Lincoln Electric Welding System AC 1500 User Manual

RETURN TO MAIN MENU  
IM914  
October, 2010  
Single Phase Variable Voltage Power Source For Automatic AC Welding  
IDEALARC AC-1500  
For use with machines having Code Numbers 11418  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation  
... and thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED 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.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
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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 WEbꢀSITE 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  
Technical Specifications.......................................................................................................A-1  
Location ...............................................................................................................................A-2  
Input Wiring ..........................................................................................................................A-2  
Output Connections..............................................................................................................A-2  
Wire Feeder Connections .............................................................................................A-2  
Connection of AC-1500 to NA-4 with Switch for ‘Current Control’ .......................................A-3  
Connection of AC-1500 to NA-4 with rheostat for current control or LT-6............................A-3  
Output Studs ................................................................................................................A-4  
Auxiliary Power ............................................................................................................A-4  
Duty Cycle............................................................................................................................A-4  
________________________________________________________________________________  
Operation.........................................................................................................................Section b  
Safety Precautions and Graphic Symbols..............................................................B-1  
Product Design Application ..................................................................................................B-2  
Setting the Machine or Remote Control ...............................................................................B-2  
Setting the Output Current ...................................................................................................B-2  
Weld with Manual Electrodes...............................................................................................B-2  
Product Description .......................................................................................................B-2,B-3  
________________________________________________________________________________  
Accessories.....................................................................................................Section C  
Optional Kit............................................................................................................C-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 and Dimension Print..........................................................Section F  
________________________________________________________________________  
Parts Pages.................................................................................P-556, P-28, P-84 Series  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - IDEALARC™ AC-1500  
INPUT - SINGLE PHASE ONLY  
Input Current at 100% Rated Output  
Scott Connection  
Standard Voltage  
Single Phase Output  
380/50/60  
310  
358  
Idle Current With P.F. Capacitors  
70  
Power Factor @ Rated load With P.F. Capacitors  
71%  
Rated Input Current With P.F. Capacitors  
310 Amp Single Phase  
358 Amp Scott-connection  
RECOMMENDED INPUT WIRE GROUNDING CONDUCTOR AND FUSE SIzES*  
Input Input Amps  
Volts/  
Hz.  
Copper Wire Size – 75˚C in Conduit  
Super Lag Fuses  
Size in Amps  
Power Input Wires Grounding Conductor  
1
Scott  
1
T&b  
Scott  
T&b  
Term. Phase Term. Conn.  
#3 31007 #2  
(25mm )  
1
T&b  
Scott  
T&b  
1
Scott  
Phase  
Conn.  
Phase  
Term.  
Conn.  
Term.  
Phase  
Conn.  
380/50  
310  
358  
500MCM 31013 600MCM 31015  
(250mm )  
31007  
400  
500  
2
2
2
2
(300mm )  
(35mm )  
RATED OUTPUT  
Duty Cycle  
AMPS AC  
100%  
1500 @ 44 Volts  
Current Range  
240/1500  
OUTPUT (SMAW)  
“MIN” Terminal  
“MED” Terminal  
“MAX” Terminal  
44  
Volts  
Amps  
30-44  
38-44  
240-600  
460-1060  
890-1500  
Maximum Open  
Circuit Voltage  
86  
PHYSICAL DIMENSIONS  
Weight  
Height  
Width  
Depth  
1649lbs.  
748(kg.)  
53.50 in.  
( 1358.9mm.)  
22.30 in.  
(566.4mm.)  
38.00in.  
(965.2mm.)  
Thomas & Betts wire terminals (or equal) recommended above are required to comply with applicable U.L. standards for safety. A #30 hex  
(Allen) key wrench is required for assembly of terminals to wire. Based on National Electrical Code - 100% Duty Cycle 40˚C (104˚F)  
Ambient.  
*
RATING: IP21 ENCLOSURE, INSULATION 155°(F)  
IDEALARC™ AC-1500  
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A-2  
A-2  
INSTALLATION  
LOCAtION  
The AC-1500 does not have an input contactor. Therefore,  
include an external starter or disconnect switch when plan-  
ning the input circuit.  
