Lincoln Electric Idealarc DC-1500 User manual

Con tant Voltage and Con tant Current DC Arc Welding Power
Source, 3 Pha e Rectifier Type
For use with machines having Code Numbers 8294 and above.
SVM202-A
July, 2010
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 THROUGHOUT. And,
most importantly, think before you
act and be careful.
SERVICE MANUAL
IDEALARC® DC-1500
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] AX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
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SAFETY
i i
IDEALARC® DC-1500
FOR ENGINE
powered equipment.
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.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel-
ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi-
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
EEP CHILDREN AWAY. PACEMA ER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. or additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, lorida 33135 or CSA Standard W117.2-1974. A ree 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.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic ields (EM ). Welding
current creates EM fields around welding cables and
welding machines
2.b. EM fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EM fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EM fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
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.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above or Diesel Engines The Above or Gasoline Engines
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SAFETY
ii ii
IDEALARC® DC-1500
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
5.d. Shielding gases used for arc welding can displace air and
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’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOC can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
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
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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SAFETY
iii iii
IDEALARC® DC-1500
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTING
SPAR S can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. or information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS 4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow N PA 51B “ Standard for ire Prevention
During Welding, Cutting and Other Hot Work”, available from
N PA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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SAFETY
iv iv
IDEALARC® DC-1500
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. aire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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SAFETY
IDEALARC® DC-1500
Elect omagnetic Compatibility (EMC)
Confo mance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
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.
Int oduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and T reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com-
plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of A ea
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
v v
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SAFETY
IDEALARC® DC-1500
Elect omagnetic 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. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Ea thing of the Wo kpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capaci-
tance, selected according to national regulations.
Sc eening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
tions. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
vi vi
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
I I
IDEALARC® DC-1500
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-118
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TABLE OF CONTENTS - INSTALLATION SECTION
A-1 A-1
IDEALARC® DC-1500
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Wiring & Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
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INSTALLATION
A-2 A-2
IDEALARC® DC-1500
TECHNICAL SPECIFICATIONS – IDEALARC® DC-1500
INPUT - THREE PHASE ONLY
OUTPUT
1Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
RECOMMENDED INPUT WIRE AND FUSE SIZES
Standard Voltage
380/440/460
Input Current at Rated Output
216/187/184
Duty Cycle
100%
Volts at Rated Amperes
60
Amps
1500
Mode
Contstant Current
Contstant Voltage
Current Range
200-1500 Amps
200-1500 Amps
Maximum Open
Circuit Voltage
98 VDC
Auxiliary Power
115 VAC, 8 Amps
RATED OUTPUT
Input
Voltage/ requency
460/60
380/440/50/60
Type 75C Copper
Ground Wire in Conduit
AWG (IEC) Sizes
3 (25mm2)
Type 75C Copper
Wire in Conduit
AWG (IEC) Sizes
000 (85 mm2)
Input Ampere Rating on
Nameplate
184
use (Super Lag)
or Breaker Size
300
PHYSICAL DIMENSIONS
HEIGHT
57.2 in
1453 mm
WIDTH
22.3 in
566 mm
DEPTH
38 in
965 mm
WEIGHT
1420 lbs.
644 kg.
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INSTALLATION
A-3 A-3
IDEALARC® DC-1500
LOCATION
Install the welder in a dry location where there is free circula-
tion of air in through the louvers in the front and out through
the louvers in the back of the case. A location which minimizes
the amount of smoke and dirt drawn into the machine
reduces the chance of dirt accumulation that can block air
passages and cause overheating.
IN UT WIRING
Failure to fuse the input lines per the specifications in this
manual will constitute customer abuse and void the war-
ranty.
------------------------------------------------------------------------
Be sure the voltage, phase and frequency of the input power is
as specified on the welder nameplate.
Have a qualified electrician remove the lower right side case
panel and connect 3 phase AC power to terminals L1, L2and
L3of the input contactor in accordance with the Na-tional
Electrical Code, all local codes and the wiring diagram located
inside the machine.
