IDEALARC AC-1200

OPERATOR’S MANUAL

IM283-CNovember, 2001

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machines having Code Numbers 10291C, 10292C, 10465 and 10466.

Single Phase Variable Voltage Power Source For Automatic AC Welding

®

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming 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 products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vv

INSTALLATION

LocationInstall the welder in a dry location where there is free circu-lation of air in through the louvers in front and outthrough the louvers in the back of the case. A locationwhich minimizes the amount of smoke and dirt drawn intothe machine reduces the chance of dirt accumulation thatcan block air passages and cause overheating.

Input WiringHave a qualified electrician make the complete input con-nection in accordance with the National Electrical Code,all local codes and the connection diagram located insidethe machine.

Be sure the voltage, phase and frequency of the input poweris as specified on the welder nameplate.

For most installations, connect the AC-1200 to single phasepower or to one phase of a three phase line. Unbalancedline conditions can be easily avoided by properly balancingthe AC-1200 with other machinery on the lines.

When installing two or four Scott connected AC-1200machines for AC-AC tandem arc welding, three phase inputpower must be used. The terminals for connections to pro-vide an output phase angle less than or greater than theusual 90% phase angle are included on the input panel.

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 bringthe input power lines through the hole in the back of thecase. See the table below for reccomended sizing of inputleads and overcurrent protection.

The frame of the welder must be grounded, A stud markedwith the symbol located on the welder base below

the panel is provided for this purpose. See the NationalElectrical Code for details on proper grounding methods.

Output Connections

a. Wire Feeder ConnectionTurn the input power to the welder off. Remove thescrew and lift the hinged door on the front of the controlpanel to expose the terminal strips. Connect the leadsof the wire feeder input control cable to the terminalstrips exactly as specified in the appropriate connectiondiagram. The AC-1200 to NA-4 connection diagramsare included in the NA-4 Operating Manual IM-278.Attach the control cables to the panel at the right ofthe terminal strip using the clamps provided.

If connecting the AC-1200 to an older NA-4 with thetoggle 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-15667on page 5. The ‘Remote Control’ cord can be lengthenedto any length by properly splicing a four conductor cordto the standard 25’ cord before connecting to the AC-1200 terminal strip.

If connecting the AC-1200 to an LAF-4 or the AC con-trols of the LT-34 tractor, the AC-1200 must be orderedwith the required ‘–NL’ optional circuit installed. Thiskit includes the K-775 ‘Remote Control’. Connect inaccordance with diagram S-15666 on page 5.

To connect the AC-1200 to any other wire feeder, writeto the factory for instructions giving complete nameplateinformation for the specific equipment.

When connection to the terminal strips are completed,close the door and replace the screw.

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.

Recommended Input Wire, Grounding Conductor and Fuse SizesBased on National Electrical Code - 100% Duty Cycle 40˚C (104˚F) Ambient

Copper Wire Size - 75˚C in Conduit Super Lag FusesInput Amps Power Input Wires Grounding Conductor Size in Amps

InputVoltage/ 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 31013 250MCM 31013 #4 31007 #3 31007 300 350

440/50/60 190 219 #4/0 31013 250MCM 31013 #4 31007 #3 31007 300 350

380/50/60 230 254 250MCM 31013 350MCM 31015 #3 31007 #3 31007 300 400

INSTALLATION

Connection of AC-1200 (with NL Option) S-15666to LAF-4 or LT-34 4-18-75

Connection of AC-1200 to NA-4 S-15667with Switch for ‘Current Control’ 4-18-75

Connection of AC-1200 toNA-4 with rheostat for current controlor LT-6.

S-156026-22-84H

INSTALLATION

b. Output Studs

Connect the work cables to the ‘To Work’ stud on thefront of the Ac-1200. Connect the electrode cables tothe ‘Min,’ ‘Med’ or ‘Max’ studs for the output desired.Actual current ranges for each stud are indicated on thenameplate above each stud. Recommended cable sizesare listed below. Both teh ‘To Work’ and ‘Max’ studshave two terminals to simplify connection of recom-mended cables in parallel. Tighten the nuts with awrench.

Select cables required for combined work and electrodecable lengths up to 150’ from the following table:

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 availablefrom #31 and #32 on the AC-1200 terminal strip.

Duty Cycle

The AC-1200 is rated for 100% duty cycle at 1200 ampsand 44 volts.

DutyCycle One 4/0 Two 4/0 Three 4/0 Four 4/0100% 500 930 1150 135080%* 560 1040 1290 1510

* Based on 10 minute cycle.

