Lincoln Electric IDEALARC IM318-B User's Manual
Contents
1. 5 2 Chinese Korean Do not touch electrically live parts 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 moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se pe a e terra Ni amp mh O f SS MARHE FRANEACRHEUCE JT Wd7 2 5 f amp TE ATUBSHELTFEL e k BAZ IR 2x404 7 JE WINE H amp e B RMI ERR e 3544 SHES Ne HY se yya AU PHA e 2749 AXIS HS3 OMAR l gw Gall laf oye daa dea ag iY d ily gS elall AA Gadi Jai JR aua le ile woe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e KAPTU SODMTOBEEER EVA fbi I els Hc AIX uie why Jus ALIM Aal aa Wear eye ear and body protection Prot jas2. SNVHI J H 943MOd LE PHAIOBINOO u3iNHOJSNVH L 012 6 8 74 lt lt vez lt lt 9 e lt s 62 gt gt 7 SES lt lt ee 92 gt gt 2 DE lt lt 1 U L ssg amp 4t 2 0L oz ei Wei Wei 300 5NITT3A fouinoo 1 1nd1no YMS LOdU 0L JA MOTS 202 8 151 MS 0334 GALVAILOY DEI xnv 3 3 4 5 KE 193NNO93H sang T asn4 ea 1574 vs Addis OL EN 3sn44o w HOLOVINOO ANNI J ag od 12 A AYTAY NOIL9310Hd 1VISOWH3HL uos SHOLON a HANHOASNVEL ivisOWH3Hl 212 AHVIWIHd 2 012 i vue 5 SCH ALIEV10d P MOTS V8 lqouoza C HAMOd LAS AYTAY NDIOO TH3INI ze RECH 3504 40 WNIW
3. RETURN TO MAIN MENU IM318 B IDEALARL DL 1 500 dre 208 Constant Voltage and Constant Current DC Arc Welding Power Source 3 Phase Rectifier Type For use with machines having Code Numbers 8294 and above 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 thought ful 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 OPERATOR S MANUAL ISO 9001 5 CN si I d a Designed and Manufactured Under a Quality Program Certified b ABS Quality E to ISO 9001 Req 8 CERTIFICATE NUMBER 30273 For codes below 8294 see 280 IDLALARC Care LINCOLN Copyright Lincoln Global Inc 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 l SAFETY i AA WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer bi
4. talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you Tha OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment 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 posses sion at that time Lincoln Electric is not in a position to warrant or guarantee suc
5. 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 4 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 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 spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is
6. 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 adequate lifting capacity EQUIPMENT can cause injury 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 N e Have an electrician install and service this equipment e 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 war ranty 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 12 and L of the input contactor in accordance with the Na tional 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
7. S MRK e do Gel tee Asal OMAR Aga y Gils l l jlgall l a Ja y e 4 Gel S i di Ae Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG EE BIR Chinese Ss LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR 125MM PBHOA A OHRBEE lt K BA 3880 CT EW TRHORASMEK HDT FEU ARAM 3E XE PR IN XE RI JE Pk BI BI JL R FA ER b SIE TR AA BO 59 EJ ECKE Eel oor ol AHIXIAIAE SAAD HA OK 4e EPEA SHC Jali abal Af gl Cilaglas quil y ud AA alal gall Sal allai agil gaai L LINCOLN 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
8. 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 PROBLEMS SYMPTOMS Variable or sluggish welding arc POSSIBLE CAUSE Poor work or electrode connection Welding leads too small Welding current or voltage too low TROUBLESHOOTING GUIDE REMEDY Check and clean all connections Check table on page 4 Check procedures for recommended settings Machine will not shut off Output control not functioning on the machine Input contacts frozen Pilot relay contacts stuck closed Output Control switch in the wrong position Faulty output control switch Faulty Output Control rheostat Leads or connections open in Control Circuit Faulty Firing Circuit or Control Fault Protection P C board Check for approximately 13 inch over travel of contacts Check and replace if necessary Place switch in Output Control at DC 1500 Check and replace if found faulty Check and replace if found faulty Check lead continuity and connections for an open and repair if necessary 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 Output control not functioning on remote control Output Control switch in the wrong positi
9. 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 4 DC 1500 to correspond to the polarity of the electrode cable connection Set the mode switch on the front of the DC 15000 to Constant Voltage Innershield or Constant Volt age Sumerged Arc Set the toggle switch on the front of the DC 1500 to Output Control Remote Set the output as required for the procedures using the K775 Remote Output Control shipped with the NL Op tion 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 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 diagra
10. 0 are wired into the NL kit for easy connection to the DC 1500 terminal strip FASTEN THESE CABLES THE DC 1500 CASE AS SHOWN USING THE CABLE CLAMPS AND SCREWS PROVIDED CABLE TO 775 FIELD CONTROL CABLE TO WIRE FEEDER 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 Remove the cover of the NL option for access to the terminal strip 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 man ual Secure the cables to the case with the clamps and screws provided 10 Using the same diagram connect the leads from the option kit to the DC 1500 terminal strip 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 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 sep arate POS NEG switch The factory installed NL Option does not have an Inch Speed control 3 It cannot be