The frame of the welder must be grounded. A stud marked
with the symbol located on the fan shroud is provided for
this purpose. See the U.S. National Electrical Code for
details on proper grounding methods.
Recommended Input Wire, Grounding Wire and Fuse Sizes
Based on National Electrical Code For 60 Hertz,
3 hase Welders at 100% Duty Cycle
NOTE: The standard machines are designed to operate on
460 volt-60 Hertz, 440 volt-50 Hertz and 380 volt-50 Hertz
input power systems. However, to use the machines on 380
volt-50 Hertz power, reconnect the transformer input leads
in accordance with the connection diagram pasted to the
inside of the lower right side case panel.
OUT UT CONNECTION (Turn ower Source
Off)
a. Output Studs
The “Positive” and “Negative” output studs are located
on the front panel. Two of each are provided to simplify
connecting multiple electrode or work cables as sug-
gested in the table below.
Connect the electrode cables to the “Positive” studs for
electrode positive (DC+) polarity or to the “Negative”
stud for electrode negative (DC-) polarity as required by
the welding procedures. Connect the work cables to the
other set of studs. Tighten the nuts with a wrench.
b. Auxiliary Power
This machine supplies the 1000 volt-amperes of 115
volt, AC power needed for the automatic wire feeders.
The power is available from terminals #31 and #32 on
the terminal strip.
c. “NL Option” (K783) (OBSOLETE)
Installation of an NL option is required when connecting
a DC-1500 to LA -3, NA-2, LT-3 or LT-34 wire feeding
systems. See the section on page 9 entitled “NL Option
Kit” for full information.
d. Wire eeder Connection — Without NL Option
Turn the welder off. Remove the screw and lift the
hinged door on the front of the control panel to expose
the terminal strips. Connect the leads of the wire feeder
input control cable to the terminal strip exactly as speci-
fied in the appropriate connection diagram included in
the wire feeder Operating Manual. Attach the control
cable to the panel at the right of the terminal strip using
the clamp attached to the control cable. Close the door
and replace the screw.
To connect the DC-1500 to wire feeders not covered in
available connection diagrams, write to the factory for
instructions giving complete nameplate information for
the DC-1500 and wire feeder.
Copper Wire Size
Type 75° In Conduit
Input Amps 3 Input Grounding Super Lag Fuse
Volts Input Wires Conductor Size in Amps
460 184 000 3 300
Suggested Copper Cable Sizes — 80% Duty Cycle
Below 1000 amps Two 4/0
1000 to 1200 amps Three 4/0 Up to
1200 to 1500 amps our 4/0 200’
WARNING
FALLING
EQUIPMENT can
cause injury.
• Do not lift this machine usin lift
bale if it is equipped with a
heavy accessory such as a trail-
er or as cylinder.
• Lift only with equipment of
adequate liftin capacity.
• Be sure machine is stable when
liftin .
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before workin on
equipment.
• Do not touch electrically hot
parts.
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INSTALLATION
A-4 A-4
IDEALARC® DC-1500
e. Optional Remote Control (K775)
This control is included as part of the “NL Option”.
Connect it to the “NL Option” box per instructions shipped
with the option. (Not required with the NA-3, NA-5, LT-7 or
LT-56.)
It can be purchased separately when the DC-1500 is used
for other applications.
To install, turn the power off. Remove the screw and lift
the hinged door on the front of the control panel to expose
the terminal strips. Connect the numbered leads to the
appropriate terminals — 75 to 75, etc — on the terminal
strip and the green lead to the stud marked with the sym-
bol . Attach the control cord to the panel at the right
of the terminal strip using a suitable clamp. Close the door
and replace the screw. The Remote Control cord can be
lengthened to any length by properly splicing an appropri-
ate four conductor rubber-covered cable to the standard
25’ cord before connecting to the DC-1500 terminal strip.
f. Connecting for Air Carbon Arc
To use the DC-1500 for air carbon arc or other appli-
cations, disconnect all wire feeder welding cables and
control leads and connect a jumper between #2 and #4 on
the terminal strip on the front of the DC-1500. With the #2
to #4 jumper connected, the output studs are en-ergized
whenever the machine is on.
g. DC-1500 Paralleling Kit
A kit for field installation only, (order K1900-1) is avail-able
for paralleling two DC-1500’s for currents up to 3000
amperes, 100% duty cycle. Complete installation instruc-
tions are shipped with the kit.
h. Connecting for High requency Starting
As shipped, these welders can be used with a high fre-
quency unit for improved automatic welding starting char-
acteristics.