To Set For Machine or Remote Control

The output can be controlled either from the AC-1200,the wire feeder or other remote locations.

To adjust the current from the wire feeder or other remotelocations, set the toggle switch on the front of the AC-1200to ‘Output Control Remote’. To adjust the output currentfrom the AC-1200, set this switch to ‘Output Control atAC-1200’.

To Set the Output Current

Start the AC-1200 using the line disconnect switch orbreaker installed with the input wiring. The red pilot light onthe front panel indicates when the welder is on.

Adjust the output current from minimum to maximum with-in the range set by the output stud connections using eitherthe ‘Output Control’ rheostat on the AC-1200 (toggleswitch set on ‘Panel Control’) or the wire feeder or otherremote rheostat (toggle switch set on ‘Output Control Re-mote’).

To Weld With Manual Electrodes

Turn the welder off, disconnect the wire feeder leads andconnect a jumper between #2 and #4 on the AC-1200terminal strip. This closes the output contactors makingthe output studs electrically ‘hot’ whenever the machineis on. Adjust the output current as described above. Cau-tion: If the wire feeder electrode cables are left connectedto the output studs, the wire feeder nozzle and electrodewill be electrically ‘hot’.

OPERATING INSTRUCTIONS

MAINTENANCE

WARNING: Have qualified personnel do the maintenance and troubleshooting work. Turn the power off before working insidethe machine. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guardsonly when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest carewhen working near moving parts.

1. Every three months, blow out the machine with compressed air. More frequent cleaning may be necessary in areas withchemical or metallic particles and large quantities of dust.

2. The fan motors have sealed bearings which require no service.

AC-1200 TROUBLE SHOOTING

TROUBLE CAUSE WHAT TO DO

Welder will not start. Supply line fuse blown. Look for possible cause and repair.Replace fuse.

Open supply line lead. Repair.Wrong supply line voltage. Provide nameplate specified voltage.

Welder will not weld (Contactors Electrode or ground cable loose or broken. Tighten connection or repair broken cable.operating properly)

Welder control circuit dead; No voltage across Check Control Transformer primary voltageControl Transformer X1-X2. and if OK, replace transformer.

Welder will not weld (Contactors Thermostat on coil tripped. Welder overheated Check operation of fans and make surenot operating). (Fan motors operating). there is no obstruction to air flow. Do

not operate in excess of welder rating.

Fuse (or thermostat – below code 7600) on SCR’s or diodes on heat sink assembly or P.C.control panel open; Control circuit overloaded. board failed –see Trouble “Welder welds at(Fan motors operating) max. or min. only – no control”. Make repairs

and replace fuse.

Circuit across #2 and #4 not working properly. Check connections at terminal strip and wirefeeder. Relay contacts not closing. Repair asrequired.

Wire feeder control power; No voltage across Check fuse and replace if no good.#31 and #32.

Welder welds at min. only – Remote control switch in wrong position. Switch to ‘Panel Control’ for welder rheostat.no control. control and “Remote Control” for other control.

Control rheostat open. Replace rheostat.

Control circuit open. 1. No voltage across #41 and #44 – Repair broken leads or reconnect loose leads.

2. Diodes or SCR’s on heat sinks open or dis-connected. Repair or replace.

3. P.C. board plug disconnected – Checkplug connection and plug in properly.

4. P.C. board failed. Determine causeand replace board.

5. Open circuit ar R1 – Repair or replace.

Open saturable reactor control coil or connection. Repair connection or replace coil.

Welder welds at max. only – Diodes or SCR’s on heat sink assemblies Determine cause if possible andno control. shorted. replace shorted device.

Shorted or grounded current controll rheostat. Replace rheostat.

Output By-Pass Capacitors open or disconnected. Replace or reconnect.

Free wheeling diode open or disconnected. Replace or reconnect.

P.C. board components failed. Determine cause if possible and replace P.C.board.

Contacts chatter. Low supply line voltage. Check with Power Company.

Faulty contactor. Repair or replace.

DIAGRAMS

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DIAGRAMS

AC-1200 SCOTT CONNECTION DIAGRAM

DIAGRAMSAC-1200 AND PARALLELED DC-1000’s

DIAGRAMSAC-1200 AND DC-1500’s

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 specificdiagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illeg-ible, write to the Service Department for a replacement. Give the welder code number.

NOTES

NOTES

NOTES

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

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READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •