Constant Voltage and Constant Current DC Arc Welding
Power Source, 3 Phase Rectifier Type
®
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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, OPERATE 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-B
June, 2008
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S 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.
Mar ʻ95
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.
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 below Threshold Limit Values (TLV)
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.
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.
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.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
vapors
AUG 06
to
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs 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.
Jan, 07
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.
Mar. ʻ93
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
“Product Registration”. 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 “Quick Links” and then
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.
INSTALLATION
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 circulation 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.
• Turn the input power off at the
fuse box before working on
equipment.
3 Phase Welders at 100% Duty Cycle
NOTE: The standard machines are designed to operate 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)
a. 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.
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’
ELECTRIC SHOCK
can kill.
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
and L3of the input contactor in accordance with the National 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.
Recommended Input Wire, Grounding Wire and Fuse Sizes
Based on National Electrical Code For 60 Hertz,
Input Amps 3 Input Grounding Super Lag Fuse
Volts Input Wires Conductor Size in Amps
460 184 000 3 300
• Do not touch electrically hot
parts.
Copper Wire Size
Type 75° In Conduit
1
, L
b. 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.
c. “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
2
feeding systems. See the section on page 9 entitled “NL
Option Kit” for full information.
d. 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 specified 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.
-5-
INSTALLATION
e. 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 NA-3,
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 Remote Control cord can be lengthened to any length by
properly splicing an appropriate four conductor rubbercovered cable to the standard 25’ cord before connecting
to the DC-1500 terminal strip.
f. Connecting for Air Carbon Arc
To use the DC-1500 for air carbon arc or other applications, 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 energized whenever the machine is on.
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”.
g. DC-1500 Paralleling Kit
A kit for field installation only, (order K1900-1) is available for paralleling two DC-1500’s for currents up to
3000 amperes, 100% duty cycle. Complete installation
instructions are shipped with the kit.
h. 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)
OPERATING INSTRUCTIONS
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.
DUTY CYCLE
The DC-1500 is rated for 100% duty cycle at 1500 amps
and 60 volts.
To 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.
• Wear eye, ear and body protection.
ARC RAYS
can burn.
• Keep flammable material away.
WELDING SPARKS
can cause fire or
explosion.
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.
To 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.
-6-
OPERATING INSTRUCTIONS
To 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, however, 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 DC-1500 “Output
Control” rheostat, set this switch to “Output Control at DC1500”.
To Set the Welder Output
With the toggle switch set to “Output Control at DC-1500”,
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.
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
5
and
/8” carbons, short (100’) cable lengths can lead to
1
/2”
occasional tripout 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.
Combined Total
Electrode and
Carbon Typical
Size Current Range (Min) (Max) Lead Size
1
/2600-1000 Amps 250’ 825’ 2 — 4/0
5
/8800-1200 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 also to the chart on page 9.)
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.
-7-
OPERATING INSTRUCTIONS
2. Arc striking with DC-1500 mode switch on Cv sub-arc or
CV Innershield — There are a number of basic tech-
niques 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
a. Except for long stickout Innershield procedures and
b. Cut electrode to a sharp point.
c. For cold starts, make certain work piece is clean
d. For hot starts, travel should be started before wire
e. Set NA-3 open circuit voltage control to approxi-
f. Run a test weld, setting the proper current, voltage
g. Once the proper welding procedure is established
1
/8and 3/32solid wire.
1
Tiny Twinarc
/16procedures, an NA-3 start board is
not needed. If a start board is not needed, 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.
and electrode makes positive contact with plate.
contacts the work (“on the fly” starting).
mately the same setting as the weld setting. For
initial test welds, choose the voltage setting based
on the table below. 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.
Approximate Voltage Voltage Control Setting
22-24 2
34-36 4
46-48 6
56-60 8
and travel speed.
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 cause the electrode to stub.
h. For Twinarc welding, clipping both wires to equal
lengths will be beneficial to make consistently good
starts.
3. Single Innershield Wire — Procedures and techniques
are the same as above, except starting is generally better
3
“hot” than “cold”. For electrical stickouts above 1
/4an
NA-3 start board is required.
4. Twinarc Innershield — Procedures and techniques are
the same as above, except starting is generally better
“hot than “cold”. Use of an NA-3 start board improves
starting.
1
5. Twinarc Submerged Arc
/16— Procedures and tech-
niques 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.
a. 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.
b. Turn the start board timer to maximum.