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.  
Remove the right side panel of the AC-1500 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 overcurrent protection.  
INput WIRING  
The frame of the welder must be grounded, A stud marked  
with the symbol  
located on the welder base below  
the panel 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  
• Do not touch electrically hot  
parts.  
ELECTRIC  
SHOCK  
can kill.  
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-1500 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 provided.  
Failure to fuse the input lines per the specifications  
in this manual will constitute customer abuse and  
void the warranty.  
---------------------------------------------------------------  
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.  
If connecting the AC-1500 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 accordance with the connection diagram S-15667  
on page 5. The ‘Remote Control’ cord can be lengthened  
to any length by properly splicing a four conductor cord  
to the standard 25’ cord before connecting to the AC-  
1500 terminal strip.  
Be sure the voltage, phase and frequency of the input power  
is as specified on the welder nameplate.  
For most installations, connect the AC-1500 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-1500 with other machinery on the lines.  
To connect the AC-1500 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-1500  
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 90º phase angle are included on the input panel.  
When connection to the terminal strips are completed,  
close the door and replace the screw.  
IDEALARC™ AC-1500  
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A-3  
A-3  
INSTALLATION  
S-15667  
Connection of AC-1500 to NA-4  
with switch for ‘Current Control’  
6-18-76A  
Connection of AC-1500 to NA-4  
with rheostat for current control.  
S-15602  
6-22-84H  
IDEALARC™ AC-1500  
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A-4  
A-4  
INSTALLATION  
Output stuDs  
Connect the work cables to the ‘To Work’ stud on the  
front of the AC-1500. Connect the electrode cables to  
the ‘Min,’ ‘Med’ or ‘Max’ studs for the output desired.  
Actual current ranges for each stud are indicated on the  
nameplate above each stud. Recommended cable sizes  
are listed below. Both the ‘To Work’ and ‘Max’ studs  
have two terminals to simplify connection of recommend-  
ed cables in parallel. Tighten the nuts with a wrench.  
Select cables required for combined work and electrode  
cable lengths up to 150’ from the following table:  
Maximum Allowable Current for Copper Welding Cable  
Duty  
Cycle  
100%  
One 4/0  
650  
two 4/0  
1000  
Four 4/0  
1200  
Five 4/0  
1500  
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.  
AuxILIARy pOWER  
1000 volt-amperes of 115 volt AC power are available  
from #31 and #32 on the AC-1500 terminal strip.  
Duty CyCle  
The AC-1500 is rated for 100% duty cycle at 1500 amps  
and 44 volts.  
IDEALARC™ AC-1500  
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b-1  
b-1  
OPERATION  
GRAPHIC SYMbOLS THAT APPEAR  
ON THIS MACHINE OR IN THIS  
MANUAL  
SAFETY PRECAUTIONS  
Read and understand this entire section before oper-  
ating the machine.  
Output Control  
1
3
Single Phase  
WARNING  
Remote Control Setting  
Local Control Settin  
Three Phase  
ELECTRIC SHOCK  
can kill.  
Uo Rated No-Load Voltage  
• Do not touch electrically live parts  
or electrode with skin or wet  
clothing.  
Input Power Type U1 Rated Input Voltage  
• Insulate yourself from work and  
ground.  
Submerged Arc Welding U2 Rated Welding Voltage  
• Always wear dry insulating  
gloves.  
Transformer Type  
Fuse  
X
Rated Duty Cycle  
FUMES AND GASES  
can be dangerous.  
I1 Rated Input Current  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
High Voltage Indicator  
High Temperature Indicator  
Rated Frequency  
I2  
Rated Welding Current  
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-1500  
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b-2  
b-2  
OPERATION  
PRODUCT DESIGN APPLICATION  
PRODUCT DESCRIPTION  
The IDEALARC™ AC-1500 is an upgraded design  
with the following additional features:  
Specifications are 50 Hz, 380 volt unit with a Power  
factor correction as a standard feature.  
• Higher output current and duty cycle capabilities.  