11. 8 26 35 V Control 26 o 76 0 Exciter 21 1 77 O 77 9 GND e K775 remote control mounted at tractor e 6 104211231 LT 3 Remote 414243 1 DC Control Box e Mn To LT 3 tractor Sn ned control box 2132 31 29 5 Tape up spare leads Not used Electrode Cable to Automatic Equipment Work This diagram shows the electrode connected positive To change polarity turn power source off reverse the electrode and work connect it io the dlactrode Gable qoina t leads at the power source and position the switch on the power going source and th NL option kit to the proper polarity Also reverse the automatic equipment the the of the voltmeter the LT 3 N B On codes below 8234 this is 67 and the control box M13322 LT 3 or LT 34 67 lead can be connected TER 2 26 82C either to 67 or to the electrode cable ter Contactor drop out delay switch on the NL option kit must be in the On position minal as shown Terminal 82 not present on later DC 1500 s 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 N A On codes above 8234 extend lead 67 and N C Terminals 73 and 74 not present on earlier DC 1500 s 17 DIMENSION PRINT 60291 5 492 81 7 18 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG
12. H3I H31N32 INVH9VIG 9UV IV3Gl dINV 00SLOd 15 DIAGRAMS Connection of DC 1500 to NA 5 N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications To NA 5 Input Cable Plug N B Extend lead 21 using 14 or larger insulated wire physically suitable for Power Source W J Control Cable the installation An S16586 remote voltage sensing work lead is avail able 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 Figs 7 31 32 N C Tape up bolted connection ND 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 GND gt N F Connect the jumpers on the NA 5 voltage board as follows connect RED NH jumper to pin S connect WHITE jumper to pin B N G Set the DC 1500 controls as follows Set the control switch t
13. Twin Over Tiny Twin 35 VV Board Mode Switch NA 3 Inch Speed Dial Setting 9 NA 5 Arc Striking Wire Speed NA 3 OCV Control NA 5 Arc Striking Volts Control NA 3 Start Board Req d 9 DC 1500 Output Control Switch Machine or Remote Remote Remote Remote Remote Remote Remote DC 1500 Mode Switch CV Innershield CV CV Innershield Innershield CV Submerged CV Arc 9 Innershield CV Submerged Arc 9 35 5 CC CVS DC 1500 Output Control Inoperative Inoperative Inoperative Inoperative Inoperative Starting is best with hot starting Start button is pressed with wire above the work f 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 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 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 Exact dial setting depends on cable size and length carbon size etc H Get the OCV control
14. able 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations iv SAFETY iv PR CAUTIONS DE S RET Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Mainte
15. arbons short 100 cable lengths can lead to 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 mini mize 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 op eration See the table below for optimum cable size and length Electrode and Work Work Lead Length Carbon Typical Size Current Range Lead Size 1 2 600 1000 Amps 825 2 4 0 5 8 800 1200 925 3 4 0 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 Electrode and 250 375 carbons not recommended for use with the DC 1500 because the high surge currents that occur with this diameter can cause the DC 1500 fault pro tection circuitry to trip the machine off the line if the operator does not gouge in such a way to limit the cur rents 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
16. chains or cables until they fail Also see item 1 c 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 Do not use a welding power source for pipe thawing LINCOLN 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders avail
17. e los ojos los o dos y el Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen und K r perschutz Use prote o para a vista ouvido e corpo HRUSBHICRBRELTE Lio E J 3 10555 15557 A ez 712 Bol Soares d y due de Lily us l di en e READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES 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 HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie
18. e output stud and is not broken ELECTRIC aieo Geena Parts Do not touch electrically hot 13 P C BOARD TROUBLESHOOTING GUIDE 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 LED L4 indicates when fault protection circuit is being activated 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 for P C board troubleshooting Terminals 2 and 4 jumpered on DC 1500 Output Control at DC 1500 Variable Voltage opera tion 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 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 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 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
