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Lincoln Electric IDEALARC SVM 122-A manual

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Table of contents for the manual

  • Page 1

    SVM 122-A Oct. 1996 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTIO[...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i LINCOLN ® ELECTRIC IDEALARC DC-400 FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operat[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii LINCOLN ® ELECTRIC IDEALARC DC-400 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conf[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii LINCOLN ® ELECTRIC IDEALARC DC-400 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Cod[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv LINCOLN ® ELECTRIC IDEALARC DC-400 PRÉCAUTIONS DE SÛRETÉ Pour votre pr opr e pr otection lir e et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté[...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v LINCOLN ® ELECTRIC IDEALARC DC-400 Page Safety .................................................................................................................................................i-iv Installation ............................................................................................[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 LINCOLN ® ELECTRIC IDEALARC DC-400 Installation T echnical Specifications Idealarc DC-400 ..................................................................................A-2 Input and Output Sp[...]

  • Page 8

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 LINCOLN ® ELECTRIC IDEALARC DC-400 TECHNICAL SPECIFICA TIONS - IDEALARC DC-400 INPUT - THREE PHASE ONL Y Standard V oltage Input Current @ Rated Output 20[...]

  • Page 9

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only qualified personnel should install, use, or ser- vice this[...]

  • Page 10

    INPUT CONNECTIONS Be sure the voltage, phase, and fr equency of the input power is as specified on the rating plate, lo- cated on the case front contr ol panel. See Figure A.1. Input supply line entry is through a hole in the case rear top panel. A r emovable door covers the input connection box, which contains the input contactor (CR1) and reconne[...]

  • Page 11

    Have a qualified electrician connect the input power leads to the L1, L2, and L3 terminals of the input con- tactor . Follow all national and local electrical codes. Use a three-phase line. Refer to the connection dia- gram located on the inside cover of the access panel cover . Also see Figure A.3. INPUT WIRE AND FUSE SIZE Fuse the input circuit w[...]

  • Page 12

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-6 A-6 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE A.4 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOL TS AC, 50/60 HZ THE LINCOLN ELECTRIC CO., CLEVEL[...]

  • Page 13

    OUTPUT CONNECTIONS The output (welding) cables are connected to the output terminals marked “+” and “-”. See T able A.1 for recom- mended cable sizes for the combined lengths of elec- trode and work cables. They ar e located at the lower right and lower left cor ners of the front panel. Strain relief for the cables is pr ovided by routing t[...]

  • Page 14

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-8 A-8 LINCOLN ® ELECTRIC IDEALARC DC-400 T ABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE AND WORK CABLES Up to 50 ft 50 - 100 ft 100 - 150 ft [...]

  • Page 15

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 LINCOLN ® ELECTRIC IDEALARC DC-400 - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ...............[...]

  • Page 16

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 LINCOLN ® ELECTRIC IDEALARC DC-400 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUC[...]

  • Page 17

    GENERAL DESCRIPTION The Idealarc DC-400 is an SCR contr olled thr ee-phase input, DC output power source for welding and cut- ting. It uses a single range potentiometer control. The welder’ s unique combination of transformer , three- phase semiconverter rectifier , capacitor bank, arc con- trol choke, and solid state contr ol system deliver out-[...]

  • Page 18

    CONTROLS AND SETTINGS All operator controls and settings ar e located on the case front assembly . See Figure B.1 for their loca- tions. FIGURE B.1 – CASE FRONT CONTROLS 1. POWER SOURCE PILOT LIGHT : This light indi- cates that the power source input contactor is ener gized (closed). This also means that the main power transformer and all auxilia[...]

  • Page 19

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-5 B-5 LINCOLN ® ELECTRIC IDEALARC DC-400 7. AUXILIAR Y POWER AND REMOTE CONTROL CONNECTIONS FOR WIRE FEEDER AND OTHER EQUIPMENT (115V AND 42V): The 14- pin amphenol[...]

