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IM318-B
®
June, 2008
IDEALARC DC- 1500
Constant Voltage and Constant Current DC Arc Welding
Power Source, 3 Phase Rectifier Type
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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT REA
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i i SAFETY 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, birth 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
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a.Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mate
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• 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 Linco
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INSTALLATION 3 Phase Welders at 100% Duty Cycle WARNING NOTE: The standard machines are designed to operate on 460 volt-60 Hertz, 440 volt-50 Hertz and 380 volt-50 Hertz • Do not lift this machine using lift bale if it is equipped with a input power systems. However, to use the machines on 380 heavy accessory such as a trailer volt-50 Hertz power, reconnect the transformer input leads or gas cylinder. in accordance with the connection diagram pasted to the inside of the lower right side case
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INSTALLATION control leads and connect a jumper between #2 and #4 e. Optional Remote Control (K775) on the terminal strip on the front of the DC-1500. With the #2 to #4 jumper connected, the output studs are en- This control is included as part of the “NL Option”. ergized whenever the machine is on. 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.) WARNING: If the electrode leads to the wire are not disconnected per
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OPERATING INSTRUCTIONS To Set for Machine or Remote Control The output can be controlled either at the wire feeder or 3. The VV (CC) mode is available for high current, large the DC-1500. When the NL Option Kit is installed, how- puddle submerged arc procedures that cannot be done ever, output is controlled only from the K775 Remote Con- as well with the constant voltage mode. trol usually mounted at the wire feeder. 4. Air Carbon Arc Gouging or Cutting — For air carbon To adjust the output f
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OPERATING INSTRUCTIONS This usually results in a bad start where the wire 2. Arc striking with DC-1500 mode switch on Cv sub-arc or tends to “blast-off”. CV Innershield — There are a number of basic tech- If the voltmeter needle hesitates before coming up niques for good arc striking that apply to all processes to the desired voltage, the OCV is set too low. This and power sources. It may not be necessary in every will cause the electrode to stub. application to follow these guidelines, but when
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OPERATING INSTRUCTIONS General Set-Up Procedures When Using DC-1500 and Lincoln Automatic Head NA-5 b. If striking is still not satisfactory, see the NA-5 op- (See chart below.) erating manual for information on the feed motor 1. Install the NA-5 per the information in the NA-5 op- acceleration. erating manual (IM-305). Connect the NA-5 to the c. If installed, adjust the “Start Controls” to set the DC-1500 as described on the connection diagram. welding procedures for the time set on the timer t
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OPERATING INSTRUCTIONS NL Option Kit (Not Required With NA-3, NA-5, LT-7 or LT-56) 4. Using the same diagram, connect the leads from the The K783 NL option kit (for field installation) is designed option kit to the DC-1500 terminal strip. to permit use of the NA-2, LAF-3, LT-3 and the LT-3 section 5. Feed the K775 control cable through the clamp on the of the LT-34 tractor with DC-1500’s assigned code 7687 front of the NL option box and connect the leads to and above. It provides the necessary D
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OPERATING INSTRUCTIONS 3. Remove the blue jumper lead connected between #1 on NOTE: The “Hot Start Control” does not affect the the coil of the main relay and #7 on the coil of the starting method of the LAF-3, i.e., “cold” start, “hot” transfer relay. (The main relay is the upper right relay start, etc. See IM-198-B, Sec. 2.4.9. when facing the left end of the control box. The transfer 11.Set the NL Option “Contactor Drop-Out Delay” switch relay is just to the left of the main relay.) to “On”.
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TROUBLESHOOTING GUIDE WARNING ELECTRIC SHOCK can kill. • Have a qualified individual install and service this equipment. • Turn the input supply power OFF Note: To locate the “Firing Circuit” and “Control/Fault at the disconnect switch or fuse Protection Circuit” P.C. 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. ------------------------------------------
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TROUBLESHOOTING GUIDE PROBLEMS POSSIBLE CAUSE REMEDY (SYMPTOMS) Variable or sluggish welding arc. a. Poor work or electrode connection. a. Check and clean all connections. b. Welding leads too small. b. Check table on page 4. c. Welding current or voltage too low. c. Check procedures for recommended settings. Machine will not shut off. a. Input contacts frozen. a. Check for approximately .13 inch over travel of contacts. b. Pilot relay contacts stuck closed. b. Check and replace if necessary. Ou
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P.C. BOARD TROUBLESHOOTING GUIDE 3. LED L3 indicates power is being applied to fault pro- If no voltage and there is voltage at terminals 203 and tection relay 2CR, when wire feeder button is pressed 204 on terminal strip TS-1 this indicates a broken lead or jumper is connected across 2 and 4. or loose terminal on either lead 203 or 204.If voltage is present and LED L7 is not lit, replace P.C. board. 4. LED L4 indicates when fault protection circuit is being activated. 2. LED L8 indicates AC pow
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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..
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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. N.B. Extend lead 21 using #14 or larger insulated wire physically suitable for 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
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DIAGRAMS Connection of DC-1500 to NA-3 (All), LT-5 or LT-7 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 fut
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DIMENSION PRINT -18- 22.30 38.00 15.28 3.69 53.50 20.00 36.12 .406 DIA. MTG. HOLES 4-18-75B 4-18-75B S-15709