19. epoo ueu d nbe eu BAIN jueujeoe doi JO 20S eu 01 e14 eidel s su JI sjeued einsoj oue y euo UO euiuoeui eui episui paysed s epoo sejnomed e oyioeds oul enueui siy Aq paJeAoo seuluoeuu eq jou Aew 1009 2513 Had STOSWAS 1V21812373 l S N V ZA1L9310Hd dd 1NOH4 Nv3 asva asvo SE xd 70001020611 ON 1VIH3S 9NIQ323Hd SANIHOVW LHDIT 10719 ANY 13 40 NOLLOSNNOO ON 202 SVM ZE LE SVM VIE d39NVHO AVIT ONIMOTIO1 IHL OSTY 0001020761 ON TVIHAS 5NIG323Hd SANIHOVN LON SWALI 3S3HL EN 9002 20 90 ANNI 33S 1N3H2344IQ 38 AVW S35V L10A 1ndNI H3HLO SNOLLO3NNOO GALOANNOD NMOHS 3HV 1 ANY EL ZL LL SH3IWHOJSNVHI ILON AJUO 10 SI 4141 310 17 od 1 52 802 11 99 ON 01 gt gt 59 6 6 gt gt 202 lt lt 8 ET 1 L v5 lt lt 9 9 gt gt 907 90 lt 9 9 lt 802 lt lt r 092 9 1 lt lt gt gt voz SIz z 2 lt soz 19 t lt lt ET c I 3SVHdH31NI H3WHOJSNVHL uawodNivW SL J w ________ 4 p 6 e o
20. f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria eta A 59tEM 257 Feu CORAVHELTIBELTFEL e manm e c EUR Ez BK aR e 2475 HAMAL e 877 8 amp MAS 218 741214 37 amp Q all oe Land dui ay e eo jul baa jaa yi aach Jaial e J All call us Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e FHR 4 X 1R FE FTF e e SHA AHS Aa Aj d it J a El jui dall e 279011 Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e IL RJ gt 4 f e H BR dR JT IH SUUS Se
21. 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 Copper Wire Size Type 75 In Conduit 3 Input Wires Grounding Conductor Super Lag Fuse Size in Amps 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 sug gested 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 Three 4 0 SEI Four 4 0 200 1000 to 1200 amps 1200 to 1500 amps b Auxiliary Power This machine supplies the 1000 volt amperes of 115 volt AC powe
22. h advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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 infor
23. ing up to the desired voltage the OCV is set too ow 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 Single Innershield Wire Procedures and techniques are the same as above except starting is generally better hot than cold For electrical stickouts above 1 an NA 3 start board is required 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 Twinarc Submerged Arc e Procedures and tech niques are the same as above except starting is best when using CV Innershield and the NA 3 start board 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 C Set start board current 1 to 1 dial 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 pro cedure will provide a current setting lower than the 3 current setting and a voltage setting
24. it Remove the jumper tomatic equipment Source and position the leads on the back of the lead connected between 1 on the coil NB On codes below 8234 this is 67 ameter and voltmeter in the LAF 3 control box the main relay and 7 on the coil of and the LAF 3 67 lead can be Contactor drop out delay switch on the NL option the transfer relay The main relay is the connected either to the 467 ter must be in the on position upper right relay when facing the left end minal or the electrode cable ter of the control box The transfer relay is The 4 0 cables shown will handle up to 1000 amps just to the left of the main relay minal as shown Terminal 82 not at 80 duty cycle For higher currents or duty present on later D C 1500 s cycle add additional cables to the power source N C Terminals 73 amp 74 not present on output studs M13321 earlier D C 1500 s 2 26 82C 16 DIAGRAMS Connection of DC 1500 to NA 3 LT 5 or LT 7 Control Cable 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 Power Source If using an older control cable Connect lead 275 to 75 on terminal C 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 futu
25. ling 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L 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 287 standards
26. ly from the K775 Remote Con trol 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 DC 1500 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 for variable voltage while other machines use the terminology CC for constant cur rent 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 dy namic characteristics of the machine under welding con ditions 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 appro
27. m M13321 2 Remove the cover from the LAF 3 control box 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 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 O
28. mation 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 WEB SITE at www lincolnelectric com Choose Quick Links and then 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 A 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
29. n This circuit delays opening of the output con tactor 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 cir cuit when the option is used with LT 3 and LT 34 wire feed ers 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 A WARNING e Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on equipment ELECTRIC SHOCK can kill Do not touch electrically hot parts GENERAL MAINTENANCE 1 The fan motors have sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air chan nels 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 rec tifier or transformer reaches the maximum safe operating temperature because of frequent o
30. nearly equal to the desired welding procedure e With the start board time delay set at maximum establish the correct arc striking procedure as de scribed 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 weld ing procedure The start board current and voltage should be as close to the welding procedure as pos sible while still getting satisfactory starts g Now decrease the start time as low as possible for optimum starts Arc striking with the DC 1500 mode switch in VV a 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 1 OPERATING INSTRUCTIONS General Set Up Procedures When Using DC 1500 and Lincoln Automatic Head NA 5 See chart below Install the NA 5 per the information in the NA 5 op erating manual IM 305 Connect the NA 5 to the DC 1500 as described on the connection diagram 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 Preset the Start if used Weld and Crater if used Controls to the wire speed and
