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IM283-C
October, 2010
®
IDEALARC AC-1200
Single Phase Variable Voltage Power Source For Automatic AC Welding
For use with machines having Code Numbers 10291C, 10292C, 10465 and 10466.
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, OPER-
ATE OR REPAIR THIS EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
OPERATOR’SꢀMANUAL
Copyright © 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 WEBꢀSITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
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
ventilation. In confined spaces or in some circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
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.
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 spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
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.
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.
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.
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.
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
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.
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” 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
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
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.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
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.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, 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.
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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
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
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.
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.
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 lev-
age, 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.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique 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
defonctionnement.
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.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
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.
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.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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 ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
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.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
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.
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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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank 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’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.
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.
• 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.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. 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.
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TAbLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Location ...............................................................................................................................A-1
Input Wiring ..........................................................................................................................A-1
Output Connections..............................................................................................................A-1
a. Wire Feeder Connections .........................................................................................A-1
Ratings: ................................................................................................................................A-1
Connection of AC-1200 (with NL Option) to LAF or LT34....................................................A-2
Connection of AC-1200 to NA-4 with Switch for ‘Current Control’ .......................................A-2
Connection of AC-1200 to NA-4 with rheostat for current control or LT-6............................A-2
b. Output Studs .............................................................................................................A-3
c. Auxiliary Power..........................................................................................................A-3
Duty Cycle............................................................................................................................A-3
________________________________________________________________________________
Operation.........................................................................................................................Section b
Safety Precautions.................................................................................................B-1
To set for machine or Remote Control .................................................................................B-1
To set Output Current...........................................................................................................B-1
________________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide....................................................................................E-2,E-3
________________________________________________________________________
Wiring Diagrams..............................................................................................Section F
________________________________________________________________________
PARTS PAGES ................................................................................... P-119, P-28, P-84
________________________________________________________________________
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A-1
A-1
INSTALLATION
The AC-1200 does not have an input contactor. Therefore,
include an external starter or disconnect switch when plan-
ning the input circuit.
Remove the right side panel of teh AC-1200 and bring the input
power lines through the hole in the back of the case. See the
table below for reccomended sizing of input leads and overcur-
rent protection.
LOCATION
Install the welder in a dry location where there is free circu-
lation of air in through the louvers in front and out through
the louvers in the back of the case. A location which mini-
mizes the amount of smoke and dirt drawn into the
machine reduces the chance of dirt accumulation that can
block air passages and cause overheating.
The frame of the welder must be grounded, A stud marked with
INPuT WIRING
the symbol
located on the welder case back hole in the
back of the case is provided for this purpose. See the National
Electrical Code for details on proper grounding methods.
WARNING
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
OuTPuT CONNECTIONS
a. Wire Feeder Connection
Turn the input power to 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 strips exactly as
specified in the appropriate connection diagram. The AC-1200
to NA-4 connection diagrams are included in the NA-4
Operating Manual IM-278. Attach the control cables to the
panel at the right of the terminal strip using the clamps pro-
vided.
• Do not touch electrically hot
parts.
ELECTRIC SHOCK
can kill.
Failure to fuse the input lines per the specifications
in this manual will constitute customer abuse and
void the warranty.
If connecting the AC-1200 to an older NA-4 with the toggle
switch type ‘Current Control’ (below code 7532), a K-775
‘Remote Control’ must be purchased and instal-led in accor-
dance with the connection diagram S-15667 on page 5. The
‘Remote Control’ cord can be lengthened to any length by prop-
erly splicing a four conductor cord to the standard 25’ cord
before connecting to the AC-1200 terminal strip.
---------------------------------------------------------------
Have a qualified electrician make the complete input con-
nection in accordance with the National Electrical Code,
all local codes and the connection diagram located inside
the machine.
Be sure the voltage, phase and frequency of the input power
is as specified on the welder nameplate.
If connecting the AC-1200 to an LAF-4 or the AC controls of
the LT-34 tractor, the AC-1200 must be ordered with the
required ‘–NL’ optional circuit installed. This kit includes the
K-775 ‘Remote Control’. Connect in accordance with dia-
gram S-15666 on page 5.
