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Lincoln Electric 122-A User's Manual

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3. 060 1N4004 POWER UP OUTPUT CLAMP Return to Section TOC Return to Master TOC Lor 022 259 usi V j o a 4 TUS 475K x2 5 CAPACITOR 040 EE SN 9 VOLTAGE 184004 Vie PROTECTION N m Le a es La 075 4 CURRENT SWITCH 013 016 1 4004 1N4004 267 L C R88 332K 33 300v 124 gt D64 x gt LA GC CURRENT A 8 047 gt 7 D4 1N4004 Return to Master TOC Return to Section TOC LIMITER Cu 1N4004 LIMITER C56 CONTROL WIRE CURRENT AMP C V CONTROL
4. cO ASL 10 007615 Z8H ii Mv l 492 0792 00 615 t 9 H GzH vezu s lt ESIH ET B GOTH lt TGH 8 9 O X001 5 91 OEY ETY 21 ITY o Mv l Gv 0827 007615 9 85 98H OLY D2 tc Mv l 21972 1 92 00 615 4 9v1H ZY bY 9E n coc M2 l 2 yl HIS 2209 2 20 211 ENO 210 TNO 2 10 2 89 702211 1 90 5 O 65 134 13 2 5 0 211 E m 5 oc LLI 70 21 L 5 80 90 D 0 18 8 44 80191051 0140 01 00081 5 1120 RE 5 5 2 8 jo 5 309 3H 8 2815 1 r H3QU3H ZI 8 2815 1 093 01 8 2815 1 Le 5 mj S 30010 83 37 S6SEGNI 1 20 211 1 viza z a E 3 828ESNI 2 20 211 1 2120 LJ aft GE VNI 0 20 211 1 2170 8 vEGNI 202211 1 0120 o gt SrGEGNI 06 20 211 1 670 sp m 15 85 20211 1 820 e 81 ZGNI 61 20211 1 170 62 20 211 9 970 5708 70 70 2207170 2 2 20 220 120 E i OD amp 30010 SOOPNI 6 2 6 040 690 890 72087020610 280 180 Os 080 6 0 840 220 9 0
5. NEGATIVE POSITIVE TO WORK 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 Connectthe wire feeder control cable leads to the Idealarc DC 400 terminal strip as shown in Figure C 9 4 Connectthe wire feeder control cable ground lead to the frame terminal marked n 5 Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpose Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 21 lead to work cable for ease of use ELECTRODE CABLE TO AUTOMATIC EQUIPMENT NOTE Using the extended 21 lead eliminates the need to use the LN 9 s remote work lead accessory which has a direct work lead jack 6 Connect LN 9 wire feeder control jumpers on Voltage Control board See LN 9 Operator s Manual NOTE The connection diagram shown in Figure C 9 shows the electrode connected for positive polarity To change polarity a Set the Idealarc DC 400 POWER toggle switch to the OFF 0 position b Move the electrode cable to the negative output t
6. LINK 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX L3 olw o 2 DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TO PROVIDE AT LINES ys LEAST 600 VOLT INSULATION 2 774 5 9 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND TRANSFORMER LEADS 11 TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN i 4 CONNECT TERMINAL GROUND PER LOCAL AND NATIONAL ELECTRIC H1 CODES GND 2 gt 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS PILOT DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE TRANSF USE SECURE THE REMAINING HEX NUTS IN PLACE i CONNECTION FOR LOWEST RATING PLATE VOLTAGE 50 OR 60 HZ LINK 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 3 o w CR 2 DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TO PROVIDE AT LINES L2 5 o LEAST 600 VOLT INSULATION INPUT CONTACTOR 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS L1 o jo TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN H1 4 CONNECT TERMINAL GROUND PER LOCAL AND NATIONAL ELECTRIC GND H2 e CODES PILOT 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A M15009 IDEALARC DC 400 LINCOLN B Return to Section TOC Return to
7. B 8 LN 7 and LN 9 Semiautomatic Wire B 9 Overload PrOteCtlOri ieicei id Heu dE Feu dede sii Du Eae B 9 Auxiliary POW Gi S ES B 9 o 7 E Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o 515 o PEN 9 gt g 8 mlt 5 2 1 Return to Section TOC Return to Master TOC B 2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be 3 dangerous 40 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held com bustibles ARC RAYS can burn Wear eye ear and body protection S Observe additional Safety Guidelines detailed in the beginning of this manual IDEALARC DC 400 LINCOLN 5 Return to Section
8. R66 1 00M Dt i 10 184004 1 087 i S a 1N4004 68 5 014 017 4004 004 7 1N4004 D 02 4 404 4 1N4004 D49 1N4004 18V T alt 031 D54 1N4004 Yu 4 7 D43 1N4004 di 184004 n CC LOW VOLTAGE STABILIZER J2 034 1 004 Ti zg 035 6 SW 1404 Ojo O O Fle E x Oja gt 918 2 a 10K ARO FORCE CONTROL Y 028 POT 1N4004 ARC FORCE MIN OUTPUT BUFFER Y 57 B Ae 7
9. 7 5 INSTALLATION INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate lo cated on the case front control panel See Figure A 1 FIGURE A 1 RATING PLATE LOCATION wa GAR OARS CH lo o Ble 1 DC 400 o o o EE 1 RATING PLATE GROUND CONNECTION The frame of the welder must be grounded An earth grounding lead must be connected to the grounding terminal marked on the input box floor with the sym bol 777 INPUT SUPPLY CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate Input supply line entry is through a hole in the case rear top panel A removable door covers the input connection box which contains the input contactor CR1 and reconnect panel assembly for multiple volt age machines Input power is connected to the three line terminals on the input contactor See Figure A 2 FIGURE A 2 REAR PANEL Oo L J L J 1 INPUT SUPPLY LINE ENTRY HOLE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL A WARNING ELECTRIC SHOCK can kill e Have a qualified electrician install and service this equip ment Turn the input po
10. 2 Safety e tona dee ovd d 3 Select Suitable eene nnne nennen nenne A 3 EP 3 M A 3 o E Stac i T S 3 9 isiratennpreine E A 4 Ground fo 4 Input Supply Connections one eere tapa dodi A 4 2 9 Input Wire and Fuse Size 5 Reconnect Procedure 3 1 nenne nennen nnn nne A 6 Output 7 Wire Feeder Connections teet ht d d a D rd A 8 Connections for Stick TIG Air carbon Arc Operations A 8 o 7 E Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O E o o o c 3 B tc Return to Section TOC O O o 9 gt Return to Master INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC DC 400 INPUT THREE PHASE ONLY Standard Voltage Input Current Rated Output 208V 87A 230V 78A 460V 39A 575 32 RATED OUTPUT Volts at Rated Amps OUTPUT Current Maximum Open Mode Range Circuit Voltage Auxiliary Power Cons
11. F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The input contactor operates the fan runs the pilot light is lit but the machine has no welding out put POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 If the amber thermal protection light is lit the primary or sec ondary thermostat is open Allow machine to cool Make certain the output trigger circuit 2 and 4 is being acti vated either by an external clo sure or by the output terminals switch 53 Check the 10A circuit breaker in the 42VAC line If remote control is not being used make certain the Output Control switch S2 is in the OUTPUT CONTROL LOCAL position Check for loose or faulty weld cable connections TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the Main Transformer 2 Perform the SCR Diode Rectifier Bridge Test 3 The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this m
12. o 2 3 Return to Section TOC Return to Master TOC o 7 5 4 5 7 OPERATION Turn the Start Board Timer to maximum Set Start Board current and voltage control a Set the Start Board current control to 1 1 2 dial numbers below that set on the NA 3 cur rent control b Setthe Start Board voltage control equal with the NA 3 voltage control setting NOTE These Start Board current and voltage set tings result in a start up current that is lower than the NA 3 current setting and approximately equal with the NA 3 voltage setting for the desired welding procedure Establish the correct arc striking procedure with the NA 3 Start Board timer set at maximum a For the best starting performance the NA 3 Open Circuit Voltage Control and Voltage Control setting should be the same Set the Inch Speed Control for the slowest inch speed possible b To adjust the Open Circuit Voltage Control to get the best starting performance make repeated starts observing the NA 3 voltmeter When the voltmeter pointer swings smoothly up to the desired arc voltage without undershooting or overshooting the desired arc voltage the Open Circuit Voltage Control is set properly If the voltmeter pointer overshoots the desired voltage and then returns to the desired voltage the Open Circuit Voltage Control is set too high This can result in a bad star
13. 1 Return to Section TOC Return to Master TOC F 4 F 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam age is evident when the sheet metal cover s are removed Machine is dead no output no fan no pilot light POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service Facility for technical assistance Make sure that the input Power switch is in the ON position Check the three phase input voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 216 383 2531 or 1 800 833 9353 WELD 1 Check the Power switch S1 for proper operation 2 Check the leads associated with the Power switch S1 and the control transformer T2 for loose or faulty connections See Wiring Diagram 3 Perform the Control Trans CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5