RATINGS
IP21 enclosure
Main Transformer insulation class 155 ( )
WARNING: If the electrode leads to the wire are not
disconnected per instructions, the wire feeder nozzle or
gun and electrode will be electrically “hot”.
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TABLE OF CONTENTS - OPERATION SECTION
B-1 B-1
IDEALARC® DC-1500
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Duty Cycle, Polarity & Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3/B-5
Connecting to Wire eeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6/B-7
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OPERATION
B-2 B-2
IDEALARC® DC-1500
DUTY CYCLE
The DC-1500 is rated for 100% duty cycle at 1500 amps
and 60 volts.
To Set olarity
Connect the electrode cable to the “Positive” or “Negative”
studs depending upon the electrode polarity desired. Con-
nect the work cable to the other studs.
Set the “Electrode Negative — Electrode Positive” switch
to correspond to the polarity of the electrode cable connec-
tion. This switch setting is necessary for proper operation
of the Lincoln wire feeder attached to the power source.
To Start the Welder
Press the “On-Off” pushbuttons to start and stop the welder.
The red pilot light near the center of the control panel in-
dicates when the welder is on.
OPERATING INSTRUCTIONS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothin .
• Insulate yourself from work and
round.
ARC RAYS
can burn.
• Wear eye, ear and body protection.
WELDING SPARKS
can cause fire or
explosion.
• Keep flammable material away.
FUMES AND
GASES can be
dan erous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathin zone.
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OPERATION
B-3 B-3
IDEALARC® DC-1500
To Set for Machine or Remote Control
The output can be controlled either at the wire feeder or the
DC-1500. When the NL Option Kit is installed, however, out-
put is controlled only from the K775 Remote Con-trol usually
mounted at the wire feeder.
To adjust the output from the wire feeder, set the toggle
switch on the front of the DC-1500 to “Output Control
Remote”. To adjust the output using the DC-1500 “Output
Control” rheostat, set this switch to “Output Control at DC-
1500”.
To Set the Welder Output
With the toggle switch set to “Output Control at DC-1500”,
rotating the “Output Control” rheostat on the DC-1500 from
1 to 10 increases the machine output from minimum to max-
imum. The same full range control is set from the wire feed-
er or K775 when the toggle switch is set to “Output Control
Remote”.
Set the output as required by the welding procedures.
Mode Switch
The toggle switch labeled CV Innershield, CV submerged
arc, VV submerged arc, is used to select the proper welder
characteristics for the process being used.
NOTE: Some machines say ”VV” for variable voltage while
other machines use the terminology “CC” for constant cur-
rent.
The CV Innershield Mode permits the DC-1500 to produce
essentially a flat output characteristic that can be varied from
approximately 20 to 60 volts. In this position the dy-namic
characteristics of the machine under welding con-ditions pro-
vides optimum welding characteristics for Innershield weld-
ing and other open arc processes.
The CV Submerged Arc Mode also produces an essentially
flat output characteristics that can be varied from approxi-
mately 20 to 60 volts. The dynamic characteristics of the CV
Submerged Arc Mode are such that excellent submerged arc
welding can be obtained for most procedures that previously
required a constant current type power source.
The VV Submerged Arc Mode permits the DC-1500 to pro-
duce a constant current output characteristic through the
range of 200A-28V to 1500A-60V with an open circuit voltage
of 45 to 98 volts. Although almost all submerged arc welding
can now be done in the CV mode, the VV mode is avail-
able for those procedures where VV (CC) may still be desir-
able.