1
c. Set start board current 1 to 1
/2dial numbers below
NA-3 front control settings.
d. 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.
e. With the start board time delay set at maximum,
establish the correct arc striking procedure as described previously by changing OCV and inch speed.
f. 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.
g. Now decrease the start time as low as possible for
optimum starts.
7. Arc striking with the DC-1500 mode switch in VV.
a. NA-3 — The NA-3 variable voltage board mode
switch should be set to the VV position.
b. Set OCV control at 6.5 to 7.0.
c. Other techniques recommended in the previous sec-
tions for good arc striking apply here also.
-8-
OPERATING INSTRUCTIONS
General Set-Up Procedures When Using DC-1500 and
Lincoln Automatic Head NA-5
(See chart below.)
1. Install the NA-5 per the information in the NA-5 operating manual (IM-305). Connect the NA-5 to the
DC-1500 as described on the connection diagram.
2. Place the DC-1500 mode switch in the proper position
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:
a. 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.
b. If striking is still not satisfactory, see the NA-5 op-
erating manual for information on the feed motor
acceleration.
c. 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.
d. 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.
e. Set the “Burnback Time” to provide the stopping
characteristics needed.
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 13/4” over 13/4” Innershield Solid Wire Tiny Twin 1/
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
16(1)
(4)
—
—
—
16
Over 1/
(4)
(6)
— 6.5 - 7.0 —
(2)
—
Puddle
—
(2)
NA-3S NA-5
(3)
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 page 7 for details on how to set the controls. If an NA-3 start board is not required, it
should be electrically disconnected 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 based on the table
on page 7.
-9-
OPERATING INSTRUCTIONS
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 pg 6, paragraph e.)
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 dropout 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 DC-1500 terminal strip.
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 filling features built into the NA-2 circuit.
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.
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 included at the back of this manual. Secure the cables to the case with the clamps and
screws provided.
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.
2. Remove the cover from the LAF-3 control box.
-10-
OPERATING INSTRUCTIONS
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 IM-198-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.
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.
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.
MAINTENANCE
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.
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.
• Do not touch electrically hot parts.
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.
-11-
TROUBLESHOOTING GUIDE
WARNING
ELECTRIC SHOCK can kill.
• Have a qualified individual install
and service this equipment.
• Turn the input supply power OFF
at the disconnect switch or fuse
box before working on this equipment.
• Do not touch electrically hot parts.
------------------------------------------------------------------------
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE CAUSE REMEDY
(SYMPTOMS)
Input contactor (CR1) chatters.
Machine input contactor does not operate.
Machine input contactor operates but no output
when trying to weld.
Machine has maximum output but no control.
Machine does not have maximum output.
Machine has output but trips off immediately.
a. Faulty input contactor (1CR).
b. Low line voltage.
c. Faulty pilot relay (2CR).
a. Supply line fuse blown.
b. Contactor power circuit dead.
c. Broken power lead.
d. Wrong input voltage.
e. Primary or power SCR thermostats open.
f. Open input contactor coil.
g. Faulty on-off switch.
h. Faulty pilot relay (2CR).
a. Electrode or work lead loose or broken.
b. Open main transformer (T5) primary or secondary circuit.
c. “Firing Circuit” P.C. board not connected or is
faulty.
d. Output pilot relay (6CR) not operating or faulty.
a. “Output Control” switch (SW4) in wrong position.
b. “Output Control” switch faulty.
c. Open in feed back circuitry.
d. Faulty “Control/Fault Protection” or “Firing Circuit”
P.C. boards.
e. Output control potentiometer open (lead no. 75).
a. One input fuse blown.
b. One phase of main transformer open.
c. Faulty “Control/Fault Protection” or “Firing Circuit”
P.C. boards.
d. Output control potentiometer defective.
e. Output control potentiometer leads open 226,
237, 236, 73, 74, 76, 77.
a. Machine has either an internal or external short
circuit on the output.
b. Faulty “Control/Fault Protection” P.C. board.
c. Machine output voltage applied to control leads.
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.
a. Repair or replace.
b. Check with power company.
c. Replace relay.
a. Replace if blown. Look for reason first.
b. Check pilot transformer T1 and associated leads
and 5 amp fuse.
c. Check input voltage at contactor.
d. Check voltage against nameplate.
e. Check for overheating. Make sure both fans are
operating and there is no obstruction to free air flow.
