Lincoln Electric IDEALARC DC-1500 Operator's Manual
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Lincoln Electric IDEALARC DC-1500 Operator's Manual

Lincoln Electric IDEALARC DC-1500 Operator's Manual

Constant voltage and constant current dc arc welding power source, 3 phase rectifier type
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RETURN TO MAIN MENU
IM318-B
®
IDEALARC DC- 1500
August, 2007
C C o o n n s s t t a a n n t t V V o o l l t t a a g g e e a a n n d d C C o o n n s s t t a a n n t t C C u u r r r r e e n n t t D D C C A A r r c c W
W e e l l d d i i n n g g
P P o o w w e e r r S S o o u u r r c c e e , , 3 3 P P h h a a s s e e R R e e c c t t i i f f i i e e r r T T y y p p e e
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 INST LL, OPER TE OR
REP IR THIS EQUIPMENT
WITHOUT
RE DING
THIS
M NU L
ND THE S FETY
PREC UTIONS CONT INED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPER TOR'S M NU L
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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  • Page 1 RETURN TO MAIN MENU IM318-B ® IDEALARC DC- 1500 August, 2007 C C o o n n s s t t a a n n t t V V o o l l t t a a g g e e a a n n d d C C o o n n s s t t a a n n t t C C u u r r r r e e n n t t D D C C A A r r c c W W e e l l d d i i n n g g P P o o w w e e r r S S o o u u r r c c e e , , 3 3 P P h h a a s s e e R R e e c c t t i i f f i i e e r r T T y y p p e e For use with machines having Code Numbers 8294 and above.

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Fumes And Gases

    SAFETY 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 “hot”...
  • Page 4 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.
  • Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 6 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.

  • Page 7: Installation

    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 • 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...

  • Page 8: Duty Cycle

    INSTALLATION control leads and connect a jumper between #2 and #4 e. Optional Remote Control (K775) on the terminal strip on the front of the DC-1500. With the #2 to #4 jumper connected, the output studs are en- This control is included as part of the “NL Option”. ergized whenever the machine is on.
  • Page 9 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.
  • Page 10 OPERATING INSTRUCTIONS This usually results in a bad start where the wire rc striking with DC-1500 mode switch on Cv sub-arc or tends to “blast-off”. CV Innershield — There are a number of basic tech- If the voltmeter needle hesitates before coming up niques for good arc striking that apply to all processes to the desired voltage, the OCV is set too low.
  • Page 11 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.
  • Page 12 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.

  • Page 13: Maintenance

    OPERATING INSTRUCTIONS NOTE: The “Hot Start Control” does not affect the 3. Remove the blue jumper lead connected between #1 on the coil of the main relay and #7 on the coil of the starting method of the LAF-3, i.e., “cold” start, “hot” transfer relay.

  • Page 14: Troubleshooting Guide

    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.
  • Page 15 TROUBLESHOOTING GUIDE PROBLEMS REMEDY POSSIBLE CAUSE (SYMPTOMS) Variable or sluggish welding arc. Poor work or electrode connection. a. Check and clean all connections. b. Welding leads too small. b. Check table on page 4. Welding current or voltage too low. c.
  • Page 16 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.
  • Page 17 DIAGRAMS -15-...
  • Page 18 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.
  • Page 19 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.
  • Page 20 NOTES -18-...
  • Page 21 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. AVISO DE Insulate yourself from work and ground. Spanish PRECAUCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 22 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. AVISO DE remove fumes from breathing zone. Spanish PRECAUCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 23 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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