Lincoln Electric IDEALARC AC-1200 Service Manual
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Lincoln Electric IDEALARC AC-1200 Service Manual

Lincoln Electric IDEALARC AC-1200 Service Manual

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IDEALARC
AC-1200 / AC-1500
For use with machines having Code Numbers:
10291C, 10292C, 10465, 10466,
11418, 11869, 12387
SERVICE MANUAL
SVM225-A
| Issue D ate 17-Sep
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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Summary of Contents for Lincoln Electric IDEALARC AC-1200

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. ® IDEALARC AC-1200 / AC-1500 For use with machines having Code Numbers: 10291C, 10292C, 10465, 10466, 11418, 11869, 12387 SERVICE MANUAL SVM225-A...

  • Page 2: Electric And Magnetic Fields

    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.

  • Page 3: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations.
  • Page 8 Parts Manual ........
  • Page 9 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Location .

  • Page 10: Input Wiring

    INSTALLATION LOCATION OUTPUT CONNECTIONS Install the welder in a dry location where there is free A. Wire Feeder Connection circulation of air in through the louvers in front and out Turn the input power to the welder off. Remove the through the louvers in the back of the case.
  • Page 11 INSTALLATION FIGURE A.1 – RECOMMENDED INPUT WIRE, GROUNDING CONDUCTOR AND FUSE SIzES BASED ON NATIONAL ELECTRICAL CODE - 100% DUTY CYCLE 40˚C (104˚F) AMBIENT Copper Wire Size - 75º in Conduit Super Lag Fuses Size In Power Input Wires Grounding Conductor Input Amps Amps Input...

  • Page 12: Duty Cycle

    INSTALLATION FIGURE A.4 – CONNECTION OF AC-1200 TO NA-4 WITH RHEOSTAT FOR CURRENT CONTROL OR LT-6 AC-1200 WARNING: Turn power source off before making these connections. GND. TO AUTOMATIC Connect the control cable ground lead to the CONTROL BOX frame terminal marked near the power source terminal strip.
  • Page 13 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 14: Operation

    OPERATION SAFETY PRECAUTIONS TO SET FOR MACHINE OR REMOTE CONTROL Read and understand this entire section before operat- ing the machine. The output can be controlled either from the AC-1200, the wire feeder or other remote locations. To adjust the current from the wire feeder or other WARNING remote locations, set the toggle switch on the front of the AC-1200 to ‘Output Control Remote’.
  • Page 15 OPERATION FIGURE B.1 – AC-1200 SCOTT CONNECTION DIAGRAM TWO SINGLE MACHINES SCOTT CONNECTED WARNING Disconnect input power before servicing. Do not operate with covers removed. 3 PHASE SUPPLY LINES Do not touch electrically live parts. PHASE SEQUENCE A-C-B (N.A.) Only qualified persons should install, use ELECTRIC SHOCK or service this equipment.
  • Page 16 OPERATION FIGURE B.2 – AC-1200 SCOTT CONNECTION DIAGRAM TWO PARALLEL MACHINES SCOTT CONNECTED TO TWO OTHER PARALLEL MACHINES FOR DESIRED PHASE ANGLE, INTERCONNECT MACHINES (AS SHOWN BELOW). BOTH PHASE ANGLES MUST BE THE SAME. TO GROUND PER NATIONAL ELECTRICAL CODE WORK WORK N.B.
  • Page 17 OPERATION FIGURE B.3 – AC-1200 AND PARALLELED DC-1000’S DOUBLE TANDEM ARC WELDING DC, AC, AC, AC (LAST TWO ARCS SCOTT CONNECTED) FRAMES OF ALL WELDING POWER SOURCES MUST BE GROUNDED PER NATIONAL ELECTRIC CODE. PHASE SEQUENCE A-C-B PRIMARY PRIMARY SECONDARY SECONDARY SCOTT CONNECTED...
  • Page 18 OPERATION FIGURE B.4 – AC-1200 AND DC-1500’S DOUBLE TANDEM ARC WELDING DC, AC, AC, AC (LAST TWO ARCS SCOTT CONNECTED) FRAMES OF ALL WELDING POWER SOURCES MUST BE GROUNDED PER NATIONAL ELECTRIC CODE. PHASE SEQUENCE A-C-B PRIMARY PRIMARY SECONDARY SECONDARY SCOTT AC-1200 CONNECTED...
  • Page 19 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
  • Page 20 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Have qualified personnel do the maintenance and troubleshooting work. • Turn the input power OFF at the disconnect switch or fuse box before working on this equip- ment. • Do not touch electrically live parts or electrode with skin or wet clothing.
  • Page 21 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 22: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 - INPUT LINE VOLTAGE, POWER FACTOR CAPACITORS AND MAIN TRANSFORMER MIN. TERMINAL STRIP 2 / 4 31/32 OUTPUT REMOTE CONTROL CONTROL DC CONTROL COILS MED. CONTROL TRANSFORMER 115 VAC TO X2 SENSING CONTROL PILOT LEADS BOARD LIGHT MAX.
  • Page 23 THEORY OF OPERATION FIGURE E.3 - OUTPUT RECTIFICATION, CONTROL & FEEDBACK MIN. TERMINAL STRIP 2 / 4 31/32 OUTPUT REMOTE CONTROL CONTROL DC CONTROL COILS MED. CONTROL TRANSFORMER 115 VAC TO X2 SENSING CONTROL PILOT LEADS BOARD LIGHT MAX. AUX. FUSE UPPER (31) GATES...
  • Page 24 THEORY OF OPERATION FIGURE E.4 - PROTECTION DEVICES & CIRCUITS MIN. TERMINAL STRIP 2 / 4 31/32 OUTPUT REMOTE CONTROL CONTROL DC CONTROL COILS MED. CONTROL TRANSFORMER 115 VAC TO X2 SENSING CONTROL PILOT LEADS BOARD LIGHT MAX. AUX. FUSE UPPER (31) GATES...