31. ng information for the equipment being used 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 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 though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 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 cir cuits This can create fire hazards or overheat lifting
32. nir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou to
33. o 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 Connect to Work 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 516889 7 6 84G A WARNING Connection of DC 1500 With NL Option Kit K783 to LAF 3 Obsolete Do not operate with covers removed e Disconnect welding power source before servicing e Do not touch electrically live parts e Only qualified persons should install use or service this machine ELECTRIC SHOCK can kill NB Connect the red lead to terminal 22 a UE K775 remote control 9 mounted at LAF 3 4 211021 To LAF 3 D 0 213231 ER A XEN wi Tape up leads NA On codes above 8234 extend This diagram shows the electrode connected po For best arc striking when connected to lead 67 and connect it to the sitive To change polarity turn power source off an LAF 3 make the following inside the electrode cable going to the au reverse the electrode and work leads at the power LAF 3 control un
34. on Faulty output control switch Faulty remote control rheostat Leads or connections open in Control Circuit Faulty Firing or Control Fault Protection P C board Place switch in Output Control Remote Check and replace if found faulty Check and replace if found faulty Check all leads and connections internal and remote for continuity and repair if necessary 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 OCV setting too high Defective control board Reduce setting Replace control board P C BOARD TROUBLESHOOTING GUIDE CONTROL FAULT PROTECTION P C BOARD WARNING Have an electrician install and service this equipment 1 LED L1 indicates AC input voltage is present at pins 255 256 If not lit check the voltage across the sec winding of the control transformer T7 The age should be approximately 115 volts If not the Turn the input power off at the problem is in the power supply and not the P C board fuse box before working on equipment 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 neg ativ
35. on terminal strip TS 1 and pins 9 and 12 on the connector LED L1 through L6 indicate gate signals are being sup plied to the main power SCR s L1 through L6 respec tively 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 H u DI a 1 LED L7 indicates AC power being supplied to P C board board and the Control Fault Protection P C board from control transformer T2 If not lit check voltage that is not broken and is connected to each connector across terminals 203 and 204 on the terminal strip lo If the lead shows continuity and LED L1 through L6 are H iwi 1 cated on the left side of the bottom fan baffle Voltage not lit replace the Firing Circuit P C board If any i j i should be approximately 115 volts If no voltage indi one of the LED s L1 through L6 is not lit and lights L7 RIK pi H LE cates a supply problem check wiring and transformer through L9 lit replace the Firing Circuit P C If voltage is present turn the machine off remove the board 12 pin harness plug from the P C board turn the ma If troubleshooting guide indicates a possible P C board chine back on and check the voltage across pins 2 and problem the guide on page can be used to locate the 3 on the plug This should be appr
36. our body 1 f Do not put your hands near the engine fan Do not attempt to override the idler by pushing on the throttle control rods while the engine is running 2 4 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 MY 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 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 5 Do not work next to welding power source Mar 95 LINCOLN SAFETY 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 knee
37. oximately 115 volts problem OUTLINE FOR DC 1500 TROUBLESHOOTING GUIDE NO WELDER OUTPUT MACHINE HAS OUTPUT BUT ERRATIC WELDING INPUT CONTACTOR ON TERMINALS 2 4 CLOSED TRIPS OFF IMMEDIATELY CHECK PROCEDURE CHECK CONTROL BOARD CHECK FOR SHORT LED L5 BETWEEN ELECTRODE AND CHECK MODE SWITCH FOR WORK LEADS REMOVE PROPER POSITION FOR EXTERNAL LEADS FROM PROCESS BEING USED IF OFF IF ON THE OUTPUT TERMINALS CHECK LED S CHECK LED L1 CHECK FIRING BOARD IF TROUBLE STILL L4 L5 L6 MG cR LED S PERSISTS FOR EQUAL IF OFF IF ON CHECK LED L3 ON BRILLJANCY ALL CONTROL FAULT 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 cm 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 15 DEFECTIVE T7 LEAD CHECK DEFECTIVE AND SHOULD TRANSFORMER CONNECTIONS LED S BE REPLACED TO SCR S L7 L8 L9 IF ONE IF ON AND AAWARNING OR MORE OTHER LIGHTS ARE OUT ARE PT Have an electrician install and service this equipment CHECK AC REPLACE INPUT TO FIRING Turn the input power off at the BOARD BOARD fuse box before working on 203 204 205 206 equipment vu Do not touch electrically hot parts POSSIBLE RVE ELECTRIC SHOCK TRANSFORMERS can kill T2 T3 OR T4 14 DIAGRAMS Jequunu