  • Page 20

    WELDING OPERA TION OPERA TING STEPS LOCAL CONTROL The following procedur es are for using the Idealar c DC-400 in the local control mode of operation. For remote contr ol of the machine, see the REMOTE CONTROL section. Before operating the machine, make sur e you have all materials needed to complete the job. Be sure you ar e familiar with and have[...]

  • Page 21

    NA-3 AUTOMA TIC WIRE FEEDER 1. Set the DC-400 OUTPUT CONTROL switch to “Remote.” NOTE: Later model NA-3 automatic wire feeders are capable of cold starts when the NA-3 Mode switch is in the CV or CC mode posi- tion. Some earlier models are capable of cold starting only in the CC mode position. Cold starting enables you to inch the wire down to [...]

  • Page 22

    4. T urn the Start Board Timer to maximum. 5. Set Start Boar d current and voltage contr ol. a. Set the Start Board curr ent control to 1-1/2 dial numbers below that set on the NA-3 cur- rent contr ol. b. Set the Start Board voltage contr ol equal with the NA-3 voltage control setting. NOTE: These Start Board curr ent and voltage set- tings result [...]

  • Page 23

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-9 B-9 LINCOLN ® ELECTRIC IDEALARC DC-400 LN-7 AND LN-9 SEMIAUTOMA TIC WIRE FEEDERS OR OTHER CONST ANT SPEED WIRE FEEDERS T o use the LN-7, LN-9, or other constant w[...]

  • Page 24

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories..................................................................[...]

  • Page 25

    OPTIONS/ACCESSORIES F ACTOR Y INST ALLED OPTION DIODE OPTION This factory installed option allows use of the cold- start and cold electrode sensing featur es of the NA-3, NA-5, or NA-5R automatic wire feeders. See the topic, Connecting the NA-3 [NA-5] to the Idealarc DC-400 in this section of the manual. FIELD INST ALLED OPTIONS The following optio[...]

  • Page 26

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACCESSORIES C-3 C-3 LINCOLN ® ELECTRIC IDEALARC DC-400 Multiprocess Switch Operation The operation of the Multiprocess Switch is as follows: A semiautomatic or automatic wire fe[...]

  • Page 27

    REMOTE OUTPUT CONTROL (K857 WITH K864 ADAPTER PLUG OR K775) The K857 has a 6-pin MS-style connector . The K857 requir es a K864 adapter cable which connects to the 14-pin connector on the machine. An optional “remote output contr ol” is available. This is the same remote contr ol that is used on the Lincoln R3R and DC-600 power sources (K775). [...]

  • Page 28

    ACCESSORIES C-5 C-5 LINCOLN ® ELECTRIC IDEALARC DC-400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Amptrol Only: The Amptrol pr ovides remote curr ent control thr ough the full range of the power source. Amptrol Plus Remo[...]

  • Page 29

    ACCESSORIES C-6 C-6 LINCOLN ® ELECTRIC IDEALARC DC-400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAP ACITOR DISCHARGE CIRCUIT (K828-1) Mounts inside the DC-400. Recommended when: • DC-400 is used in conjunction with a[...]

  • Page 30

    FIGURE C.4 – NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC DC-400 5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece. a. Make a bolted connection using A WG #14 or lar ger insulated wir e. T ape the bolted connec- tion with insulating tape. b. An S-16586- X remote voltage sensing work lead is available fo[...]

  • Page 31

    5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece. a. Make a bolted connection using A WG #14 or lar ger insulated wir e. T ape the bolted connec- tion with insulating tape. b. An S-16586- X remote voltage sensing work lead is available for this purpose. c. Keep the #21 lead electrically separate from th[...]

  • Page 32

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACCESSORIES C-9 C-9 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE C.7 IDEALARC DC-400/LN-7 WITH K584 INPUT CABLE ASSEMBL Y CONNECTION DIAGRAM SEMIAUTOMA TIC WIRE FEEDERS CONNECTING [...]

  • Page 33

    CONNECTING THE LN-7 TO THE IDEALARC DC-400 (TERMINAL STRIP) 1. Disconnect main AC input power to the Idealarc DC-400. 2. Set the Idealarc DC-400 POWER toggle switch to the OFF (0) position. 3. Connect the wire feeder control cable leads to the Idealarc DC-400 terminal strip as shown in Figur e C.8. 4. Connect the wire feeder control cable gr ound l[...]