Faulty thermostats — replace.
f. Replace coil.
g. Replace switch.
h. Replace relay.
a. Repair connection.
b. Repair.
c. All nine light emitting diodes (L1 thru L9) must be
lit. (See “P.C. Board Troubleshooting Guide”.)
d. Check relay by connecting a jumper across terminals 2 and 4 on DC-1500 terminal strip. Replace if
faulty.
a. Check position of switch.
b. Check switch and replace if faulty.
c. Check wiring and control and “Firing Circuit” P.C.
board wiring harness plugs.
d. All light emitting diodes must be lit, except L4 on
“Control/Fault Protection” board. (See “P.C. Board
Troubleshooting Guide.”)
e. Check and replace if faulty.
a. Check and replace if blown after checking for reason for blown fuse.
b. Check for open and repair.
c. 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.”)
d. Check and replace if faulty.
e. Check and repair broken leads.
a. Check internally and externally for any shorts and
remove or repair.
b. If no short circuits, LED L4 must be lit (See “P.C.
Board Troubleshooting Guide”).
c. Check control cable or wire feeder for shorted or
grounded control leads.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
-12-
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE CAUSE
REMEDY
(SYMPTOMS)
Variable or sluggish welding arc. a. Poor work or electrode connection. a. Check and clean all connections.
Machine will not shut off. a. Input contacts frozen. a. Check for approximately .13 inch over travel
Output control not functioning on a. “Output Control” switch in the wrong a. Place switch in “Output Control at
the machine. position. DC-1500”.
Output control not functioning on a. “Output Control” switch in the wrong a. Place switch in “Output Control Remote”.
remote control. position.
Machine trips off with High a. OCV setting too high. a. Reduce OCV setting.
Current Procedures on starting. b. Defective control board. b. Replace control board.
b. Welding leads too small. b. Check table on page 4.
c. Welding current or voltage too low. c. Check procedures for recommended settings.
of contacts.
b. Pilot relay contacts stuck closed. b. Check and replace if necessary.
b. Faulty output control switch. b. Check and replace if found faulty.
c. Faulty “Output Control” rheostat. c. Check and replace if found faulty.
d. Leads or connections open in “Control d. Check lead continuity and connections for an
Circuit”. open and repair if necessary.
e. Faulty “Firing Circuit” or “Control/Fault e. All light emitting diodes must be lit on both
Protection” P.C. board. P.C. boards, except L4 on “Control/Fault
Protection” board. (See “P.C. Board
Troubleshooting Guide.”)
b. Faulty output control switch. b. Check and replace if found faulty.
c. Faulty remote control rheostat. c. Check and replace if found faulty.
d. Leads or connections open in “Control d. Check all leads and connections, internal and
Circuit”. remote, for continuity and repair if
necessary.
e. Faulty “Firing” or “Control/Fault e. All light emitting diodes must be lit on both
Protection” P.C. board. P.C. boards, except L4 on “Control/Fault
Protection” board. (See “P.C. Board
Troubleshooting Guide.”)
ELECTRIC
SHOCK Can kill.
P.C. BOARD TROUBLESHOOTING GUIDE
WARNING
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
• Do not touch electrically hot
parts.
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 supplied 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.
-13-
P.C. BOARD TROUBLESHOOTING GUIDE
3. LED L3 indicates power is being applied to fault protection 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
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 located 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.
If voltage is present, turn the machine off, remove the
12-pin harness plug from the P.C. board, turn the machine back on and check the voltage across pins 2 and
3 on the plug. This should be approximately 115 volts.
DC-1500. Variable Voltage operation.
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 “Firing” 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 are lit, replace the “Firing Circuit” P.C.
board.
If troubleshooting guide indicates a possible P.C. board
problem, the guide on page ? can be used to locate the
problem.
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
ELECTRIC SHOCK
can kill.
CHECK PROCEDURE
CHECK LED’S
WARNING
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
• Do not touch electrically hot parts.
-14-
DIAGRAMS
-15-
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..
DIAGRAMS
Connection of DC-1500 to NA-5
Above diagram shows electrode connected positive. 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
-16-
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.
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
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 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)
This diagram shows the electrode connected positive. To change
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.
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.
-17-
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
38.00
4-18-75B
DIMENSION PRINT
.406 DIA.
MTG. HOLES
4-18-75B
S-15709
15.28
22.30
36.1220.00
3.69
53.50
-18-
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
E
L10742-17
ENGINEERING CONTROLLED
MANUFACTURER:
CHANG
No
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● Do not operate with panel open or
guards off.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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