38. perate Supply line fuse blown Replace if blown Look for reason first Contactor power circuit dead Check pilot transformer T1 and associated leads and 5 amp fuse Broken power lead c Check input voltage at contactor Wrong input voltage d Check voltage against nameplate Primary or power SCR thermostats open e Check for overheating Make sure both fans are operating and there is no obstruction to free air flow Faulty thermostats replace Open input contactor coil f Replace coil Faulty on off switch g Replace switch Faulty pilot relay 2CR h Replace relay Machine input contactor operates but no output Electrode or work lead loose or broken Repair connection when trying to weld Open main transformer T5 primary or sec Repair circuit c Firing Circuit P C board not connected or is All nine light emitting diodes L1 thru L9 must faulty lit See P C Board Troubleshooting Guide d Output pilot relay 6CR not operating or faulty d Check relay by connecting a jumper across termi nals 2 and 4 on DC 1500 terminal strip Replace if faulty Machine has maximum output but no control Output Control switch SW4 in wrong position fa Check position of switch Output Control switch faulty b Check switch and replace if faulty Open in feed back circuitry c Check wiring and control and Firing Circuit P C Faulty Control Fault P
39. poriz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank fuel is spilled wipe it up and do not start engine until fumes have been eliminated ELECTRIC AND SR MAGNETIC FIELDS 359 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety ees minimize exposure to EMF fields from the welding circuit 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 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 y
40. r 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 connect ing 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 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 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 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 f
41. racteristics RATINGS IP21 enclosure Main Transformer insulation class 155 F OPERATING INSTRUCTIONS AAWARNING Do not touch electrically live parts electrode with skin or wet clothing Insulate yourself from work and ground ELECTRIC SHOCK can kill Keep your head out of fumes P Use ventilation or exhaust to C 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 Con nect the work cable to the other studs Wear eye ear and body protection ARC RAYS can burn e 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 connec tion 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 in dicates when the welder is on 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 how ever output is controlled on
42. re applications 31 N B Extend lead 21 using 14 or larger insulated wire physically 4 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 Negative up bolted connection Electrode Cable to Automatic Equipment d N D Terminals 73 and 74 not present on earlier DC 1500 To Work 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 S15534 on power source to proper polarity Also reverse the leads on the back of the ammeter and voltmeter in the automatic control box 2 26 82B Awarnine e Do not operate with covers removed e Disconnect welding power source before servicing e Do not touch electrically live parts e Only qualified persons should Connection of DC 1500 With NL Option Kit K783 to LT 3 or LT 34 Obsolete ELECTRIC SHOCK N B can kill install use or service this am machine 3221 L4 NL Option E 21 10 e E 0 ET D 31 5 o2 o Connect the red lead to NA Negative Positive terminal 22 j S sl
43. ront 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 077 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 f Connecting for Air Carbon Arc To use the DC 1500 for air carbon arc or other 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 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 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 h Connecting for High Frequency Starting As shipped these welders can be used with a high fre quency unit for improved automatic welding starting cha
44. rotection or Firing Circuit board wiring harness plugs P C boards d All light emitting diodes must be lit except L4 on Control Fault Protection board See P C Board Troubleshooting Guide Output control potentiometer open lead no 75 fe Check and replace if faulty Machine does not have maximum output One input fuse blown a Check and replace if blown after checking for rea son for blown fuse One phase of main transformer open b Check for open and repair Faulty Control Fault Protection or Firing Circuit Jc All light emitting diodes must be lit on both P C P C boards boards except L4 on Control Fault Protection board See P C Board Troubleshooting Guide d Output control potentiometer defective d Check and replace if faulty e Output control potentiometer leads open 226 e Check and repair broken leads 237 236 73 74 76 77 Machine has output but trips off immediately a Machine has either an internal or external short Check internally and externally for any shorts and circuit on the output remove or repair b Faulty Control Fault Protection P C board b If no short circuits LED L4 must be lit See P C Board Troubleshooting Guide c Machine output voltage applied to control leads Je 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