  • Page 34

    CONNECTING THE LN-8 OR LN-9 TO THE IDEALARC DC-400 (TERMINAL STRIP) 1. Disconnect main AC input power to the Idealarc DC-400. 2. Set the Idealarc DC-400 POWER toggle switch to the OFF (0) position. 3. Connect the wire feeder control cable leads to the Idealarc DC-400 terminal strip as shown in Figur e C.9. 4. Connect the wire feeder control cable g[...]

  • Page 35

    CONNECTING THE LN-8 OR LN-9 TO THE IDEALARC DC-400 (14-PIN AMPHENOL) 1. Disconnect main AC input power to the Idealarc DC-400. 2. Set the POWER toggle switch to the OFF (0) posi- tion. 3. Connect the electrode cable from the LN-8 or LN-9 to the “+” terminal of the welder . Connect the work cable to the “-” terminal of the welder . Reverse t[...]

  • Page 36

    CONNECTING THE LN-742 TO THE IDEALARC DC-400 (14-PIN AMPHENOL) 1. Disconnect main AC input power to the Idealarc DC-400. 2. Set the POWER toggle switch to the OFF (0) posi- tion. 3. Connect the electrode cable from the LN-742 to the “+” terminal of the welder . Connect the work cable to the “-” terminal of the welder . Reverse this hookup f[...]

  • Page 37

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 LINCOLN ® ELECTRIC IDEALARC DC-400 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions...........[...]

  • Page 38

    SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this mainte- nance. • T urn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preventative maintenance at least once every [...]

  • Page 39

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-3 D-3 LINCOLN ® ELECTRIC IDEALARC DC-400 5 7 8 6 9 3 4 2 1  12 10  11 FIGURE D.1 – GENERAL COMPONENT LOCA TIONS 1. CONTROL P ANEL 2. SCR/DIODE BRIDGE 3. MA[...]

  • Page 40

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 LINCOLN ® ELECTRIC IDEALARC DC-400 Theory of Operation ............................................................................................................. Section E General Description ..............................................[...]

  • Page 41

    GENERAL DESCRIPTION The DC-400 is a multiprocess welder power sour ce capable of both constant voltage and constant current operation. Its power system is SCR controlled with solid state electronic cir cuitry . Minimum to maximum output is obtained with a single potentiometer control. INPUT LINE VOL T AGE, CONT ACTOR AND MAIN TRANSFORMER The desire[...]

  • Page 42

    OUTPUT MODE AND CONTROL, RECTIFICA TION AND FEEDBACK The three-phase AC output fr om the main transformer secondary is rectified and contr olled through the SCR/ diode bridge. Output current and voltage is sensed at the shunt and output terminals. This feedback infor- mation is processed in the contr ol board. The contr ol board compar es the comma[...]

  • Page 43

    PROTECTIVE DEVICES AND CIRCUITS T wo thermostats protect the DC-400 fr om excessive operating temperatures and overload conditions. Excessive operating temperatures may be caused by insufficient cooling air or by operating the machine beyond the duty cycle and output rating. The primary thermostat, located on the nose of the bottom center primary c[...]

  • Page 44

    SCR OPERA TION A silicon controlled r ectifier (SCR) is a three terminal device used to control rather lar ge curr ents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is current flow fr om anode to cathode. In the ON state, the SCR acts like a closed switch. When the SCR is turned[...]

  • Page 45

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 LINCOLN ® ELECTRIC IDEALARC DC-400 T roubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ..........................................[...]

  • Page 46

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may [...]

  • Page 47

    ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T ur n the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failur es. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting [...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for[...]

  • Page 49

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for[...]

  • Page 50

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for[...]

  • Page 52

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for[...]

  • Page 53

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for[...]

  • Page 54

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If f[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If f[...]

  • Page 56

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 F-12 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If f[...]

