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IM283-C
®
October, 2010
IDEALARC AC- 1200
Single Phase Variable Voltage Power Source For Automatic AC Welding
For use with machines having Code Numbers 10291C, 10292C, 10465 and 10466.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation ...
and thoughtful operation on your
part. DO NOT INSTALL, OPER-
ATE OR REPAIR THIS EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY
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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 ELECTRIC SHOCK can ARC RAYS can burn. 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 mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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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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vi vi TAbLE OF CONTENTS Page Installation.......................................................................................................................Section A Location ...............................................................................................................................A-1 Input Wiring ..........................................................................................................................A-1 Output Connections...............................
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A-1 A-1 INSTALLATION The AC-1200 does not have an input contactor. Therefore, LOCATION include an external starter or disconnect switch when plan- Install the welder in a dry location where there is free circu- ning the input circuit. lation of air in through the louvers in front and out through Remove the right side panel of teh AC-1200 and bring the input the louvers in the back of the case. A location which mini- power lines through the hole in the back of the case. See the mizes the amoun
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S-15666 Connection of AC-1200 (with NL Option) to LAF-4 or LT-34 4-18-75 A-2 A-2 INSTALLATION Connection of AC-1200 to NA-4 S-15667 with Switch for ‘Current Control’ 4-18-75 Connection of AC-1200 to NA-4 with rheostat for current control or LT-6. S-15602 6-22-84H IDEALARC® AC-1200
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A-3 A-3 INSTALLATION b. Output Studs Connect the work cables to the ‘To Work’ stud on the front of the Ac-1200. Connect the electrode cables to the ‘Min,’ ‘Med’ or ‘Max’ studs for the output desired. Actual current ranges for each stud are indicated on the name- plate above each stud. Recommended cable sizes are listed below. Both teh ‘To Work’ and ‘Max’ studs have two terminals to simplify connection of recommended cables in parallel. Tighten the nuts with a wrench. Select cables required fo
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b-1 b-1 OPERATION SAFETY PRECAUTIONS TO SET FOR MACHINE OR REMOTE CONTROL Read and understand this entire section before oper- ating the machine. The output can be controlled either from the AC- 1200, the wire feeder or other remote locations. WARNING To adjust the current from the wire feeder or other remote locations, set the toggle switch on the front of ELECTRIC SHOCK the AC-1200 to ‘Output Control Remote’. To adjust the can kill. output current from the AC-1200, set this switch to ‘Output C
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Have qualified personnel do the mainte- nance and troubleshooting work. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ See additional warning i
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E-1 E-1 TROUbLESHOOTING HOW TO USE TROUbLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. _______________________________________________________________
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E-2 E-2 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS POSSIbLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Welder will not start. Supply line fuse blown. Look for possible cause and repair. Open supply line lead. Replace fuse. Wrong supply line voltage. Repair. Provide nameplate specified voltage. Welder will not weld (Contactors Electrode or ground cable loose or Tighten connection or repair broken operating properly) broken. cable. Welder control circ
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E-3 E-3 TROUbLESHOOTING PRObLEMS POSSIbLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Welder welds at max. only no con- Diodes or SCR’s on heat sink Determine cause if possible and trol. assemblies shorted. replace shorted device. Shorted or grounded current controll Replace rheostat. rheostat. Output By-Pass Capacitors open or Replace or reconnect. disconnected. Free wheeling diode open or discon- Replace or reconnect. nected. P.C. board components failed. Determine cause if possible and repl
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F-1 F-1 DIAGRAMS IDEALARC® AC-1200 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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SEC. PRIMARY PRS IM EA CR . Y F-2 F-2 DIAGRAMS AC-1200 SCOTT CONNECTION DIAGRAM M13026 N.DE ., LN. EC C T A E RTE N IC . K N N N N N NO S IL .E .D .B .C .A H A L T O ..... T E C S : WA K To T IEl F f nt we ut E 2 h T r 1W A e a . er e h .ur o w c m R l w e Vo d c b b tDo e CA r e D D D a i O o o ta u o tn e I T w R sWO E a y r o n ifo ltd n g ls se t i t o O S d p o n n UT a vo n o e c l
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F-3 F-3 DIAGRAMS AC-1200 SCOTT CONNECTION DIAGRAM IDEALARC® AC-1200
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F-4 F-4 DIAGRAMS AC-1200 AND PARALLELED DC-1000’s IDEALARC® AC-1200
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F-5 F-5 DIAGRAMS AC-1200 AND DC-1500’s IDEALARC® AC-1200
