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IM914
October, 2010
™
IDEALARC AC- 1500
Single Phase Variable Voltage Power Source For Automatic AC Welding
For use with machines having Code Numbers 11418
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGH
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Linco
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vi vi TAbLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Location ...............................................................................................................................A-2 Input Wiring ............................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - IDEALARC™ AC-1500 INPUT - SINGLE PHASE ONLY Input Current at 100% Rated Output Standard Voltage Single Phase Output Scott Connection 380/50/60 310 358 Idle Current With P.F. Capacitors Rated Input Current With P.F. Capacitors 70 310 Amp Single Phase Power Factor @ Rated load With P.F. Capacitors 358 Amp Scott-connection 71% RECOMMENDED INPUT WIRE GROUNDING CONDUCTOR AND FUSE SIzES* Input Input Amps Copper Wire Size – 75˚C in Conduit Super Lag Fu
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A-2 A-2 INSTALLATION LOCAtION The AC-1500 does not have an input contactor. Therefore, Install the welder in a dry location where there is free circu- include an external starter or disconnect switch when plan- lation of air in through the louvers in front and out through ning the input circuit. the louvers in the back of the case. A location which mini- mizes the amount of smoke and dirt drawn into the Remove the right side panel of the AC-1500 and bring the machine reduces the chance of dir
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A-3 A-3 INSTALLATION Connection of AC-1500 to NA-4 S-15667 with switch for ‘Current Control’ 6-18-76A Connection of AC-1500 to NA-4 with rheostat for current control. S-15602 6-22-84H IDEALARC™ AC-1500
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A-4 A-4 INSTALLATION Output stuDs Connect the work cables to the ‘To Work’ stud on the front of the AC-1500. Connect the electrode cables to the ‘Min,’ ‘Med’ or ‘Max’ studs for the output desired. Actual current ranges for each stud are indicated on the nameplate above each stud. Recommended cable sizes are listed below. Both the ‘To Work’ and ‘Max’ studs have two terminals to simplify connection of recommend- ed cables in parallel. Tighten the nuts with a wrench. Select cables required for c
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b-1 b-1 OPERATION GRAPHIC SYMbOLS THAT APPEAR SAFETY PRECAUTIONS ON THIS MACHINE OR IN THIS MANUAL Read and understand this entire section before oper- ating the machine. Output Control 1 Single Phase WARNING Remote Control Setting 3 Three Phase ELECTRIC SHOCK can kill. Local Control Settin Uo Rated No-Load Voltage • Do not touch electrically live parts or electrode with skin or wet clothing. Input Power Type U1 Rated Input Voltage • Insulate yourself fro
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b-2 b-2 OPERATION PRODUCT DESCRIPTION PRODUCT DESIGN APPLICATION The IDEALARC™ AC-1500 is an upgraded design Specifications are 50 Hz, 380 volt unit with a Power with the following additional features: factor correction as a standard feature. • Higher output current and duty cycle capabilities. Output terminals, control power terminal strip, and controls are recessed or hinged covered to affect a It is a single phase transformer-saturable reactor type "dead front". Due to the excessive amount
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b-3 b-3 OPERATION Hand Welding with stick electrode or semiautomatic Pilot light indicates when the supply lines to the arc welding is not recommended since OCV exceeds welder are electrically "hot". This means that the the 80 volts RMS limit allowed by standards for such welder input power and control transformers are ener- use. (Unit is within 100 volt allowable limit for auto- gized when the pilot light is on. matic or mechanically guided welding.) Input Circuit Plan: The AC-1500 is not inte
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C-1 C-1 ACCESSORIES OPTIONAL KIT: Remote control K775. IDEALARC™ AC-1500
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D-1 D-1 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 equipment. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ See additional warning inf
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E-1 E-1 TROUbLESHOOTING HOW TO USE TROUbLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. _______________________________________________________________
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E-2 E-2 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS POSSIbLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Welder will not start. Supply line fuse blown. Look for possible cause and repair. Open supply line lead. Replace fuse. Wrong supply line voltage. Repair. Provide nameplate specified voltage. Welder will not weld (Contactors Electrode or ground cable loose or Tighten connection or repair broken operating properly) broken. cable. Welder control circ
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E-3 E-3 TROUbLESHOOTING PRObLEMS POSSIbLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Welder welds at max. only no con- Diodes or SCR’s on heat sink Determine cause if possible and trol. assemblies shorted. replace shorted device. Shorted or grounded current controll Replace rheostat. rheostat. Output By-Pass Capacitors open or Replace or reconnect. disconnected. Free wheeling diode open or discon- Replace or reconnect. nected. P.C. board components failed. Determine cause if possible and repl
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C E P P B R U LL A E O E -E - -P R A W B R B C A D E L E L E T C A 1 U C R R D I5 C T E O IF 3 C O K L 7 A A R O C L S R T S O C YR O MD BE OLS T TR R C A A T B O N N 2 O N S S T A F F T A 3 O O R R U R R D O X M M .LE ER R R B 1 H 4 1 5 8 5 V V 58 B R 5C C R 8U O ER M NR T O N E R T .C 1 N O E . T L1 7 7 3 2 7 2 3 42 1 5 6 7 1 5 S C R 7W O EN M ITT 5 O C R 8 T H O EL N.B. 53 5 7 M 2 7T 7 4R 6 6 54T 1H T 3E O P R R 5 P A E 7 M N T M 2 O E E M O L S R T T T M R E A IN TALS R CE OS NIT S 5 A