  • Page 57

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS (SY[...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SY[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 LINCOLN ® ELECTRIC IDEALARC DC-400 INPUT CONT ACTOR TEST W ARNING Service and repair should be performed by only Lincoln Electric factory[...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 LINCOLN ® ELECTRIC IDEALARC DC-400 INPUT CONT ACTOR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the mach[...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 LINCOLN ® ELECTRIC IDEALARC DC-400 TEST FOR CONT ACT CONTINUITY 1. Disconnect the main input supply power to the machine. 2. Remove the t[...]

  • Page 62

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING CONTROL TRANSFORMER (T2) VOL T AGE TEST Service and repair should be performed by only Lincol[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 LINCOLN ® ELECTRIC IDEALARC DC-400 CONTROL TRANSFORMER (T2) VOL T AGE TEST (continued) FIGURE F .3 – CONTROL TRANSFORMER AND LEAD LOCA [...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-20 F-20 LINCOLN ® ELECTRIC IDEALARC DC-400 CONTROL TRANSFORMER (T2) VOL T AGE TEST (continued) 6. T est for 115V AC between leads X1 and #231. NO[...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING MAIN TRANSFORMER (T1) VOL T AGE TEST Service and repair should be performed by only Lincoln E[...]

  • Page 66

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 LINCOLN ® ELECTRIC IDEALARC DC-400 MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) FIGURE F .5 – INPUT CONT ACTOR, RECONNECT P ANEL, A[...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 LINCOLN ® ELECTRIC IDEALARC DC-400 8. Read the meter . a. If proper voltage is pr esent for all three phases, proper main input supply vo[...]

  • Page 68

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 LINCOLN ® ELECTRIC IDEALARC DC-400 12. T est for 115V AC between leads #31 and #32 on the terminal strip. Also test for 42V AC between pi[...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 LINCOLN ® ELECTRIC IDEALARC DC-400 Plug P1 PHASE ANGLE WINDING VOL T AGES From Lead # T o Lead # Expected V AC 201 204 21 V AC 202 204 21[...]

  • Page 70

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-26 F-26 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST Service and repair should be performed by only Linco[...]

  • Page 71

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 LINCOLN ® ELECTRIC IDEALARC DC-400 ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F .9 – CONTROL BOARD AND SNUBBER BOARD P[...]

  • Page 72

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 LINCOLN ® ELECTRIC IDEALARC DC-400 ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) 8. Remove the red insulating paint from the heat [...]

  • Page 73

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory train[...]

  • Page 74

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-30 F-30 LINCOLN ® ELECTRIC IDEALARC DC-400 ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2[...]

  • Page 75

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-31 F-31 LINCOLN ® ELECTRIC IDEALARC DC-400 ACTIVE SCR TEST (continued) 8. Remove the red insulating paint from the heat sink test points. See Fig[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 LINCOLN ® ELECTRIC IDEALARC DC-400 ACTIVE SCR TEST (continued) 9. Construct the circuit shown in Figure F .16. One 6-volt lantern battery[...]

  • Page 77

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note[...]

  • Page 78

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note[...]

  • Page 79

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note[...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note[...]

  • Page 81

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note[...]

  • Page 82

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no [...]

  • Page 83

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 LINCOLN ® ELECTRIC IDEALARC DC-400 This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “gap[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT Service and repair should be performed by only Li[...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-41 F-41 LINCOLN ® ELECTRIC IDEALARC DC-400 INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F .17 – INPUT CONT ACTOR CLEANING AND[...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-42 F-42 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT Service and repair should be performed by only [...]

  • Page 87

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-43 F-43 LINCOLN ® ELECTRIC IDEALARC DC-400 F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT (continued) FIGURE F .18 – F AN MOTOR MOUNTING DET AIL[...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING SCR/DIODE RECTIFIER ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-45 F-45 LINCOLN ® ELECTRIC IDEALARC DC-400 SCR/DIODE RECTIFICER ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .19 – SCR/DIODE ASSEMBL[...]

  • Page 90

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-46 F-46 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING SCR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric [...]