45. rth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 amp Cutting ANSI Standard 249 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 AN 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 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes Gi 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 va
46. sharp point For cold starts make certain work piece is clean and electrode makes positive contact with plate d For hot starts travel should be started before wire contacts the work on the fly starting e 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 below Set the inch control to 2 These are approximate settings only until the weld ing 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 4 6 8 f Run a test weld setting the proper current voltage and travel speed 9 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 start ing In general a low inch speed will provide the best starting Adjust the OCV by making repeated starts and ob serving the voltmeter action With proper adjustment of the OCV control the voltmeter needle will swing smoothly up to the de sired arc voltage and thus provide repeatable starts If the voltmeter swings above then back to the de sired 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 com
47. 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 au tomatically 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 OPERATING INSTRUCTIONS 2 Arc striking with DC 1500 mode switch on Cv sub arc or CV Innershield There 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 and 7 solid wire a for long stickout Innershield procedures and Tiny Twinarc procedures 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 discon nected 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 elec trically disconnected and the jumper plug replaced b Cut electrode to a
48. 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 Inoperative Inoperative OPERATING INSTRUCTIONS NL Option Kit Not Required With NA 3 5 LT 7 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 2 Inch speed control used for LT tractor only Hot start control used to obtain optimum arc strik ing Polarity switch changes polarity of control circuit to correspond with electrode polarity 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 equip ment is located under the front cover All necessary control leads for connection to the DC 150
49. ut autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret 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 prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER ku TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan
50. verload or high room tem perature plus overload the contactor drops out stopping the welder The thermostat automatically reset when the tem perature reaches a safe operating level Press the On but ton to start the welder The power rectifiers are also protected by a special solid state circuit With the occurrence of a short circuit or ex cessively 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 TROUBLESHOOTING GUIDE AA WARNING ELECTRIC SHOCK can kill e Have a qualified individual install and service this equipmenit e the input supply power OFF Note To locate the Firing Circuit and Control Fault at the disconnect switch or fuse Protection Circuit PC boards remove the upper box before working on this equip case panel on the left side of the machine The ment names are printed on the boards Do not touch electrically hot parts Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE REMEDY SYMPTOMS Input contactor CR1 chatters Faulty input contactor OCH Repair or replace Low line voltage Check with power company Faulty pilot relay 2CR Replace relay Machine input contactor does not o
51. voltage specified in the procedure 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 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 op erating 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 re placed 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 RECOMMENDED SET UP PROCEDURES FOR NA 3 DC 1500 NA 5 DC 1500 INNERSHIELD Single Innershield Stickout under 1 7 Single Innershield Stickout over 1 Twinarc Innershield Equipment and Control Settings Wire Feed Type Control Solid Wire High Current Very Large Puddle Tiny
52. within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 manufacturer s instructions for this SE AUG 06 LINCOLN 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 Also see item 1 b SAFETY WELDING and CUTTING gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire 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 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 249 1 and the operati
53. xi mately 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 pre viously required a constant current type power source The VV Submerged Arc Mode permits the DC 1500 to pro duce a constant current output characteristic through the range of 200A 28V to 1500A 60V with an open circuit volt age 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 gen eral rules to follow in the selection of the mode switch posi tion 1 Use the CV Innershield mode for all Innershield weld ing Use the CV Submerged Arc mode for most submerged arc welding However some high speed welding pro cedures may perform better on the CV Innershield mode 3 The VV CC mode is available for high current large puddle submerged arc 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 carbons start with the machine control set at 4 and increase as required for long cable lengths With and c
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