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IM318-B
庐
IDEALARC DC-
1500 August, 2007
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 READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR鈥橲 MANUAL
Copyright 漏 2007 Lincoln Global Inc.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
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 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of 鈥淎rc Welding Safety鈥? 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
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 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar 驶95
magneto wire as appropriate.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
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 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? 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. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
FUMES AND GASES
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
can be dangerous.
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 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
鈥? Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
鈥? DC Manual (Stick) Welder. your head out of the fume. Use enough
鈥? AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically 鈥渉ot鈥?.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5. b. The operation of welding fume control equipment is affected
3.f. Maintain the electrode holder, work clamp, welding cable and
by various factors including proper use and positioning of
welding machine in good, safe operating condition. Replace
the equipment, maintenance of the equipment and the spe-
damaged insulation.
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.g. Never dip the electrode in water for cooling.
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of
electrode holders connected to two welders because voltage
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
between the two can be the total of the open circuit voltage
coming from degreasing, cleaning or spraying operations.
of both welders.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.i. When working above floor level, use a safety belt to protect
ucts.
yourself from a fall should you get a shock.
5.d. Shielding gases used for arc welding can displace air and
3.j. Also see Items 6.c. and 8.
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始s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
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
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI 鈥? Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
鈥? A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically 鈥渉ot鈥? parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances鈥?, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or 鈥淧recautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,鈥? available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer始s
through lifting chains, crane cables or other alternate cir-
recommendations.
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B 鈥? Standard for Fire Prevention
During Welding, Cutting and Other Hot Work鈥?, 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.
SAFETY
iv iv
PR脡CAUTIONS DE S脹RET脡 6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
Pour votre propre protection lire et observer toutes les instructions
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
茅chauffement et un risque d始incendie.
S没ret茅 Pour Soudage A L始Arc
8. S始assurer que la masse est connect茅e le plus pr茅s possible
1. Protegez-vous contre la secousse 茅lectrique:
de la zone de travail qu始il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d始autres
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
endroits 茅loign茅s de la zone de travail, on augmente le risque
quand la machine 脿 souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, c芒bles de grue, ou autres circuits. Cela peut provoquer
ou les v茅tements mouill茅s. Porter des gants secs et sans
des risques d始incendie ou d始echauffement des chaines et des
trous pour isoler les mains.
c芒bles jusqu始脿 ce qu始ils se rompent.
b. Faire tr茅s attention de bien s始isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuli茅rement important pour le soudage de t么les
les positions assis ou couch茅 pour lesquelles une grande
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
partie du corps peut 锚tre en contact avec la masse.
produit des fume茅s toxiques.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble
de soudage et la machine 脿 souder en bon et s没r 茅tat
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
defonctionnement.
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
refroidir.
du solvant pour produire du phosg茅ne (gas fortement toxique)
e. Ne jamais toucher simultan茅ment les parties sous tension
ou autres produits irritants.
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
parce que la tension entre les deux pinces peut 锚tre le
11. Pour obtenir de plus amples renseignements sur la s没ret茅,
total de la tension 脿 vide des deux machines.
voir le code 鈥淐ode for safety in welding and cutting鈥? CSA
f. Si on utilise la machine 脿 souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-茅lectrode s始applicuent aussi au pistolet de
soudage.
PR脡CAUTIONS DE S脹RET脡 POUR
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
LES MACHINES 脌 SOUDER 脌
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie
TRANSFORMATEUR ET 脌
du corps.
REDRESSEUR
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant appropri茅 1. Relier 脿 la terre le chassis du poste conformement au code de
ainsi qu始un verre blanc afin de se prot茅ger les yeux du ray- l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
onnement de l始arc et des projections quand on soude ou de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
quand on regarde l始arc. bonne mise 脿 la terre.
b. Porter des v锚tements convenables afin de prot茅ger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I始installation et l始entretien du poste seront
l驶arc. effectu茅s par un 茅lectricien qualifi茅.
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables. 3. Avant de faires des travaux 脿 l始interieur de poste, la debranch-
er 脿 l始interrupteur 脿 la boite de fusibles.
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de
soudage. Se prot茅ger avec des v锚tements de protection libres 4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur
de l始huile, tels que les gants en cuir, chemise 茅paisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
Mar. 驶93
zones o霉 l始on pique le laitier.
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 鈥⑩?⑩?? 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 such 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始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 鈥? 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 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.
鈥? 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.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. 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:
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
NOTE: The standard machines are designed to operate on
WARNING 460 volt-60 Hertz, 440 volt-50 Hertz and 380 volt-50 Hertz
input power systems. However, to use the machines on 380
鈥? Do not lift this machine using lift
volt-50 Hertz power, reconnect the transformer input leads
bale if it is equipped with a
in accordance with the connection diagram pasted to the
heavy accessory such as a trailer
inside of the lower right side case panel.
or gas cylinder.
鈥? Lift only with equipment of
adequate lifting capacity.
FALLING OUTPUT CONNECTION (Turn Power Source
EQUIPMENT can Off)
鈥? Be sure machine is stable when
cause injury. lifting.
a. Output Studs
LOCATION
The 鈥淧ositive鈥? and 鈥淣egative鈥? output studs are located
Install the welder in a dry location where there is free cir- on the front panel. Two of each are provided to simplify
connecting multiple electrode or work cables as sug-
culation of air in through the louvers in the front and out
gested in the table below.
through the louvers in the back of the case. A location which
minimizes the amount of smoke and dirt drawn into the
Connect the electrode cables to the 鈥淧ositive鈥? studs for
machine reduces the chance of dirt accumulation that can
electrode positive (DC+) polarity or to the 鈥淣egative鈥?
block air passages and cause overheating.
stud for electrode negative (DC-) polarity as required
by the welding procedures. Connect the work cables to
INPUT WIRING
the other set of studs. Tighten the nuts with a wrench.
WARNING Suggested Copper Cable Sizes 鈥? 80% Duty Cycle
鈥? Have an electrician install and Below 1000 amps Two 4/0
Up to
service this equipment. 1000 to 1200 amps Three 4/0
200鈥?
1200 to 1500 amps Four 4/0
鈥? Turn the input power off at the
fuse box before working on
equipment. b. Auxiliary Power
ELECTRIC SHOCK 鈥? Do not touch electrically hot This machine supplies the 1000 volt-amperes of 115
parts.
can kill. volt, AC power needed for the automatic wire feeders.
The power is available from terminals #31 and #32 on
the terminal strip.
Failure to fuse the input lines per the specifications in this
manual will constitute customer abuse and void the war-
c. 鈥淣L Option鈥? (K783)
ranty.
---------------------------------------------------------------------
Installation of an NL option is required when connect-
Be sure the voltage, phase and frequency of the input power
ing a DC-1500 to LAF-3, NA-2, LT-3 or LT-34 wire
is as specified on the welder nameplate.
feeding systems. See the section on page 9 entitled 鈥淣L
Option Kit鈥? for full information.
Have a qualified electrician remove the lower right side case
panel and connect 3 phase AC power to terminals L1, L2
d. Wire Feeder Connection 鈥? Without NL Option
and L3 of the input contactor in accordance with the Na-
tional Electrical Code, all local codes and the wiring diagram
Turn the welder off. Remove the screw and lift the
located inside the machine.
hinged door on the front of the control panel to expose
the terminal strips. Connect the leads of the wire feeder
The frame of the welder must be grounded. A stud marked
input control cable to the terminal strip exactly as spec-
with the symbol located on the fan shroud is provided
ified in the appropriate connection diagram included in
for this purpose. See the U.S. National Electrical Code for
the wire feeder Operating Manual. Attach the control
details on proper grounding methods.
cable to the panel at the right of the terminal strip using
the clamp attached to the control cable. Close the door
Recommended Input Wire, Grounding Wire and Fuse Sizes
and replace the screw.
Based on National Electrical Code For 60 Hertz,
3 Phase Welders at 100% Duty Cycle
To connect the DC-1500 to wire feeders not covered in
available connection diagrams, write to the factory for
Copper Wire Size
instructions giving complete nameplate information for
Type 75掳 In Conduit
the DC-1500 and wire feeder.
Input Amps 3 Input Grounding Super Lag Fuse
Volts Input Wires Conductor Size in Amps
460 184 000 3 300
-5-
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 鈥淣L Option鈥?.
ergized whenever the machine is on.
Connect it to the 鈥淣L Option鈥? 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 instructions, the wire feeder nozzle or
It can be purchased separately when the DC-1500 is
gun and electrode will be electrically 鈥渉ot鈥?.
used for other applications.
To install, turn the power off. Remove the screw and
g. DC-1500 Paralleling Kit
lift the hinged door on the front of the control panel to
expose the terminal strips. Connect the numbered leads
A kit for field installation only, (order K1900-1) is avail-
to the appropriate terminals 鈥? 75 to 75, etc 鈥? on the
able for paralleling two DC-1500鈥檚 for currents up to
terminal strip and the green lead to the stud marked
3000 amperes, 100% duty cycle. Complete installation
with the symbol . Attach the control cord to the
instructions are shipped with the kit.
panel at the right of the terminal strip using a suitable
clamp. Close the door and replace the screw. The Re-
h. Connecting for High Frequency Starting
mote Control cord can be lengthened to any length by
properly splicing an appropriate four conductor rubber-
As shipped, these welders can be used with a high fre-
covered cable to the standard 25鈥? cord before connecting
quency unit for improved automatic welding starting
to the DC-1500 terminal strip.
characteristics.
f. Connecting for Air Carbon Arc
RATINGS
IP21 enclosure
To use the DC-1500 for air carbon arc or other appli-
Main Transformer insulation class 155 (F)
cations, disconnect all wire feeder welding cables and
OPERATING INSTRUCTIONS
WARNING
鈥? Do not touch electrically live parts or 鈥? Wear eye, ear and body protection.
electrode with skin or wet clothing.
鈥? Insulate yourself from work and
ground.
ELECTRIC SHOCK ARC RAYS
can kill. can burn.
鈥? Keep your head out of fumes. 鈥? Keep flammable material away.
鈥? Use ventilation or exhaust to
remove fumes from breathing zone.
FUMES AND WELDING SPARKS
GASES can be can cause fire or
dangerous. explosion.
DUTY CYCLE Set the 鈥淓lectrode Negative 鈥? Electrode Positive鈥? switch
to correspond to the polarity of the electrode cable connec-
The DC-1500 is rated for 100% duty cycle at 1500 amps
tion. This switch setting is necessary for proper operation
and 60 volts.
of the Lincoln wire feeder attached to the power source.
To Set Polarity
To Start the Welder
Connect the electrode cable to the 鈥淧ositive鈥? or 鈥淣egative鈥?