Set-up for Various rocesses
Selection of mode switch position — There are several gen-
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.
3. The VV (CC) mode is available for high current, large
puddle submerged arc procedures that cannot be done
as well with the constant voltage mode.
4. Air Carbo Arc Gougi g or Cutti g — or air carbon arc
gouging, the constant voltage Innershield mode is used
with the output control set between 4 and max. depend-
ing on the application, carbon size, etc. Up to 1/2” carbons,
start with the machine control set at 4 and increase as
required for long cable lengths. With 1/2” and 5/8” carbons,
short (100’) cable lengths can lead to occasional tripout of
the protection circuit when the carbon is shorted to the
work. Cutting back the output setting will reduce the short
circuit current and minimize tripping. Longer cable lengths
do an even better job since this also reduces the short cir-
cuit current but even more significantly permits raising the
open circuit voltage (by increasing control setting) for
smoother operation. See the table below for optimum
cable size and length.
If ever longer leads are used and the output control is
already set on max., the unit has reached its maximum air
carbon arc capability.
3/4” carbons are not recommended for use with the DC-
1500 because the high surge currents that occur with this
diameter can cause the DC-1500 fault protection circuitry
to trip the machine off the line, if the operator does not
gouge in such a way to limit the currents.
General Set-Up rocedures When Using DC-1500 and
Lincoln Automatic Head NA-3
(Read the following and refer also to the chart on page 9.)
1. NA-3 — The NA-3 should be set for the mode being used
on the power source. If using either of the CV modes, the
NA-3 VV board switch should be set for CV. If the power
source is used in the VV mode, then the NA-3 VV board
mode switch should be placed in the VV position.
All NA-3’s when used with the DC-1500 are capable of
cold starting with the variable voltage board mode switch
in VV. Cold starting permits the wire to be inches down to
the work, automatically stop and automatically energize
the flux hopper valve. All NA-3’s made after September
1976, are capable of cold starting on either CV or VV set-
tings of the variable voltage board switch.
Combined Total
Electrode and Electrode
Carbon Typical Work Lead Length and Work
Size Current Range (Min) (Max) Lead Size
1/2600-1000 Amps 250’ 825’ 2 — 4/0
5/8800-1200 Amps 375’ 925’ 3 — 4/0
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OPERATION
B-4 B-4
IDEALARC® DC-1500
2. Arc striki g with DC-1500 mode switch o Cv sub-arc or
CV I ershield — There are a number of basic tech-
niques for good arc striking that apply to all processes
and power sources. It may not be necessary in every
application to follow these guidelines, but when striking
problems do occur, following the suggestions below
should provide trouble-free starting. These procedures
apply to all single solid wire, Innershield wire, and Twinarc
1/8and 3/32 solid wire.
a. Except for long stickout Innershield procedures and
Tiny Twinarc 1/16 procedures, an NA-3 start board is
ot needed. If a start board is ot needed, it should
be removed from the machine, or at least discon-
nected and the logic board jumper plug replaced.
Leaving it connected makes the setup for arc striking
more difficult. Also, if a crater board is ot needed,
it should be removed from the NA-3 or at least elec-
trically disconnected and the jumper plug replaced.
b. Cut electrode to a sharp point.
c. or cold starts, make certain work piece is clean and
electrode makes positive contact with plate.
d. or hot starts, travel should be started before wire
contacts the work (“on the fly” starting).
e. Set NA-3 open circuit voltage control to approximate-
ly the same setting as the weld setting. or initial test
welds, choose the voltage setting based on the table
below. Set the inch control to 2.
These are approximate settings only until the weld-ing
procedure has been set.
It should be noted that with the DC-1500 the OCV
required for optimum starting is lower than that
required with other type power sources.
f. Run a test weld, setting the proper current, voltage
and travel speed.
g. Once the proper welding procedure is established and
if the start is poor — wire blast-off, stub, etc., adjust
the OCV and inch speed for optimum start-ing. In gen-
eral, a low inch speed will provide the best starting.