For most installations, connect the AC-1200 to single phase
power or to one phase of a three phase line. Unbalanced
line conditions can be easily avoided by properly balancing
the AC-1200 with other machinery on the lines.
To connect the AC-1200 to any other wire feeder, write to the
factory for instructions giving complete nameplate information
for the specific equipment.
When installing two or four Scott connected AC-1200
machines for AC-AC tandem arc welding, three phase input
power must be used. The terminals for connections to pro-
vide an output phase angle less than or greater than the
usual 90% phase angle are included on the input panel.
When connection to the terminal strips are completed, close
the door and replace the screw.
RATING: IP21 ENCLOSURE, INSULATION 155(F)
Recommended Input Wire, Grounding Conductor and Fuse Sizes
Based on National Electrical Code - 100% Duty Cycle 40˚C (104˚F) Ambient
Copper Wire Size - 75˚C in Conduit Super Lag Fuses
Power Input Wires Grounding Conductor Size in Amps
Input Amps
Input
Voltage/ 1 Phase Scott 1 Phase T & B
Scott
T & B 1 Phase T & B Scott T & B 1 Phase Scott
Hertz
Conn.
Term.
Conn.
Term.
Term. Conn. Term.
Conn.
460/60
182
209
#4/0
#4/0
31013 250MCM 31013
31013 250MCM 31013
#4
#4
#3
31007
31007
31007
#3 31007
#3 31007
#3 31007
300
300
300
350
440/50/60 190
380/50/60 230
219
350
254 250MCM 31013 350MCM 31015
400
Thomas & Betts wire terminals (or equal) recommended above are required to comply with applicable U.L. stan-
dards for safety. A #30 hex (Allen) key wrench is required for assembly of terminals to wire.
IDEALARC® AC-1200
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A-2
A-2
INSTALLATION
Connection of AC-1200 (with NL Option)
to LAF-4 or LT-34
Connection of AC-1200 to NA-4
with Switch for ‘Current Control’
S-15667
4-18-75
S-15666
4-18-75
Connection of AC-1200 to
NA-4 with rheostat for current control or LT-6.
S-15602
6-22-84H
IDEALARC® AC-1200
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A-3
A-3
INSTALLATION
b. Output Studs
Connect the work cables to the ‘To Work’ stud on the
front of the Ac-1200. 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 name-
plate above each stud. Recommended cable sizes are
listed below. Both teh ‘To Work’ and ‘Max’ studs have
two terminals to simplify connection of recommended
cables in parallel. Tighten the nuts with a wrench.
Select cables required for combined work and electrode
cable lengths up to 150’ from the following table:
Duty
Cycle
100%
80%*
One 4/0
500
Two 4/0
930
Three 4/0 Four 4/0
1150
1350
560
1040
1290
1510
* Based on 10 minute cycle.
Maximum Allowable Current for Copper Welding Cable
Cables in accessory kit recommended below have termi-
nals as required to comply with applicable U.L. stan-
dards for safety.
150’ combined length electrode and work cables.
c. Auxiliary Power
1000 volt-amperes of 115 volt AC power are available
from #31 and #32 on the AC-1200 terminal strip.
DuTy CyCLE
The AC-1200 is rated for 100% duty cycle at 1200 amps
and 44 volts.
IDEALARC® AC-1200
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b-1
b-1
OPERATION
SAFETY PRECAUTIONS
TO SET FOR MACHINE OR REMOTE
CONTROL
Read and understand this entire section before oper-
ating the machine.
The output can be controlled either from the AC-
1200, the wire feeder or other remote locations.
WARNING
To adjust the current from the wire feeder or other
remote locations, set the toggle switch on the front of
the AC-1200 to ‘Output Control Remote’. To adjust the
output current from the AC-1200, set this switch to
‘Output Control at AC-1200’.
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
T0 SET THE OUTPUT CURRENT
• Insulate yourself from work and
ground.
Start the AC-1200 using the line disconnect switch or
breaker installed with the input wiring. The red pilot
light on the front panel indicates when the welder is
on.
• Always wear dry insulating
gloves.
Adjust the output current from minimum to maximum
within the range set by the output stud connections
using either the ‘Output Control’ rheostat on the AC-
1200 (toggle switch set on ‘Panel Control’) or the wire
feeder or other remote rheostat (toggle switch set on
‘Output Control Re-mote’).
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
TO WELD WITH MANUAL ELECTRODES
Turn the welder off, disconnect the wire feeder leads
and connect a jumper between #2 and #4 on the
AC-1200 terminal strip. This closes the output con-
tactors making the output studs electrically ‘hot’
whenever the machine is on. Adjust the output cur-
rent as described above. Cau-tion: If the wire feeder
electrode cables are left connected to the output
studs, the wire feeder nozzle and electrode will be
electrically ‘hot’.
WELDING SPARKS
can cause fire or
explosion
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
Observe additional Safety Guidelines detailed
throughout this manual.
IDEALARC® AC-1200
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Have qualified personnel do the mainte-
nance 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 information
throughout this operator’s manual.
------------------------------------------------------------
1. Every three months, blow out the machine with
compressed air. More frequent cleaning may be
necessary in areas with chemical or metallic parti-
cles and large quantities of dust.
2. The fan motors have sealed bearings which require
no service.
IDEALARC® AC-1200
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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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® AC-1200
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E-2
E-2
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Welder will not start.
Supply line fuse blown.
Open supply line lead.
Wrong supply line voltage.
Look for possible cause and repair.
Replace fuse.
Repair.
Provide nameplate specified voltage.
Welder will not weld (Contactors
operating properly)
Electrode or ground cable loose or Tighten connection or repair broken
broken. cable.
Welder control circuit dead: No volt- Check Control Transformer primary
age across Control Transformer X1- voltage and if OK, replace trans-
X2.
former.
Welder will not weld (Contactors not Thermostat on coil tripped. Welder Check operation of fans and make
operating).
overheated (Fan motors operating). sure there is no obstruction to air
flow. Do not operate in excess of
Fuse (or thermostat – below code welder rating.
7600) on control panel open; Control
circuit overloaded. (Fan motors oper- SCR’s or diodes on heat sink
ating)
assembly or P.C. board failed –see
Trouble “Welder welds at max. or
Circuit across #2 and #4 not working min. only – no control”. Make repairs
properly. and replace fuse.
Wire feeder control power; No volt- Check connections at terminal strip
age across #31 and #32.
and wire feeder. Relay contacts not
closing. Repair as required.
Check fuse and replace if no good.
Welder welds at min. only no control.
Switch to ‘Panel Control’ for welder
rheostat. Control and “Remote
Control” for other control.
Remote control switch in wrong posi-
tion.
Control rheostat open.
Control circuit open.
Replace rheostat.
1.No voltage across #41 and #44 –
Repair broken leads or reconnect
loose leads.
Open saturable reactor control coil
or connection.
2. Diodes or SCR’s on heat sinks open
or disconnected. Repair or replace.
3. P.C. board plug disconnected – Check
plug connection and plug in properly.
4. P.C. board failed. Determine cause
and replace board.
1
5. Open circuit ar R – Repair or replace.
Repair connection or replace coil.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® AC-1200
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E-3
E-3
TROUbLESHOOTING
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Welder welds at max. only no con-
trol.
Diodes or SCR’s on heat sink Determine cause if possible and
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
replace P.C. board.
Contacts chatter.
Low supply line voltage.
Faulty contactor.
Check with Power Company.
Repair or replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® AC-1200
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F-1
F-1
DIAGRAMS
IDEALARC® AC-1200
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F-2
F-2
DIAGRAMS
AC-1200 SCOTT CONNECTION DIAGRAM
TWO SINGLE MACHINES SCOTT CONNECTED
WARNING
Disconnect input power before servicing.
Do not operate with covers removed.
Do not touch electrically live parts.
3 PHASE SUPPLY LINES
PHASE SEQUENCE A-C-B (N.A.)
Only qualified persons should install, use
or service this equipment.
ELECTRIC SHOCK
CAN KILL
C
B
A
N.D.,N.E.
N.D.,N.E.
N.C.
1
7
8
9
10
4
N.C.
ELEC.