Press the 鈥淥n-Off鈥? pushbuttons to start and stop the welder.
studs depending upon the electrode polarity desired. Con- The red pilot light near the center of the control panel in-
nect the work cable to the other studs. dicates when the welder is on.
-6-
OPERATING INSTRUCTIONS
To Set for Machine or Remote Control
3. The VV (CC) mode is available for high current, large
The output can be controlled either at the wire feeder or
puddle submerged arc procedures that cannot be done
the DC-1500. When the NL Option Kit is installed, how-
as well with the constant voltage mode.
ever, output is controlled only from the K775 Remote Con-
4. Air Carbon Arc Gouging or Cutting 鈥? For air carbon
trol usually mounted at the wire feeder.
arc gouging, the constant voltage Innershield mode is
To adjust the output from the wire feeder, set the toggle
used with the output control set between 4 and max.
switch on the front of the DC-1500 to 鈥淥utput Control
depending on the application, carbon size, etc. Up to
Remote鈥?. To adjust the output using the DC-1500 鈥淥utput
/2鈥? carbons, start with the machine control set at 4 and
1
Control鈥? rheostat, set this switch to 鈥淥utput Control at DC-
increase as required for long cable lengths. With 1/2鈥?
1500鈥?. and 5/8鈥? carbons, short (100鈥?) cable lengths can lead to
occasional tripout of the protection circuit when the
To Set the Welder Output carbon is shorted to the work. Cutting back the output
setting will reduce the short circuit current and mini-
With the toggle switch set to 鈥淥utput Control at DC-1500鈥?,
mize tripping. Longer cable lengths do an even better
rotating the 鈥淥utput Control鈥? rheostat on the DC-1500
job since this also reduces the short circuit current but
from 1 to 10 increases the machine output from minimum
even more significantly permits raising the open circuit
to maximum. The same full range control is set from the
voltage (by increasing control setting) for smoother op-
wire feeder or K775 when the toggle switch is set to 鈥淥utput
eration. See the table below for optimum cable size and
Control Remote鈥?.
length.
Set the output as required by the welding procedures.
Combined Total
Electrode and Electrode
Mode Switch Work Lead Length
Carbon Typical and Work
The toggle switch labeled CV Innershield, CV submerged Size Current Range (Min) (Max) Lead Size
arc, VV submerged arc, is used to select the proper welder /2 600-1000 Amps 250鈥? 825鈥? 2 鈥? 4/0
1
characteristics for the process being used. /8 800-1200 Amps 375鈥? 925鈥? 3 鈥? 4/0
5
NOTE: Some machines say 鈥漋V鈥? for variable voltage while If ever longer leads are used and the output control is
other machines use the terminology 鈥淐C鈥? for constant cur- already set on max., the unit has reached its maximum
rent. air carbon arc capability.
The CV Innershield Mode permits the DC-1500 to produce / 4鈥? carbons are not recommended for use with the
3
essentially a flat output characteristic that can be varied DC-1500 because the high surge currents that occur
with this diameter can cause the DC-1500 fault pro-
from approximately 20 to 60 volts. In this position the dy-
tection circuitry to trip the machine off the line, if the
namic characteristics of the machine under welding con-
operator does not gouge in such a way to limit the cur-
ditions provides optimum welding characteristics for
rents.
Innershield welding and other open arc processes.
The CV Submerged Arc Mode also produces an essentially General Set-Up Procedures When Using DC-1500 and
flat output characteristics that can be varied from approxi- Lincoln Automatic Head NA-3
mately 20 to 60 volts. The dynamic characteristics of the (Read the following and refer also to the chart on page 9.)
CV Submerged Arc Mode are such that excellent submerged 1. NA-3 鈥? The NA-3 should be set for the mode being
arc welding can be obtained for most procedures that pre- used on the power source. If using either of the CV
viously required a constant current type power source. modes, the NA-3 VV board switch should be set for
CV. If the power source is used in the VV mode, then
The VV Submerged Arc Mode permits the DC-1500 to pro-
the NA-3 VV board mode switch should be placed in
duce a constant current output characteristic through the
the VV position.
range of 200A-28V to 1500A-60V with an open circuit volt-
All NA-3鈥檚 when used with the DC-1500 are capable of
age of 45 to 98 volts. Although almost all submerged arc
cold starting with the variable voltage board mode
welding can now be done in the CV mode, the VV mode
switch in VV. Cold starting permits the wire to be
is available for those procedures where VV (CC) may still
inches down to the work, automatically stop and au-
be desirable.
tomatically energize the flux hopper valve. All NA-3鈥檚
made after September 1976, are capable of cold starting
Set-up for Various Processes
on either CV or VV settings of the variable voltage board
Selection of mode switch position 鈥? There are several gen- switch.
eral rules to follow in the selection of the mode switch posi-
tion.
1. Use the CV Innershield mode for all Innershield weld-
ing.
2. 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.
-7-
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 鈥渂last-off鈥?.
CV Innershield 鈥? 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 striking
problems do occur, following the suggestions below h. For Twinarc welding, clipping both wires to equal
should provide trouble-free starting. These procedures lengths will be beneficial to make consistently good
apply to all single solid wire, Innershield wire, and starts.
Twinarc 1/8 and 3/32 solid wire.
3. Single Innershield Wire 鈥? Procedures and techniques
a. Except for long stickout Innershield procedures and
are the same as above, except starting is generally better
Tiny Twinarc 1/16 procedures, an NA-3 start board is
not needed. If a start board is not needed, it should 鈥渉ot鈥? than 鈥渃old鈥?. For electrical stickouts above 13/4 an
be removed from the machine, or at least discon- NA-3 start board is required.
nected and the logic board jumper plug replaced.
Leaving it connected makes the setup for arc striking 4. Twinarc Innershield 鈥? Procedures and techniques are
more difficult. Also, if a crater board is not needed, the same as above, except starting is generally better
it should be removed from the NA-3 or at least elec- 鈥渉ot than 鈥渃old鈥?. Use of an NA-3 start board improves
trically disconnected and the jumper plug replaced. starting.
b. Cut electrode to a sharp point.
5. Twinarc Submerged Arc 1/16 鈥? Procedures and tech-
c. For cold starts, make certain work piece is clean
niques are the same as above, except starting is best when
and electrode makes positive contact with plate.
using CV Innershield and the NA-3 start board.
d. For hot starts, travel should be started before wire
contacts the work (鈥渙n the fly鈥? starting). 6. Use of the NA-3 Start Board 鈥? For those processes
e. Set NA-3 open circuit voltage control to approxi- above that recommend use of the NA-3 start board, the
mately the same setting as the weld setting. For following method should be used to set up the procedure.
initial test welds, choose the voltage setting based
a. Set start time at 0 and start current and voltage at
on the table below. Set the inch control to 2.
mid-range. Start the weld and set the proper current
These are approximate settings only until the weld- and voltage for the welding procedure.
ing procedure has been set.
b. Turn the start board timer to maximum.
It should be noted that with the DC-1500 the OCV
c. Set start board current 1 to 11/2 dial numbers below
required for optimum starting is lower than that
NA-3 front control settings.
required with other type power sources.
d. Place start board鈥檚 voltage control approximately
equal to NA-3 voltage control setting.
Approximate Voltage Voltage Control Setting
When set per c and d, above, the starting only pro-
22-24 2
cedure will provide a current setting lower than the
34-36 4
NA-3 current setting and a voltage setting nearly
46-48 6
equal to the desired welding procedure.
56-60 8
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. Run a test weld, setting the proper current, voltage
and travel speed. f. Now increase the start board current and voltage to
bring the start current and voltage closer to the weld-
g. Once the proper welding procedure is established
ing procedure. The start board current and voltage
and if the start is poor 鈥? wire blast-off, stub, etc.,
adjust the OCV and inch speed for optimum start- should be as close to the welding procedure as pos-
ing. In general, a low inch speed will provide the sible while still getting satisfactory starts.
best starting.
g. Now decrease the start time as low as possible for
Adjust the OCV by making repeated starts and ob- optimum starts.
serving the voltmeter action.
7. Arc striking with the DC-1500 mode switch in VV.
With proper adjustment of the OCV control, the
voltmeter needle will swing smoothly up to the de- a. NA-3 鈥? The NA-3 variable voltage board mode
sired arc voltage and thus provide repeatable starts. switch should be set to the VV position.
If the voltmeter swings above then back to the de- b. Set OCV control at 6.5 to 7.0.
sired welding voltage, the OCV setting is too high.
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 weld wire feed speed and the arc striking voltage
Lincoln Automatic Head NA-5 control 4 volts above the weld voltage.
(See chart below.) b. If striking is still not satisfactory, see the NA-5 op-
1. Install the NA-5 per the information in the NA-5 op- erating manual for information on the feed motor
erating manual (IM-305). Connect the NA-5 to the acceleration.
DC-1500 as described on the connection diagram. c. If installed, adjust the 鈥淪tart Controls鈥? to set the
2. Place the DC-1500 mode switch in the proper position welding procedures for the time set on the timer to
according to the process and procedure to be used. provide the bead size, penetration, or other factor
as needed for the application. If not used, this board
3. Place the machine/remote switch in remote.
should be disconnected and the jumper plug re-
4. Connect the work lead to the work or a suitable piece
placed.
of scrap. Clip the end of the electrode to a sharp point.
d. If installed, adjust the 鈥淐rater Controls鈥? to set the
5. Preset the Start (if used), Weld and Crater (if used)
welding procedures for the set time after the stop
Controls to the wire speed and voltage specified in the
button is pressed to provide the bead size or fill the
procedure.
crater as needed for the application. If not used,
6. Make several test welds, readjusting the starting and this board should be disconnected and the jumper
stopping controls in the following order: plug replaced.
a. Set the Arc Striking Wire Speed and Volts Controls e. Set the 鈥淏urnback Time鈥? to provide the stopping
for optimum arc striking. For initial test welds, set characteristics needed.
the NA-5 arc striking wire speed control to 1/2 the
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鈥? over 13/4鈥? Innershield Solid Wire Tiny Twin 1/16(1) Over 1/16 Puddle
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
CV 鈥? CV 鈥? CV 鈥? CV 鈥? CV 鈥? CV 鈥? VV 鈥?
Mode Switch
NA-3 Inch Speed
2 鈥? 2 鈥? 2 鈥? 2 鈥? 2 鈥? 2 鈥? 2 鈥?
Dial Setting (5)
NA-5 Arc Striking 鈥? 鈥? 鈥? 鈥? 鈥? 鈥? 鈥?
(4) (4) (4) (4) (4) (4) (4)
Wire Speed(5)
NA-3 OCV Control(5) 鈥? 鈥? 鈥? 鈥? 鈥? 鈥? 6.5 - 7.0 鈥?
(6) (6) (6) (6) (6) (6)
NA-5 Arc Striking (4) (4) (4) (4) (4) (4) (4)
鈥? 鈥? 鈥? 鈥? 鈥? 鈥? 鈥?
Volts Control
NA-3 Start Board 鈥? Req鈥檇 (2) 鈥? Req鈥檇 (2) 鈥? 鈥? 鈥? 鈥? 鈥?
(2) (2) (2) (2) (2)
DC-1500 Output
Control Switch 鈥? Remote Remote Remote Remote Remote Remote Remote
Machine or Remote
DC-1500 NA-3S NA-5
CV CV CV CV Submerged CV CV Submerged
Mode Innershield Innershield Innershield Arc (3) Innershield Arc (3) CC CVS
Switch
DC-1500 Output Inoperative Inoperative Inoperative Inoperative Inoperative Inoperative Inoperative
Control
Starting is best with 鈥渉ot鈥? starting. Start button is pressed with wire above the work.
(1)
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
(2)
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
(3)
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
(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.
(5)
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
(6)
on page 7.
-9-
OPERATING INSTRUCTIONS
NL Option Kit ual. Secure the cables to the case with the clamps and
screws provided.
(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
of the LT-34 tractor with DC-1500鈥檚 assigned code 7687 5. Feed the K775 control cable through the clamp on the
and above. It provides the necessary DC control power for front of the NL option box and connect the leads to
the operation of the equipment and the necessary circuitry terminals 75,76, and 77 per connection diagram.
for proper inching, cold starting and arc striking. In using 6. Replace the cover. This completes the installation.
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.) NOTE: An NL Option was factory installed inside
DC-1500鈥檚 built to codes 7562-NL, 7636-NL and 7676-NL.
The NL option kit consists of a sheet metal box, 12.5鈥? long,
The instructions for the K783 apply except as follows:
11.5鈥? deep and 5.7鈥? high. This box mounts on top of the
DC-1500 and the following controls are located on the front 1. The factory-installed NL Option does not have a sep-
of the box: arate 鈥淧OS 鈥? NEG鈥? switch.
1. Inch speed control 鈥? used for LT tractor only. 2. The factory-installed NL Option does not have an 鈥淚nch
Speed鈥? control.
2. Hot start control 鈥? used to obtain optimum arc strik-
ing. 3. It cannot be used with LT-3 or LT-34 wire feeders.
3. Polarity switch 鈥? changes polarity of control circuit to 4. The fuse protecting the 115 volt DC circuit is a 2 amp
correspond with electrode polarity. fuse located on the NL Option panel inside the welder.
4. Contactor dropout delay switch 鈥? switches in or out
Operation When Connected to the NA-2
a slight contactor dropout delay to prevent sticking of
1. Set the 鈥淧OS 鈥? NEG鈥? switch (on both NL Option &
the wire in the crater at the end of welding.
DC-1500) to correspond to the polarity of the electrode
The terminal strip for connection to the automatic equip-
cable connection.
ment is located under the front cover. All necessary control
2. Set the mode switch on the front of the DC-15000 to
leads for connection to the DC-1500 are wired into the NL
鈥淐onstant Voltage 鈥? Innershield鈥? or 鈥淐onstant Volt-
kit for easy connection to the DC-1500 terminal strip.
age 鈥? Sumerged Arc鈥?.
3. Set the toggle switch on the front of the DC-1500 to
鈥淥utput Control Remote鈥?.
4. Set the output as required for the procedures using the
K775 Remote Output Control shipped with the NL Op-
tion.
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 鈥淚nch Speed鈥? control is not in
the circuit.
6. Set the 鈥淗ot Start Control鈥? on the NL Option to 4.
7. Set the 鈥淐ontactor Drop-Out Delay鈥? switch to 鈥淥ff鈥?.
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.
Before proceeding with any installation, be certain the
Operation When Connected to the LAF-3 and the K783
DC-1500 is turned off.
NL Option Kit
1. Mount the NL option box to the top of the DC-1500
For proper arc striking and welding when using the LAF-3
with the screws used to fasten the roof and sides.
with the DC-1500 and K783 NL Option Kit, follow the
2. Remove the cover of the NL option for access to the
instructions below (Turn the input power off at the fuse box
terminal strip.
before working inside the machine.):
3. Feed the control cable from the automatic wire feed
1. Connect the DC-1500 NL option, and LAF-3 per the
control unit through the grommet on the front of the
connection diagram M13321.
NL box. Connect the control leads per the appropriate
connection diagram included at the back of this man- 2. Remove the cover from the LAF-3 control box.
-10-
OPERATING INSTRUCTIONS
NOTE: The 鈥淗ot Start Control鈥? does not affect the
3. Remove the blue jumper lead connected between #1 on
starting method of the LAF-3, i.e., 鈥渃old鈥? start, 鈥渉ot鈥?
the coil of the main relay and #7 on the coil of the
start, etc. See IM-198-B, Sec. 2.4.9.
transfer relay. (The main relay is the upper right relay
when facing the left end of the control box. The transfer 11. Set the NL Option 鈥淐ontactor Drop-Out Delay鈥? switch
relay is just to the left of the main relay.) to 鈥淥n鈥?. This circuit delays opening of the output con-
tactor for a fixed length of time after wire feeding stops
4. Replace the LAF-3 control cover.
to prevent sticking.
5. Set the 鈥淧OS 鈥? NEG鈥? switch (on both the NL Option
and the DC-1500) to correspond to the polarity of the
Operation When Connected to the LT-3 or LT-34
electrode cable connection.
Follow the same instructions as above except in Step 1,
6. Set the mode switch on the front of the DC-1500 to
connect per M13322. Omit Steps 2, 3 and 4. Set the 鈥淚nch
鈥淰ariable Voltage鈥?.
Speed鈥? control on the NL Option as low as possible so the
7. Set the toggle switch on the front of the DC-1500 to
electrode touches the work piece lightly before starting the
鈥淥utput Control Remote鈥?.
arc.
8. Set the DC-1500 welding current as required by the
procedures using the K775 Remote Output Control
Overload Protection
shipped with the NL Option.
The NL Option kit includes two fuses on the front panel.
9. Set the LAF-3 鈥淚nch Speed鈥? control near minimum so
The upper fuse (2 amp slow blow) protects the inching cir-
the electrode touches the work lightly before starting the
cuit when the option is used with LT-3 and LT-34 wire feed-
arc. The NL Option 鈥淚nch Speed鈥? control is not in
ers. The lower fuse (2.8 amp slow blow) protects the 115
the circuit.
volt DC circuit (#1 and #2). If replacing either fuse use the
10. Set the 鈥淗ot Start Control鈥? on the NL Option at #2. same size and type.
This setting does not change the open circuit voltage,
but it will improve starting, particularly at low currents.
Adjust the control for optimum starting.
MAINTENANCE
OVERLOAD PROTECTION
WARNING The DC-1500 has built-in protective thermostats. If the rec-
tifier or transformer reaches the maximum safe operating
鈥? Have an electrician install and
service this equipment. temperature because of frequent overload or high room tem-
perature plus overload, the contactor drops out stopping the
鈥? Turn the input power off at the
welder. The thermostat automatically reset when the tem-
fuse box before working on
perature reaches a safe operating level. Press the 鈥淥n鈥? but-
equipment.
ton to start the welder.
ELECTRIC SHOCK 鈥? Do not touch electrically hot parts. The power rectifiers are also protected by a special solid
can kill. 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 鈥淥n鈥? button to start the
GENERAL MAINTENANCE welder.
1. The fan motors have sealed bearings which require no An 8 amp slow blow fuse located on the front of the machine
service. protects the 115 volt auxiliary AC circuit (#31 and #32)
from overload. If replacing, use the same type and size fuse.
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.
-11-
TROUBLESHOOTING GUIDE
WARNING
ELECTRIC SHOCK can kill.
鈥? Have a qualified individual install
and service this equipment.
Note: To locate the 鈥淔iring Circuit鈥? and 鈥淐ontrol/Fault
鈥? Turn the input supply power OFF
Protection Circuit鈥? P.C. boards, remove the upper
at the disconnect switch or fuse
case panel on the left side of the machine. The
box before working on this equip-
names are printed on the boards.
ment.
鈥? Do not touch electrically hot parts.
------------------------------------------------------------------------
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE CAUSE REMEDY
(SYMPTOMS)
Input contactor (CR1) chatters. a. Faulty input contactor (1CR). a. Repair or replace.
b. Low line voltage. b. Check with power company.
c. Faulty pilot relay (2CR). c. Replace relay.
Machine input contactor does not operate. a. Supply line fuse blown. a. Replace if blown. Look for reason first.
b. Contactor power circuit dead. b. Check pilot transformer T1 and associated leads
and 5 amp fuse.
c. Broken power lead. c. Check input voltage at contactor.
d. Wrong input voltage. d. Check voltage against nameplate.
e. 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 鈥? replace.
f. Open input contactor coil. f. Replace coil.
g. Faulty on-off switch. g. Replace switch.
h. Faulty pilot relay (2CR). h. Replace relay.
Machine input contactor operates but no output a. Electrode or work lead loose or broken. a. Repair connection.
when trying to weld. b. Open main transformer (T5) primary or sec- b. Repair.
ondary circuit.
c. 鈥淔iring Circuit鈥? P.C. board not connected or is c. All nine light emitting diodes (L1 thru L9) must be
faulty. lit. (See 鈥淧.C. Board Troubleshooting Guide鈥?.)
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. a. 鈥淥utput Control鈥? switch (SW4) in wrong position. a. Check position of switch.
b. 鈥淥utput Control鈥? switch faulty. b. Check switch and replace if faulty.
c. Open in feed back circuitry. c. Check wiring and control and 鈥淔iring Circuit鈥? P.C.
d. Faulty 鈥淐ontrol/Fault Protection鈥? or 鈥淔iring Circuit鈥? board wiring harness plugs.
P.C. boards. d. All light emitting diodes must be lit, except L4 on
鈥淐ontrol/Fault Protection鈥? board. (See 鈥淧.C. Board
Troubleshooting Guide.鈥?)
e. Output control potentiometer open (lead no. 75). e. Check and replace if faulty.
Machine does not have maximum output. a. One input fuse blown. a. Check and replace if blown after checking for rea-
son for blown fuse.
b. One phase of main transformer open. b. Check for open and repair.
c. Faulty 鈥淐ontrol/Fault Protection鈥? or 鈥淔iring Circuit鈥? c. All light emitting diodes must be lit on both P.C.
P.C. boards. boards, except L4 on 鈥淐ontrol/Fault Protection鈥?
board. (See 鈥淧.C. Board Troubleshooting Guide.鈥?)
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 a. Check internally and externally for any shorts and
circuit on the output. remove or repair.
b. Faulty 鈥淐ontrol/Fault Protection鈥? P.C. board. b. If no short circuits, LED L4 must be lit (See 鈥淧.C.
Board Troubleshooting Guide鈥?).
c. Machine output voltage applied to control leads. 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 REMEDY
POSSIBLE CAUSE
(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.
Output control not functioning on a. 鈥淥utput Control鈥? switch in the wrong a. Place switch in 鈥淥utput Control at
the machine. position. DC-1500鈥?.
b. Faulty output control switch. b. Check and replace if found faulty.
c. Faulty 鈥淥utput Control鈥? rheostat. c. Check and replace if found faulty.
d. Leads or connections open in 鈥淐ontrol d. Check lead continuity and connections for an
Circuit鈥?. open and repair if necessary.
e. Faulty 鈥淔iring Circuit鈥? or 鈥淐ontrol/Fault e. All light emitting diodes must be lit on both
Protection鈥? P.C. board. P.C. boards, except L4 on 鈥淐ontrol/Fault
Protection鈥? board. (See 鈥淧.C. Board
Troubleshooting Guide.鈥?)
Output control not functioning on a. 鈥淥utput Control鈥? switch in the wrong a. Place switch in 鈥淥utput Control Remote鈥?.
remote control. position.
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 鈥淐ontrol d. Check all leads and connections, internal and
Circuit鈥?. remote, for continuity and repair if
necessary.
e. Faulty 鈥淔iring鈥? or 鈥淐ontrol/Fault e. All light emitting diodes must be lit on both
Protection鈥? P.C. board. P.C. boards, except L4 on 鈥淐ontrol/Fault
Protection鈥? board. (See 鈥淧.C. Board
Troubleshooting Guide.鈥?)
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.
P.C. BOARD TROUBLESHOOTING GUIDE
CONTROL/FAULT PROTECTION P.C. BOARD
WARNING
鈥? Have an electrician install and
1. LED L1 indicates AC input voltage is present at pins
service this equipment.
255-256. If not lit, check the voltage across the sec-
ondary winding of the control transformer T7. The volt-
鈥? Turn the input power off at the
age should be approximately 115 volts. If not, the
fuse box before working on
problem is in the power supply and not the P.C. board.
equipment. 2. LED L2 indicates welder output voltage is being sup-
ELECTRIC 鈥? Do not touch electrically hot
plied to the control circuit. If not lit, check to make
SHOCK Can kill. parts.
certain 222 from pin 2 of the 12-pin control circuit P.C.
board connector is connected to the power source neg-
ative output stud, and is not broken.
-13-
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 power being supplied to P.C. board
from control transformer T3. If not, follow the same
5. LED L5 indicates a control signal is being supplied to
procedure as above in (1) for terminals 205 and 206 on
the firing circuit. As the output control is varied, LED
terminal strip TS-1 and pins 5 and 6 on the connector.
L5 should change brilliancy.
3. LED L9 indicates AC power being supplied to P.C. board
from control transformer T4. If not, follow the same
FIRING CIRCUIT P.C. BOARD procedure as above in (1) for terminals 207 and 208 on
Machine settings Terminals #2 and #4 jumpered on terminal strip TS-1 and pins 9 and 12 on the connector.
for P.C. board DC-1500. Output Control at 4. LED L1 through L6 indicate gate signals are being sup-
troubleshooting DC-1500. Variable Voltage opera- plied to the main power SCR鈥檚 L1 through L6 respec-
tion. tively. If light L5 on the 鈥淐ontrol/Fault Protection鈥?
All nine light emitting diodes must be lit when the power circuit P.C. board and lights L7 through L9 on the 鈥淔ir-
source is turned on and the wire feed arc start button is ing鈥? circuit P.C. board are lit and LED鈥檚 L1 through L6
pressed or a jumper is connected between 2 and 4. are not lit, check lead 231 between the 鈥淔iring鈥? P.C.
board and the 鈥淐ontrol/Fault Protection鈥? P.C. board
1. LED L7 indicates AC power being supplied to P.C. board
that is not broken and is connected to each connector.
from control transformer T2. If not lit, check voltage
If the lead shows continuity and LED L1 through L6 are
across terminals 203 and 204 on the terminal strip lo-
not lit, replace the鈥滷iring Circuit鈥? P.C. board. If any
cated on the left side of the bottom fan baffle. Voltage
one of the LED鈥檚 L1 through L6 is not lit and lights L7
should be approximately 115 volts. If no voltage indi-
through L9 are lit, replace the 鈥淔iring Circuit鈥? P.C.
cates a supply problem, check wiring and transformer.
board.
If voltage is present, turn the machine off, remove the
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 approximately 115 volts. problem.