Adjust the OCV by making repeated starts and ob-
serving the voltmeter action.
With proper adjustment of the OCV control, the volt-
meter needle will swing smoothly up to the de-sired
arc voltage and thus provide repeatable starts.
If the voltmeter swings above then back to the de-
sired welding voltage, the OCV setting is too high.
This usually results in a bad start where the wire tends
to “blast-off”.
If the voltmeter needle hesitates before coming up to
the desired voltage, the OCV is set too low. This will
cause the electrode to stub.
h. or Twinarc welding, clipping both wires to equal
lengths will be beneficial to make consistently good
starts.
3. Si gle I ershield Wire — Procedures and techniques
are the same as above, except starting is generally better
“hot” than “cold”. or electrical stickouts above 13/4an NA-
3 start board is required.
4. Twi arc I ershield — Procedures and techniques are
the same as above, except starting is generally better
“hot than “cold”. Use of an NA-3 start board improves
starting.
5. Twi arc Submerged Arc 1/16 — Procedures and tech-
niques are the same as above, except starting is best when
using CV Innershield and the NA-3 start board.
6. Use of the NA-3 Start Board — or those processes
above that recommend use of the NA-3 start board, the
following method should be used to set up the procedure.
a. Set start time at 0 and start current and voltage at mid-
range. Start the weld and set the proper current and volt-
age for the welding procedure.
b. Turn the start board timer to maximum.
c. Set start board current 1 to 11/2dial numbers below NA-
3 front control settings.
d. Place start board’s voltage control approximately equal
to NA-3 voltage control setting.
When set per c and d, above, the starting only pro-
cedure will provide a current setting lower than the NA-
3 current setting and a voltage setting nearly equal to
the desired welding procedure.
e. With the start board time delay set at maximum, estab-
lish the correct arc striking procedure as described pre-
viously by changing OCV and inch speed.
f. Now increase the start board current and voltage to
bring the start current and voltage closer to the welding
procedure. The start board current and voltage should
be as close to the welding procedure as possible while
still getting satisfactory starts.
g. Now decrease the start time as low as possible for opti-
mum starts.
7. Arc striking with the DC-1500 mode switch in VV.
a. NA-3 — The NA-3 variable voltage board mode switch
should be set to the VV position.
b. Set OCV control at 6.5 to 7.0.
c. Other techniques recommended in the previous sec-
tions for good arc striking apply here also.
Approximate Voltage Voltage Control Setting
22-24 2
34-36 4
46-48 6
56-60 8
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OPERATION
B-5 B-5
IDEALARC® 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” over 13/4” Innershield Solid Wire Tiny Twin 1/16(1) Over 1/16 uddle
Wire eed 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
Mode Switch CV — CV — CV — CV — CV — CV — VV —
NA-3 Inch Speed
Dial Setting (5) 2— 2— 2 — 2 — 2 —2 — 2 —
NA-5 Arc Striking — (4) —(4) —(4) —(4) —(4) —(4) —(4)
Wire Speed(5)
NA-3 OCV Control(5) (6) —(6) —(6) —(6) —(6) —(6) — 6.5 - 7.0 —
NA-5 Arc Striking (4) (4) (4) (4) (4) (4) (4)
Volts Control —— — — — — —
NA-3 Start Board (2) — Req’d (2) — Req’d (2) —(2) —(2) —(2) —(2) —
DC-1500 Output
Control Switch — Remote Remote Remote Remote Remote Remote Remote
Machine or Remote
DC-1500 CV CV CV CV Submerged CV CV Submerged NA-3S NA-5
Mode Innershield Innershield Innershield Arc (3) Innershield Arc (3)
CC CVS
Switch
DC-1500 Output Inoperative Inoperative Inoperative Inoperative Inoperative Inoperative Inoperative
Control
b. If striking is still not satisfactory, see the NA-5 op-erat-
ing manual for information on the feed motor acceler-
ation.
c. If installed, adjust the “Start Controls” to set the weld-
ing procedures for the time set on the timer to provide
the bead size, penetration, or other factor as needed
for the application. If not used, this board should be
disconnected and the jumper plug replaced.
d. If installed, adjust the “Crater Controls” to set the
welding procedures for the set time after the stop but-
ton is pressed to provide the bead size or fill the crater
as needed for the application. If not used, this board
should be disconnected and the jumper plug replaced.
e. Set the “Burnback Time” to provide the stopping char-
acteristics needed.