Output terminals, control power terminal strip, and  
controls are recessed or hinged covered to affect a  
"dead front". Due to the excessive amount of stray  
magnetic flux developed by the saturable reactor, the  
center sections of the welder side panels are made of  
a high impact, self-extinguishing, chemical resistant  
plastic material. USE OF METALLIC PANELS IN  
THEIR PLACE WILL RESULT IN EXCESSIVE HEAT-  
ING OF THE PANELS AS WELL AS THE SHEET  
METAL SCREWS USED IN THE ASSEMBLY OF  
OTHER CASE PARTS.  
It is a single phase transformer-saturable reactor type  
power supply intended for use primarily in automatic  
or semiautomatic variable voltage AC welding applica-  
tions. It can be used to supply one automatic welder  
head or two units may be used in Scott connection to  
provide two phase power to two welder heads in tan-  
dem. The welder can be used as is with NA-4 heads  
or modified with available options to supply the earlier  
NA-4 or LAF-4, and LT-34 welding heads.  
Output welding current is available in three overlap-  
ping ranges by means of externally connecting the  
electrode cables to the Min., Med., or Max. tap elec-  
trode studs(See Technical Specifications in the  
Installation Section).  
WARNING  
Pipe Thawing with an arc welder can cause fire,  
explosion, damage to electric wiring or to the arc  
welder if done improperly. The use of an arc  
welder for pipe thawing is not approved by the  
CSA, nor is it recommended or supported by  
Lincoln Electric.  
Input Line Voltage Compensation maintains a rea-  
sonably constant output within a range of ±10%  
change in supply line voltage.  
------------------------------------------------------------------------  
SETTING THE MACHINE OUTPUT OR  
REMOTE CONTROL  
Cooling of the welder is accomplished by drawing air  
in through the louvered case front panel, through the  
reactor and transformer assemblies, and out the lou-  
vered case rear panel. The two totally enclosed fan  
motors used have sealed ball bearings and require no  
lubrication maintenance.  
The output can be controlled either from the AC-1500,  
the wire feeder or other remote locations.  
To adjust the current from the wire feeder or other  
remote locations, set the toggle switch on the front of  
the AC-1500 to ‘Output Control Remote’. To adjust the  
output current from the AC-1500, set this switch to  
‘Output Control at AC-1500’.  
Handling of the welder and any attached devices  
should be done with a fork-lift or pallet-jack capable of  
loads exceeding the combined weight of the system.  
Overload/Thermal Protection is provided in three  
areas: the 115 volt AC auxiliary power is fused for 8  
amps; the saturable reactor control power circuit is  
protected by a 40 amp fuse; the welder output power  
circuit is protected by the familiar current transformer-  
Klixon thermostat breaker. In the event of a control cir-  
cuit or welder overload, the output contactors will  
open and the fan motors will continue to operate. If  
the overload is detected by the thermostatic breaker,  
the temperature light located on the front panel will  
illuminate until a safe operating temperature is  
reached.  
SETTING THE OUTPUT CURRENT  
Start the AC-1500 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.  
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-  
1500 (toggle switch set to ‘Local Control’) or the wire  
feeder or other remote rheostat (toggle switch set to  
‘Remote Control’).  
Output Contactor control is provided by two S78  
contactors connected in parallel. Input line contactors  
are not provided. The customer is expected to provide  
line starting and circuit breaking equipment.  
IDEALARC™ AC-1500  
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b-3  
b-3  
OPERATION  
Hand Welding with stick electrode or semiautomatic  
arc welding is not recommended since OCV exceeds  
the 80 volts RMS limit allowed by standards for such  
use. (Unit is within 100 volt allowable limit for auto-  
matic or mechanically guided welding.)  
Pilot light indicates when the supply lines to the  
welder are electrically "hot". This means that the  
welder input power and control transformers are ener-  
gized when the pilot light is on.  
Input Circuit Plan: The AC-1500 is not intended for  
the connection of flexible supply cables. Instead, the  
following table may be used for planning of supply  
cables routed in conduit (See Technical Specifications  
in the Installation Section).  
Scott Connection information for tandem arc applica-  
tion and paralleling of Scott connected units for tan-  
dem arc application is available. (See list of wiring  
diagrams.)  