  • Page 25: Scr Operation

    THEORY OF OPERATION FIGURE E.5 - SCR OPERATION SCR OPERATION A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the gate. device used to control rather large currents to a load. This gate pulse must be more positive than the cath- An SCR acts very much like a switch.
  • Page 26 NOTES IDEALARC ® AC-1200...
  • Page 27 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 28: Troubleshooting And Repair

    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.
  • Page 29 Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 30 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 1-888-935-3877. IDEALARC ®...
  • Page 31 5. P.C. board components failed. 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 1-888-935-3877. IDEALARC ®...
  • Page 32 NOTES IDEALARC ® AC-1200...

  • Page 33: Test Description

    CONTROL TRANSFORMER VOLTAGE TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 34 TROUBLESHOOTING AND REPAIR CONTROL TRANSFORMER VOLTAGE TEST PROCEDURE (continued) FIGURE F.1 – CONTROL TRANSFORMER LOCATION SCR BRIDGE CONTROL POWER FACTOR RECTIFIER ASSEMBLY TRANS CAPACITORS REACTOR COILS CONTROL CIRCUIT FUSE 40A TOP FAN DC CONTROL COILS AIR INTAKE AIR INTAKE BOTTOM FAN OUTPUT CONTACTORS LEFT SIDE PROCEDURE...
  • Page 35 TROUBLESHOOTING AND REPAIR CONTROL TRANSFORMER VOLTAGE TEST PROCEDURE (continued) FIGURE F.2 – CONTROL TRANSFORMER - P.C. BOARD X1 AND X2 LOCATION POWER FACTOR CONTROL BOARD CAPACITORS AREA RIGHT SIDE OUTPUT CONTACTORS INPUT AREA 5. Locate Control Transformer leads X1 and X2 on 8.
  • Page 36 NOTES F-10 F-10 IDEALARC ® AC-1200...
  • Page 37 D.C. CONTROL COILS VOLTAGE AND AMPERAGE TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 38 TROUBLESHOOTING AND REPAIR F-12 F-12 D.C. CONTROL COILS VOLTAGE AND AMPERAGE TEST PROCEDURE (continued) FIGURE F.3 – D.C. CONTROL COILS LOCATION SCR BRIDGE CONTROL POWER FACTOR RECTIFIER ASSEMBLY TRANS CAPACITORS REACTOR COILS CONTROL CIRCUIT FUSE 40A TOP FAN DC CONTROL COILS AIR INTAKE AIR INTAKE...
  • Page 39 CONTROL BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 40 F-14 F-14 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.4 – JUMPER AC-1200 CONTROL L5648-2 Pin 1 - Lead #43 Pin 2 - Lead #42 SCR2 Pin 3 - Lead #45 Pin 4 - Lead #41 Pin 5 - Empty Pin 6 - Lead #46 SCR3 Pin 7 - Lead #44...
  • Page 41 F-15 F-15 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR Testing is required after the removal of any mechanical part that could affect the machineʼs elec- trical characteristics, or if any electrical components are repaired or replaced. INPUT IDLE AMPS AND WATTS Input Volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW...
  • Page 42 NOTES F-16 F-16 IDEALARC ® AC-1200...
  • Page 43 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - Typical 60 HZ.
  • Page 44 ElEcTrical DiaGrams WiriNG DiaGram - Typical 60 HZ mODEls (m14314) IDEALARC AC-1200 WIRING DIAGRAM 60 HZ MODEL NOTES: N.A. CENTER TERMINAL OF FUSE HOLDER. CONTROL N.B. ONE RESISTOR ON EARLIER MACHINES. CONTROL COILS COILS (LEFT) (RIGHT) DIODE ASSEMBLY CONNECT TO GROUND...
  • Page 45 ElEcTrical DiaGrams WiriNG DiaGram - Typical 50/60 HZ mODEls (m18868) IDEALARC AC-1200 WIRING DIAGRAM 50/60 HZ MODELS NOTES: N.A. CENTER TERMINAL OF FUSE HOLDER N.B. 20 AMP SLOW BLOW FUSE (NOT PRESENT ON EARLY MODELS). CONTROL CONTROL COILS PROTECTIVE BONDING CIRCUIT...
  • Page 46 ElEcTrical DiaGrams scHEmaTic - Typical mODEls 51.1K 51.1K 51.1K 51.1K 51.1K +12V +12V 1.00K 1.00K 39.2K 39.2K 162K 6.81K 1N4007 39.2K 39.2K 1N4007 1.00K 115VAC 600V 1.00K 1.3K 1.00K CONTROL CURRENT SHUNT 47.5K 47.5K 5.62K 1.00K 1N4007 2N6027 90.9K 1N4007 6.2V 400mW 2.67K...

This manual is also suitable for:

Idealarc ac-1500

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