General Set-Up rocedures When Using DC-1500 and
Lincoln Automatic Head NA-5
(See chart below.)
1. Install the NA-5 per the information in the NA-5 operating
manual (IM-305). Connect the NA-5 to the DC-1500 as
described on the connection diagram.
2. Place the DC-1500 mode switch in the proper position
according to the process and procedure to be used.
3. Place the machine/remote switch in remote.
4. Connect the work lead to the work or a suitable piece
of scrap. Clip the end of the electrode to a sharp point.
5. Preset the Start (if used), Weld and Crater (if used)
Controls to the wire speed and voltage specified in the
procedure.
6. Make several test welds, readjusting the starting and
stopping controls in the following order:
a. Set the Arc Striking Wire Speed and Volts Controls for
optimum arc striking. or initial test welds, set the NA-
5 arc striking wire speed control to 1/2 the weld wire
feed speed and the arc striking voltage control 4 volts
above the weld voltage.
RECOMMENDED SET-U ROCEDURES FOR NA-3/DC-1500, NA-5/DC-1500
(1) Starting is best with “hot” starting. Start button is pressed with wire above the work.
(2) 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 should
be electrically disconnected and the jumper plug replaced.
(3) Some high speed welding procedures may perform better on the CV Innershield mode. Merely change the switch between CV Innershield
and CV Submerged arc position and select the best welding.
(4) 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 volts
above the welding voltage. These controls can be adjusted as required for optimum arc striking.
(5) Exact dial setting depends on cable size and length, carbon size, etc.
(6) Set the OCV control to the same dial setting as the NA-3 voltage control. or initial test welds, choose the setting based on the table
on page 7.
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OPERATION
B-6 B-6
IDEALARC® DC-1500
NL Option Kit (OBSOLETE FEATURE)
(Not Required With NA-3, NA-5, LT-7 or LT-56)
The K783 NL option kit (for field installation) is designed to
permit use of the NA-2, LA -3, LT-3 (OBSOLETE) and the
LT-3 section of the LT-34 (OBSOLETE) tractor with DC-
1500’s assigned code 7687 and above. It provides the nec-
essary DC control power for the operation of the equipment
and the necessary circuitry for proper inching, cold starting
and arc striking. In using 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.)
The NL option kit consists of a sheet metal box, 12.5” long,
11.5” deep and 5.7” high. This box mounts on top of the DC-
1500 and the following controls are located on the front of the
box:
1. Inch speed control — used for LT tractor only.
2. Hot start control — used to obtain optimum arc strik-ing.
3. Polarity switch — changes polarity of control circuit to cor-
respond with electrode polarity.
4. Contactor dropout delay switch — switches in or out a
slight contactor dropout delay to prevent sticking of the
wire in the crater at the end of welding.
The terminal strip for connection to the automatic equipment
is located under the front cover. All necessary control leads
for connection to the DC-1500 are wired into the NL kit for
easy connection to the DC-1500 terminal strip.
Before proceeding with any installation, be certain the
DC-1500 is turned off.
(OBSOLETE FEATURE)
1. Mount the NL option box to the top of the DC-1500 with
the screws used to fasten the roof and sides.
2. Remove the cover of the NL option for access to the ter-
minal strip.
3. eed the control cable from the automatic wire feed con-
trol unit through the grommet on the front of the NL box.
Connect the control leads per the appropriate connection
diagram. Secure the cables to the case with the clamps
and screws provided.
4. Using the same diagram, connect the leads from the
option kit to the DC-1500 terminal strip.
5. eed the K775 control cable through the clamp on the
front of the NL option box and connect the leads to ter-
minals 75,76, and 77 per connection diagram.