  • Page 91

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F .20 – SCR DET AILS SCR REMOV AL AND REPLACEMENT (continued) SPECIAL INSTRUCTIONS NOTE: Befo[...]

  • Page 92

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 F-48 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F .21 – 1/2” WIDE LEAF SPRING FIGURE F .22 – CLAMP ASSEMBL Y SCR REMOV AL AND REPLACEMENT[...]

  • Page 93

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 LINCOLN ® ELECTRIC IDEALARC DC-400 SCR REMOV AL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedur [...]

  • Page 94

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-50 F-50 LINCOLN ® ELECTRIC IDEALARC DC-400 SCR REMOV AL AND REPLACEMENT (continued) PROCEDURE FOR THE 5/8 INCH WIDE SPRING 1. Place a piece of sl[...]

  • Page 95

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 LINCOLN ® ELECTRIC IDEALARC DC-400 CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedur e can only be used with 1/4-28 cap screws[...]

  • Page 96

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEA T SINKS Service and repair should be performed b[...]

  • Page 97

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 LINCOLN ® ELECTRIC IDEALARC DC-400 PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver , remov[...]

  • Page 98

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-54 F-54 LINCOLN ® ELECTRIC IDEALARC DC-400 W ARNING MAIN TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Linc[...]

  • Page 99

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-55 F-55 LINCOLN ® ELECTRIC IDEALARC DC-400 REMOV AL OF LIFT BAIL 1. Remove the main input supply power to the machine. 2. With the 5/16” nut dr[...]

  • Page 100

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-56 F-56 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F .26 – CHOKE REMOV AL MAIN TRANSFORMER REMOV AL & REPLACEMENT (continued) REMOV AL OF CH[...]

  • Page 101

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-57 F-57 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F .27 – EPOXY MIX APPLICA TION AREAS MAIN TRANSFORMER REMOV AL & REPLACEMENT (continued) [...]

  • Page 102

    3. Install the bottom primary coils, one on each of the three legs of the bottom ir on assembly . The coils must be in correct position (left, center , right). Place the coils so that the leads come out at the back of the machine. See Figure F .28 for proper positioning. 4. Place insulation (Lincoln Electric part number S20728) on top of each of th[...]

  • Page 103

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-59 F-59 LINCOLN ® ELECTRIC IDEALARC DC-400 MAIN TRANSFORMER REMOV AL & REPLACEMENT (continued) 10. Mount the primary thermostat to the lead e[...]

  • Page 104

    REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE NOTE: The following procedur e assumes you have completely reassembled the transformer coils as described in the procedur e above. The lower iron has r emained in place in the machine. See Figures F .25 and F .26. 1. Resolder the choke control coil leads to the ar c control switch. 2. Attach the bo[...]

  • Page 105

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-61 F-61 LINCOLN ® ELECTRIC IDEALARC DC-400 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any r eason that requir es[...]

  • Page 106

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-62 F-62 LINCOLN ® ELECTRIC IDEALARC DC-400 RETEST AFTER REP AIR (continued) MAXIMUM ACCEPT ABLE OUTPUT VOL T AGE- A T MINIMUM OUPUT SETTINGS Mode[...]

  • Page 107

    T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - IDEALARC DC400 Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram (Codes 9847, 9848) . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Wiring Diagram (Code 9850) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 108

    NOTES IDEALARC DC400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 109

    G-2 ELECTRICAL DIAGRAMS IDEALARC DC400 Wiring Diagram (Codes 9847, 9848) L9106 12-9-94F H2 H3 H4 ELECTRICAL SYMBOLS PER 1 1 2 4 3 1 6 PIN 4 PIN 8 PIN 12 PIN J6 J3 J2 CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) NOTES 225 4 2 31 32 75 76 77 225 TS1 TS2 C6 .0047MFD/1400V 10K /2W ARC FORCE CONTROL S4C ACTUATED IN CC ONLY S4D ACTU[...]