WORK
ELEC.
WORK
1
7
8
9
10
4
100
90
80
N.B.
TEASER TRANSFORMER (TRAIL ARC)
AC-1200 OR AC1500
MAIN TRANSFORMER (LEAD ARC)
AC-1200 OR AC1500
TRAIL
ARC
LEAD ARC
TRAVEL
WORK
NOTE: The two arcs must be properly phased relative to each other, if the electrical connections are not as shown above, poor
welding will result.
A way to verify the proper phase angle and phase sequence is to measure the A.C. voltage at the welding nozzles.
ments. Back the electrode out of each wire drive,then press the NA-4 start
1. Do not weld during the voltage measure
buttons.
CAUTION - Voltage will be high between the two electrode nozzles.
2. Voltage readings between nozzles to work, and nozzle to nozzle should be per table:
PHASE
ANGLE
LEAD ARC
TO WORK
TRAIL ARC
TO WORK
LEAD ARC TO
TRAIL ARC
V
V
Value
Relationship
o
o
o
100
90
80
90 VAC
90 VAC
90 VAC
90 VAC
90 VAC
90 VAC
138 VAC
127 VAC
116 VAC
1.53 x V
1.41 x V
1.29 x V
*
If voltages do not agree, recheck all wiring and the proper sequence of the input supply lines.
o
If using the 90 phase angle connection, the phase sequence cannot be determined by voltage measurement. To determine
the phase sequence use one of the following methods.
*
1. Use a phase meter.
2. Use an oscilloscope.
o
o
3. Temporarily reconnect the machine to either the 100 tap or the 80
tap and check the voltage per note 2.
N.A. To obtain proper phase sequence at the welding arcs, the input line sequence must be A-C-B.
N.B. Interconnect machines as shown for the desired phase angle.
N.C. Frames of all welding power sources must be grounded per National Electric Code.
N.D. Electrode cables of paralleled machines should be connected to the same range tap.
N.E. The weld cables for each arc, and work must be of proper capacity for the current and duty cycle of the immediate and
future applications.
B
M13026
IDEALARC® AC-1200
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F-3
F-3
DIAGRAMS
AC-1200 SCOTT CONNECTION DIAGRAM
IDEALARC® AC-1200
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F-4
F-4
DIAGRAMS
AC-1200 AND PARALLELED DC-1000’s
IDEALARC® AC-1200
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F-5
F-5
DIAGRAMS
AC-1200 AND DC-1500’s
IDEALARC® AC-1200
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F-6
F-6
DIAGRAMS
AC-1200 WIRING DIAGRAM (With NL Option)
NOTE: This diagram is for reference only. It is not 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 illegi-
ble, write to the Service Department for a replacement. Give the welder code number.
IDEALARC® AC-1200
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NOTES
IDEALARC® AC-1200
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NOTES
IDEALARC® AC-1200
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NOTES
IDEALARC® AC-1200
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•
•
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
•
•
Keep flammable materials away.
•
•
Wear eye, ear and body protection.
WARNING
Spanish
•
No toque las partes o los electrodos
bajo carga con la piel o ropa moja-
da.
Mantenga el material combustible
fuera del área de trabajo.
Protéjase los ojos, los oídos y el
cuerpo.
AVISO DE
PRECAUCION
French
•
•
Aislese del trabajo y de la tierra.
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
•
•
Gardez à l’écart de tout matériel
inflammable.
•
•
Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
•
•
German
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Entfernen Sie brennbarres Material!
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
•
Elektroden und dem Erdboden!
Portuguese
•
•
Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
Isole-se da peça e terra.
•
Mantenha inflamáveis bem guarda-
dos.
•
Use proteção para a vista, ouvido e
corpo.
ATENÇÃO
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPOY 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 ELEKTRO-
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
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•
•
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
•
•
Turn power off before servicing.
•
•
Do not operate with panel open or
guards off.
WARNING
Spanish
•
•
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
•
•
Débranchez le courant avant l’entre-
tien.
•
•
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
•
•
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ATTENTION
German
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
•
•
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
•
•
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
•
•
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
•
•
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
•
Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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 WEBꢀSITE: www.lincolnelectric.com
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