OUTLINE FOR DC-1500 TROUBLESHOOTING GUIDE
NO WELDER OUTPUT MACHINE HAS OUTPUT BUT ERRATIC WELDING
(INPUT CONTACTOR 鈥淥N鈥? TERMINALS 2 AND 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鈥橲
CHECK LED L1 CHECK 鈥淔IRING鈥? BOARD IF TROUBLE STILL L4, L5, L6
LED鈥橲 PERSISTS, FOR EQUAL
IF OFF IF ON CHECK LED L3 ON BRILLIANCY
ALL 鈥淐ONTROL/FAULT
CHECK AC REPLACE NINE LIGHTS PROTECTION鈥? BOARD IF LIGHTS ARE NOT ALL
INPUT TO 鈥淐ONTROL/ SHOULD APPROXIMATELY EQUAL
鈥淐ONTROL/ FAULT BE ON IF LIGHT GOES ON,THEN BRIGHT, REPLACE
FAULT PROTECTION鈥? QUICKLY OUT WHEN START FIRING P.C. BOARD
PROTECTION鈥? BOARD IF YES BUTTON IS PRESSED,
BOARD IF NO 鈥淐ONTROL/FAULT
POSSIBLE CHECK GATE PROTECTION鈥? BOARD IS
DEFECTIVE T7 LEAD CHECK DEFECTIVE AND SHOULD
TRANSFORMER CONNECTIONS LED鈥橲 BE REPLACED
TO SCR鈥橲 L7, L8, L9
WARNING
IF ONE IF ON AND
OR MORE OTHER LIGHTS
ARE OUT ARE OUT 鈥? Have an electrician install and
service this equipment.
CHECK AC REPLACE
INPUT TO FIRING 鈥? Turn the input power off at the
BOARD, BOARD fuse box before working on
203-204, 205-206 equipment.
207-208
鈥? Do not touch electrically hot parts.
POSSIBLE
ELECTRIC SHOCK
DEFECTIVE
can kill.
TRANSFORMERS
T2, T3, OR T4
-14-
-15-
DIAGRAMS
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 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 along the welding
work cable. (This extended #21 lead connection replaces the need to
employ the remote work lead accessory on LN-9鈥檚 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 鈥淪鈥?, connect WHITE jumper to pin 鈥淏鈥?.
N.G. Set the DC-1500 controls as follows:
Set the control switch to 鈥淥utput Control Remote鈥?. For C.V. Submerged
Arc Processes, set the mode switch to 鈥淐.V. Submerged Arc鈥?. For Open
Arc Processes, set the mode switch to 鈥淐.V. Innershield鈥?.
Above diagram shows electrode connected po-
N.H. For proper operation, the electrode cable must be snugged under the
sitive. To change polarity, turn power off, reverse
clamp bar on the left side of the NA-5 control box.
the electrode and work leads at the power source,
and position the switch on power source to proper
polarity.
S16889
7-6-84G
WARNING
Connection of DC-1500 With NL Option Kit (K783) to LAF-3 (Obsolete) 鈥? Do not operate with covers
removed.
鈥? Disconnect welding power source
before servicing.
鈥? Do not touch electrically live
parts.
ELECTRIC SHOCK
鈥? Only qualified persons should
can kill. install, use or service this
machine.
N.A. 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 unit. Remove the jumper
tomatic equipment. source and position the leads on the back of the lead connected between #1 on the coil
ammeter and voltmeter in the LAF-3 control box. on the main relay and #7 on the coil of
N.B. On codes below 8234 this is #67
the transfer relay. (The main relay is the
and the LAF-3 #67 lead can be Contactor drop out delay switch on the NL option
upper right relay when facing the left end
connected either to the #67 ter- kit must be in the 鈥渙n鈥? position.
of the control box. The transfer relay is
minal or the electrode cable ter- 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鈥檚. cycle add additional cables to the power source
M13321
N.C. Terminals 73 & 74 not present on output studs.
earlier D.C. 1500鈥檚. 2-26-82C
-16-
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 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.
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
2-26-82B
voltmeter in the automatic control box.
WARNING
Connection of DC-1500 With NL Option Kit (K783) to LT-3 or LT-34 (Obsolete) 鈥? Do not operate with covers
removed.
鈥? Disconnect welding power source
before servicing.
鈥? Do not touch electrically live
parts.
ELECTRIC SHOCK 鈥? Only qualified persons should
can kill. install, use or service this
machine.
This diagram shows the electrode connected positive. To change
polarity, turn power source off, reverse the electrode and work
N.A. On codes above 8234 extend lead 67 and
leads at the power source and position the switch on the power
connect it to the electrode cable going to
source and th NL option kit to the proper polarity. Also reverse
the automatic equipment.
the leads on the back of the ammeter and voltmeter in the LT-3
M13322
N.B. On codes below 8234 this is #67 and the control box.
2-26-82C
LT-3 or LT-34 #67 lead can be connected
Contactor drop out delay switch on the NL option kit must be in
either to #67 or to the electrode cable ter-
the 鈥淥n鈥? position.
minal as shown. Terminal 82 not present
The 4/0 cables shown will handle up to 1000 amps at 80% duty
on later DC-1500鈥檚.
cycle. For higher currents or duty cycle add additional cables to
N.C. Terminals 73 and 74 not present on earlier
the power source output studs.
DC-1500鈥檚.
-17-
NOTES
-18-
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa moja- fuera del 谩rea de trabajo. cuerpo.
da.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des v锚te- G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
ments mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e elec- G Mantenha inflam谩veis bem guarda- G Use prote莽茫o para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 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 UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piraci贸n. mentaci贸n de poder de la m谩quina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilaci贸n o
ATTENTION
aspiraci贸n para gases.
French
G D茅branchez le courant avant l鈥檈ntre- G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
protection enlev茅s.
teur pour 么ter les fum茅es des zones
WARNUNG
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom v枚llig 枚ff- oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie f眉r gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G N茫o opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G Desligue a corrente antes de fazer
G Use ventila莽茫o e exhaust茫o para moventes.
servi莽o. G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
G N茫o toque as partes el茅tricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
鈥? World's Leader in Welding and Cutting Products 鈥?
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