Isolated Auxiliary Power of 1000 volt.-amp., 115  
volts AC is available at terminals #31 and #32 on the  
terminal strip under the hinged cover on the case front  
panel of the welder. The circuit is fused with an 8  
amp slow blow fuse located in the nameplated section  
of the welder front panel.  
Starting Device: The pushbuttons located on the  
front panel are not connected to any kind of starting or  
stopping device. They are not necessary to operating  
the welder. If pushbutton operation is desired, an input  
contactor must be professionally installed and wired to  
the pushbutton assembly. The AC-1500 does not  
have an input contactor. Therefore, include an exter-  
nal starter or disconnect switch when planning the  
input circuit. Once the input circuit is energized, the  
pilot light on the front panel should glow. High voltage  
is present inside the machine. Do not open the  
machine enclosure.  
Input Panel is made accessible by removal of the  
right side panel assembly (as viewed from front).  
Supply lines and grounding lead should be brought  
into the welder through the hole provided in the case  
rear panel. Connections to the input panel should be  
made as instructed on the wiring diagram attached to  
the welder. The grounding lead connection is to be  
made to the grounding stud provided on the welder  
base directly below the input panel.  
Location of installation should be such that the  
welder cooling air exhaust area (the case rear panel)  
is free of any obstructions that could impede air flow.  
A dry location should be chosen. The welder should  
not be placed on a surface that is inclined enough that  
it creates a risk of the machine falling over  
Control Circuit connections for wire feeder equip-  
ment are to be made per instructions on the wire feed-  
er diagram to the terminal strip provided under the  
hinged cover on the case front panel of the welding  
power supply. A strain relief strap to the right of the  
terminal strip is provided for attaching either the feed-  
er control and remote current control cables or both  
simultaneously. A grounding screw located just to the  
right of the terminal strip is provided for connecting the  
wire feeder grounding lead. All connections must be  
made with the welding power supply turned off.  
IDEALARC™ AC-1500  
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C-1  
C-1  
ACCESSORIES  
OPTIONAL KIT: Remote control K775.  
IDEALARC™ AC-1500  
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D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
• Have qualified personnel do the  
maintenance and troubleshooting  
work.  
• Turn the input power OFF at the disconnect  
switch or fuse box before working on this  
equipment.  
• Do not touch electrically live parts or electrode  
with skin or wet clothing.  
• Insulate yourself from work and ground.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
See additional warning information  
throughout this operator’s manual.  
------------------------------------------------------------  
Periodic blowing out of dust and dirt accumulated  
within the welder using an air stream is recommend-  
ed. This may be particularly desirable in atmospheres  
containing chemical or metallic particles which could  
accumulate within the welder and cause some difficul-  
ty.  
The totally enclosed fan motors have sealed ball bear-  
ings which require no lubrication maintenance.  
IDEALARC™ AC-1500  
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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-1500  
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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-1500  
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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-1500  
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F-1  
F-1  
DIAGRAMS  
FUSE  
2 T X 1  
2 T X 2  
2 T H 1  
2 T H 2  
IDEALARC™ AC-1500  
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F-2  
F-2  
DIAGRAMS  
AC-1500 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.  
Only qualified persons should install, use  
or service this equipment.  
3 PHASE SUPPLY LINES  
PHASE SEQUENCE A-C-B (N.A.)  
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  
V
TRAIL ARC  
TO WORK  
V
LEAD ARC TO  
TRAIL ARC  
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-1500  
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F-3  
F-3  
DIAGRAMS  
AC-1500 sCOtt CONNECtION DIAGRAM  
IDEALARC™ AC-1500  
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F-4  
F-4  
DIAGRAMS  
AC-1500 AND pARALLELED DC-1000’s  
M14364  
4-8-83E  
IDEALARC™ AC-1500  
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F-5  
F-5  
DIAGRAMS  
AC-1500 AND DC-1500’s  
IDEALARC™ AC-1500  
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F-6  
F-6  
DIMENSION PRINT  
IDEALARC™ AC-1500  
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NOTES  
IDEALARC™ AC-1500  
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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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