6. Replace the cover. This completes the installation.
NOTE: An NL Option was factory installed inside DC-
1500’s built to codes 7562-NL, 7636-NL and 7676-NL. The
instructions for the K783 apply except as follows:
1. The factory-installed NL Option does not have a sep-
arate “POS — NEG” switch.
2. The factory-installed NL Option does not have an “Inch
Speed” control.
3. It cannot be used with LT-3 or LT-34 wire feeders.
4. The fuse protecting the 115 volt DC circuit is a 2 amp fuse
located on the NL Option panel inside the welder.
Operation When Connected to the NA-2 (OBSOLETE
FEATURE)
1. Set the “POS — NEG” switch (on both NL Option & DC-
1500) to correspond to the polarity of the electrode cable
connection.
2. Set the mode switch on the front of the DC-15000 to
“Constant Voltage — Innershield” or “Constant Voltage
— Sumerged Arc”.
3. Set the toggle switch on the front of the DC-1500 to
“Output Control Remote”.
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 “Inch Speed” control is not in the circuit.
6. Set the “Hot Start Control” on the NL Option to 4.
7. Set the “Contactor Drop-Out Delay” switch to “Off”. Refer
to the NA-2 Operating Manual for instructions for setting
the contactor drop-out delay and crater filling features
built into the NA-2 circuit.
Operation When Connected to the LAF-3 and the K783
NL Option Kit (OBSOLETE FEATURE)
or proper arc striking and welding when using the LA -3
with the DC-1500 and K783 NL Option Kit, follow the instruc-
tions below (Turn the input power off at the fuse box before
working inside the machine.):
1. Connect the DC-1500 NL option, and LA -3 per the con-
nection diagram M13321.
2. Remove the cover from the LA -3 control box.
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OPERATION
B-7 B-7
IDEALARC® DC-1500
3. Remove the blue jumper lead connected between #1 on
the coil of the main relay and #7 on the coil of the trans-
fer relay. (The main relay is the upper right relay when
facing the left end of the control box. The transfer relay is
just to the left of the main relay.)
4. Replace the LA -3 control cover.
5. Set the “POS — NEG” switch (on both the NL Option and
the DC-1500) to correspond to the polarity of the elec-
trode cable connection.
6. Set the mode switch on the front of the DC-1500 to
“Variable Voltage”.
7. Set the toggle switch on the front of the DC-1500 to
“Output Control Remote”.
8. Set the DC-1500 welding current as required by the pro-
cedures using the K775 Remote Output Control shipped
with the NL Option.
9. Set the LA -3 “Inch Speed” control near minimum so the
electrode touches the work lightly before starting the arc.
The NL Option “Inch Speed” control is not in the circuit.
10.Set the “Hot Start Control” on the NL Option at #2. This
setting does not change the open circuit voltage, but it will
improve starting, particularly at low currents. Adjust the
control for optimum starting.
NOTE: The “Hot Start Control” does not affect the start-
ing method of the LA -3, i.e., “cold” start, “hot” start, etc.
See IM-198-B, Sec. 2.4.9.
11. Set the NL Option “Contactor Drop-Out Delay” switch to
“On”. This circuit delays opening of the output contactor
for a fixed length of time after wire feeding stops to pre-
vent sticking.
Operation When Connected to the LT-3 or LT-34
(OBSOLETE FEATURE)
ollow the same instructions as above except in Step 1, con-
nect per M13322. Omit Steps 2, 3 and 4. Set the “Inch
Speed” control on the NL Option as low as possible so the
electrode touches the work piece lightly before starting the
arc.
Overload rotection
The NL Option kit includes two fuses on the front panel. The
upper fuse (2 amp slow blow) protects the inching circuit
when the option is used with LT-3 and LT-34 wire feeders.
The lower fuse (2.8 amp slow blow) protects the 115 volt DC
circuit (#1 and #2). If replacing either fuse use the same size
and type.
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NOTES
B-8 B-8
IDEALARC® DC-1500
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