  • Page 110

    G-3 ELECTRICAL DIAGRAMS IDEALARC DC400 Wiring Diagram (Code 9850) L9107 13 14 15 16 17 18 H2 H3 H4 ELECTRICAL SYMBOLS PER E1537 CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) NOTES N.A. CIRCUITRY PRESENT ON CAPACITOR DISCHARGE ONLY. TO PROVIDE AT LEAST 600 V INSULATION. CONTROL BOARD P6 206 205 VM AM 206 231 + + - - 232 PILOT LI[...]

  • Page 111

    G-4 ELECTRICAL DIAGRAMS IDEALARC DC400 Control PC Board (G2588) Layout SHT. NO. G IDEALARC DC-400 2588-1 CONTROL P.C. BOARD ASSEMBLY IDENTIFICATION PART No. REQ'D. ITEM C23 A E M G K B F C R315 R38 R37 R65 R82 R83 R102 R36 R35 R101 R64 R104 R63 R55 R66 R57 R59 R58 R139 R56 R127 R145 R144 R143 R94 R120 R126 R40 R45 R41 R42 R74 R75 R73 R119 R129[...]

  • Page 112

    G-5 ELECTRICAL DIAGRAMS IDEALARC DC400 Starting PC Board (M14520) Layout IDENTIFICATION PART NO. REQ'D ITEM C1 D1, D2 D3, D4, D5, D6, D7 R1, R2 R3, R5 R4 R6 SCR2 SCR1 TP1 SBS1 TP2 1 1 1 1 1 1 2 5 2 2 1 1 S13490-72 S15161-19 S19400-1001 S19400-1501 T12199-1 T12199-2 S20630-1 T13640-12 T13640-18 T14648-9 T14649-4 T14805-1 50/50 4A, 400V SCR 1.5K[...]

  • Page 113

    G-6 ELECTRICAL DIAGRAMS IDEALARC DC400 Snubber PC Board (M15370) Layout ITEM PART NO. REQD DESCRIPTION C1,C2,C3 3 2 3 3 2 1 R1,R2,R3 C4,C5 TP1,TP2,TP3 TP4,TP5 TP6 T11577-68 T12733-10 T13640-12 T13640-16 T13640-18 T11577-46 .68/400 .05/600 10 2W 38J 160J 80J G-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC [...]

  • Page 114

    G-7 ELECTRICAL DIAGRAMS IDEALARC DC400 Control PC Board (G2588) Schematic 1400V .0047 C51 RF +15V -10V +15V +15V 10K R85 1.50K R301 50V 4 C33 1N4004 D55 475K R128 1N4004 D57 1.00M R80 1N4004 D56 100K R59 -7.5V X2 8 10 9 475K R99 10K R123 +15V 1N4004 D59 VOLTAGE BUFFER RECTIFIER BRIDGE +15V 1N4004 D41 1.8 20V C32 1N4004 D60 100 R126 1N4004 D42 1N400[...]

  • Page 115

    G-8 ELECTRICAL DIAGRAMS IDEALARC DC400 Starting PC Board (M14520) Schematic 55A 400V SCR2 1 3 2 38J 130V TP1 D5 D4 D3 1N4007 D2 J6 4 4A 400V SCR1 1.00K R5 1.00K R3 1.50K R4 5W 2500 R1 SBS1 G J6 2 10W 100 R6 2 1 160J 320V TP2 50V 50 C1 J6 6 J6 1 D7 D6 1N4007 D1 5W 2500 R2 J6 3 19686 S START S = COMMON CONNECTION IDEALARC DC400 ELECTRICAL SYMBOLS PER[...]

  • Page 116

    G-9 ELECTRICAL DIAGRAMS IDEALARC DC400 Snubber PC Board (M15370) Schematic 38J 130V TP3 S 160J 320V TP5 19687 225 19687 160J 320V TP4 600V .05 C4 600V .05 C5 J5 8 J5 3 J5 2 J5 4 J5 7 J5 5 SNUBBER SCHEMATIC J5 1 2W 10 R3 J5 6 80J 150V TP6 2W 10 R2 2W 10 R1 38J 130V TP2 ELECTRICAL SYMBOLS PER E1537 GENERAL INFORMATION CAPACITORS = MFD/VOLTS RESISTORS[...]