5. All light emitting diodes must be lit
on both P.C. boards, except L4
on “Control/Fault Protection”
board. (See “P.C. Board
Troubleshooting Guide.”)
1. Place switch in “Output Control
Remote”.
2. Check and replace if found faulty.
3. Check and replace if found faulty.
4. Check all leads and connections,
internal and remote, for continuity
and repair if necessary.
5. All light emitting diodes must be lit
on both P.C. boards, except L4
on “Control/Fault Protection”
board. (See “P.C. Board
Troubleshooting Guide.”)
Machine trips off with High
Current Procedures on starting.
1. OCV setting too high.
2. Defective control board.
1. Reduce OCV setting.
2. Replace control board.
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®DC-1500
Page 21
E-5
P.C. BOARD TROUBLESHOOTING GUIDE
E-5
WARNING
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
ELECTRIC
SHOCK Can kill.
CONTROL/FAULT PROTECTION P.C.
BOARD
1. LED L1 indicates AC input voltage is present at
pins 255-256. If not lit, check the voltage across
the secondary winding of the control transformer
T7. The voltage should be approximately 115 volts.
If not, the problem is in the power supply and not
the P.C. board.
2. LED L2 indicates welder output voltage is being
sup-plied to the control circuit. If not lit, check to
make certain 222 from pin 2 of the 12-pin control
circuit P.C. board connector is connected to the
power source negative output stud, and is not broken.
3. LED L3 indicates power is being applied to fault
pro-tection relay 2CR, when wire feeder button is
pressed or jumper is connected across 2 and 4.
4. LED L4 indicates when fault protection circuit is
being activated.
5. LED L5 indicates a control signal is being supplied
to the firing circuit. As the output control is varied,
LED L5 should change brilliancy.
FIRING CIRCUIT P.C. BOARD
Machine settings Terminals #2 and #4 jumpered on
for P.C. board DC-1500. Output Control at
troubleshooting
opera-
All nine light emitting diodes must be lit when the
power source is turned on and the wire feed arc start
button is pressed or a jumper is connected between 2
and 4.
1. LED L7 indicates AC power being supplied to P.C.
board from control transformer T2. If not lit, check
voltage across terminals 203 and 204 on the terminal strip lo-cated on the left side of the bottom fan
baffle. Voltage should be approximately 115 volts.
If no voltage indicates a supply problem, check
wiring and transformer.
• Do not touch electrically hot
parts.
DC-1500. Variable Voltage
tion.
If voltage is present, turn the machine off, remove
the 12-pin harness plug from the P.C. board, turn
the ma-chine back on and check the voltage
across pins 2 and 3 on the plug. This should be
approximately 115 volts.
If no voltage and there is voltage at terminals 203
and 204 on terminal strip TS-1 this indicates a broken lead or loose terminal on either lead 203 or
204.If voltage is present and LED L7 is not lit,
replace P.C. board.
2. LED L8 indicates AC power being supplied to P.C.
board from control transformer T3. If not, follow the
same procedure as above in (1) for terminals 205
and 206 on terminal strip TS-1 and pins 5 and 6 on
the connector.
3. LED L9 indicates AC power being supplied to P.C.
board from control transformer T4. If not, follow the
same procedure as above in (1) for terminals 207
and 208 on terminal strip TS-1 and pins 9 and 12
on the connector.
4. LED L1 through L6 indicate gate signals are being
supplied to the main power SCR’s L1 through L6
respectively. If light L5 on the “Control/Fault
Protection” circuit P.C. board and lights L7 through
L9 on the “Fir-ing” circuit P.C. board are lit and
LED’s L1 through L6 are not lit, check lead 231
between the “Firing” P.C. board and the
“Control/Fault Protection” P.C. board that is not
broken and is connected to each connector. If the
lead shows continuity and LED L1 through L6 are
not lit, replace the”Firing Circuit” P.C. board. If any
one of the LED’s L1 through L6 is not lit and lights
L7 through L9
board.
If troubleshooting guide indicates a possible P.C. board
problem, the guide on TABLE E.1 can be used to locate the
problem.
are lit, replace the “Firing Circuit” P.C.
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®DC-1500
Page 22
E-6
P.C. BOARD TROUBLESHOOTING GUIDE
Observe all Safety Guidelines detailed throughout this manual
TABLE E.1
OUTLINE FOR DC-1500 TROUBLESHOOTING GUIDE
(INPUT CONTACTOR “ON” TERMINALS 2 AND 4 CLOSED) TRIPS OFF IMMEDIATELY
IF OFF IF ON THE OUTPUT TERMINALS
CHECK LED L1 CHECK “FIRING” BOARD IF TROUBLE STILL L4, L5, L6
IF OFF IF ON CHECK LED L3 ON BRILLIANCY
CHECK AC REPLACE NINE LIGHTS PROTECTION” BOARD IF LIGHTS ARE NOT ALL
INPUT TO “CONTROL/ SHOULD APPROXIMATELY EQUAL
“CONTROL/ FAULT BE ON IF LIGHT GOES ON,THEN BRIGHT, REPLACE
FAULT PROTECTION” QUICKLY OUT WHEN START FIRING P.C. BOARD
PROTECTION” BOARD IF YES BUTTON IS PRESSED,
BOARD IF NO “CONTROL/FAULT
POSSIBLE CHECK GATE PROTECTION” BOARD IS
DEFECTIVE T7 LEAD CHECK DEFECTIVE AND SHOULD
TRANSFORMER CONNECTIONS LED’S BE REPLACED
NO WELDER OUTPUT MACHINE HAS OUTPUT BUT ERRATIC WELDING
CHECK CONTROL BOARD CHECK FOR SHORT
LED L5 BETWEEN ELECTRODE AND CHECK MODE SWITCH FOR
LED’S PERSISTS, FOR EQUAL
ALL “CONTROL/FAULT
TO SCR’S L7, L8, L9
IF ONE IF ON AND
OR MORE OTHER LIGHTS
ARE OUT ARE OUT
CHECK AC REPLACE
INPUT TO FIRING
BOARD, BOARD
203-204, 205-206
207-208
POSSIBLE
DEFECTIVE
TRANSFORMERS
T2, T3, OR T4
WORK LEADS, REMOVE PROPER POSITION FOR
EXTERNAL LEADS FROM PROCESS BEING USED
WARNING
• Have an electrician install and
• Turn the input power off at the
ELECTRIC SHOCK
can kill.
• Do not touch electrically hot parts.
CHECK PROCEDURE
CHECK LED’S
service this equipment.
fuse box before working on
equipment.
E-6
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®DC-1500
Page 23
F-1
DIAGRAMS
F-1
IDEALARC®DC-1500
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.
Page 24
F-2
DIAGRAMS
F-2
IDEALARC®DC-1500
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.
Page 25
F-3
DIAGRAMS
F-3
Connection of DC-1500 to NA-5
Above diagram shows electrode connected po-sitive. To
change polarity, turn power off, reverse the electrode and
work leads at the power source, and position the switch on
power source to proper polarity.
N.A. Welding cables must be of proper capacity for the current and duty cycle
of immediate and future applications.
N.B. Extend lead 21 using #14 or larger insulated wire physically suitable for
the installation. An S16586-[ ] remote voltage sensing work lead is available for this purpose. Connect it directly to the work piece keeping it
separate from the welding work cable connection to work piece. For
convenience, this extended #21 lead should be taped along the welding
work cable. (This extended #21 lead connection replaces the need to
employ the remote work lead accessory on LN-9’s which have a direct
work lead jack.)
N.C. Tape up bolted connection.
N.D. Connect the NA-5 control cable ground lead to the frame terminal marked
near the power source terminal strip. The power source must be
properly grounded.
N.E. If using an older automatic control cable with leads 75, 76, 77; connect
lead 75 to #75 on terminal strip, connect lead #76 to #74 on terminal
strip, connect lead #77 to #73 on terminal strip.
N.F. Connect the jumpers on the NA-5 voltage board as follows: connect RED
jumper to pin “S”, connect WHITE jumper to pin “B”.
N.G. Set the DC-1500 controls as follows:
Set the control switch to “Output Control Remote”. For C.V. Submerged
Arc Processes, set the mode switch to “C.V. Submerged Arc”. For Open
Arc Processes, set the mode switch to “C.V. Innershield”.
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 (Obsolete)
N.A. On codes above 8234 extend
lead 67 and connect it to the
electrode cable going to the automatic equipment.
N.B. On codes below 8234 this is #67
and the LAF-3 #67 lead can be
connected either to the #67 terminal or the electrode cable terminal as shown. Terminal 82 not
present on later D.C. 1500’s.
N.C. Terminals 73 & 74 not present on
earlier D.C. 1500’s.
This diagram shows the electrode connected positive. To change polarity, turn power source off,
reverse the electrode and work leads at the power
source and position the leads on the back of the
ammeter and voltmeter in the LAF-3 control box.
Contactor drop out delay switch on the NL option
kit must be in the “on” position.
The 4/0 cables shown will handle up to 1000 amps
at 80% duty cycle. For higher currents or duty
cycle add additional cables to the power source
output studs.
For best arc striking when connected to an
LAF-3 make the following inside the LAF-3
control unit. Remove the jumper lead connected between #1 on the coil on the
main relay and #7 on the coil of the transfer relay. (The main relay is the upper right
relay when facing the left end of the control box. The transfer relay is just to the left
of the main relay.
ELECTRIC SHOCK
can kill.
WARNING
• Do not operate with covers
removed.
• Disconnect welding power source
before servicing.
• Do not touch electrically live
parts.
• Only qualified persons should
install, use or service this
machine.
M13321
2-26-82C
IDEALARC®DC-1500
Page 26
F-4
DIAGRAMS
Connection of DC-1500 to NA-3 (All), LT-5 or LT-7
Above diagram shows electrode connected positive. To change
polarity, turn power source off, reverse the electrode and work leads
at the power source and position the switch on power source to proper polarity. Also reverse the leads on the back of the ammeter and
voltmeter in the automatic control box.
F-4
Connect the control cable ground lead to the frame terminal marked
near the power source terminal strip. The power source must be
properly grounded.
To automatic control box.
* If using an older control cable: Connect lead #75 to #75 on terminal
strip, connect lead #76 to #76 on terminal strip, connect lead #77 to
#77 on terminal strip.
N.A. Welding cables must be of proper capacity for the current and
duty cycle of immediate and future applications.
N.B. Extend lead 21 using #14 or larger insulated wire physically suit-
able for the installation. An S16586 remote voltage sensing work
lead is available for this purpose. Connect it directly to the work
piece keeping it separate from the welding work lead circuit and connection for convenience, this extended #21 lead
should be taped to the welding work lead.
N.C. Tape up bolted connection.
N.D. Terminals 73 and 74 not 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 to the
automatic equipment.
N.B. On codes below 8234 this is #67 and the
LT-3 or LT-34 #67 lead can be connected
either to #67 or to the electrode cable terminal as shown. Terminal 82 not present
on later DC-1500’s.
N.C. Terminals 73 and 74 not present on earlier
DC-1500’s.
This diagram shows the electrode connected positive. To change
polarity, turn power source off, reverse the electrode and work
leads at the power source and position the switch on the power
source and th NL option kit to the proper polarity. Also reverse the
leads on the back of the ammeter and voltmeter in the LT-3 control
box.
Contactor drop out delay switch on the NL option kit must be in the
“On” position.
The 4/0 cables shown will handle up to 1000 amps at 80% duty
cycle. For higher currents or duty cycle add additional cables to the
power source output studs.
ELECTRIC SHOCK
can kill.
WARNING
• Do not operate with covers
removed.
• Disconnect welding power source
before servicing.
• Do not touch electrically live
parts.
• Only qualified persons should
install, use or service this
machine.
M13322
2-26-82C
IDEALARC®DC-1500
Page 27
F-5
4-18-75B
38.00
DIMENSION PRINT
.406 DIA.
MTG. HOLES
4-18-75B
S-15709
F-5
15.28
22.30
36.1220.00
3.69
53.50
IDEALARC®DC-1500
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