14. F 57 F 57 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 27 EPOXY MIX APPLICATION AREAS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC REASSEMBLY OF TRANSFORMER COILS NOTE The following procedure describes a complete replacement of all primary and sec ondary transformer coils Adapt the procedure for the specific coils you may be replacing 1 Apply a coating of Lincoln Electric E2547 Epoxy Mix along both sides of the bottom iron lamination assembly in the areas where the coil sides will be mounted Coat the areas no closer than 38 inches from the top edge ofthe iron See Figure F 27 arrows Be sure that none of the epoxy drips onto the top ofthe iron assembly where it will meet the top assembly O o 5 5 o PEN 9 gt g 8 mlt 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 58 F 58 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o He o 2 3 Return to Section TOC Return to Master TOC 5 FIGURE F 28 COIL LEAD PLACEMENT MACHINE FRONT SECONDARY COIL LEADS P4 3 Install the bottom p
15. 3 az e GENERAL INFORMATION EJS ELECTRICAL SYMBOLS PER E1537 als CAPACITORS MFD VOLTS J6 2 a RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED ZIN SCR2 N DIODES 1 AMP 400 VOLT UNLESS OTHERWISE SPECIFIED W 55 OP AMPS LM124 UNLESS OTHERWISE SPECIFIED ZT 400V Vj COMMON CONNECTION HOW 100 2 1 31 16 gt e O16 D3 D4 D5 E 5 5 gt 5W 7 5 9 0V d EE 2 1N4007 1 50K 2 J 400 M EJS R1 e e b e n TP1 lo e D D6 1 0 7 180 E M a 320V ojo e 0 a 2 R e 4 e e e e e e e gt W 1N4007 2500 D1 JE Dlo tc J6 J J6 5 3 6 Y Y 218 215 216 11 17 9506 IDEALARC DC400 START SCHEMATIC S 19686 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result LELEGTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machi
16. C NG CIRCUIT 1 6 MODE BUFFER 1N4004 15K 15W oy R149 R316 R328 68 1k 1 40 100K _ R150 e 2 g GENERAL INFORMATION 68 82 2 184004 50 VOLTAGE POWER SUPPLY rt 7 FRAME TION FILE G2586 1BD EARTH GROUND CONNECTION IDEALARC DC400 CONTROL BOARD SCHEMATIC MODE INVERTER i G 2586 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result LELEGTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine IDEALARC DC400 6 8 ELECTRICAL DIAGRAMS G 8 Starting PC Board M14520 Schematic 8 5 5 99961 S 228
17. DOL uonoes DOL uonoes uumeg DOL uonoes Return to Master TOC Return to Master TOC 7 Return to Master TOC Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation eee tr e n ERR Rn ER X SEA BEAR nee Section E General Description ror rei E 2 Input Line Voltage Contactor and Main Transformer E 2 Output Mode and Control Rectification and Feedback E 3 Protective Devices and Circuits enne E 4 SCR Operation ite e e elie E 5 OUTPUT FORCE CONTROL CONTROL CONTROL TRANSFORMER FEEDBACK CONTROL BOARD NEGATIVE OUTPUT TERMINAL MAIN TRANSFORMER R F 265 B N A e N K E POSITIVE QUTPUT TERMINAL i 7 REED SWITCH INPUT CONTACTOR 115VAC REMOTE TO CONTROL CONTROL BOARD FIGURE E 1 IDEALARC DC 400 BLOCK LOGIC DIAGRAM IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fie Lm 915 nl ele 2 cc 1 Return to Section TOC Return to Master TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER OUTPUT ARC FORCE CONTROL CONTROL CONTROL
18. Perform the following daily 1 Check that no combustible materials are around the machine or in the welding or cutting area 2 Remove any debris dust dirt or materials that could block cooling air flow to the machine 3 Inspect the electrode cables for any slits or punc tures in the cable jacket Also check for any other condition that could affect the proper operation of the machine Perform periodically l In extremely dusty conditions dirt may clog the cooling air channels causing the machine to run hot Blow out the machine at regular intervals with low pressure air Clean the following parts See Figure D 1 Main transformer and choke SCR diode bridge Control PC board Starting PC board Electrode and work cable connections Fan assembly NOTE The fan motor has sealed bearings that require no service Remote control terminal strip TS1 NOTE Keeping remote control terminal strip TS1 clean is especially important in damp locations IDEALARC DC 400 LINCOLN B D 3 8 z LL 5 y SAN T o X E a _ 24 28 9 5 25 522 452 COSTES EO TO SSS lt a NOL 49159 0 901 49159 0 901 J91Se N 01 uunjeH 901 J91Se N 0 uunjeH DOL uonoes oj
19. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fc ci 8 2 2 cc 1 Return to Section TOC Return to Master TOC F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine is dead no output no fan the pilot light is lit Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check the three phase input voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines RECOMMENDED COURSE OF ACTION 1 3 Perform the nput Contactor Check the associated leads for loose or faulty connections between the input contactor CR 1 the reconnect panel and the main transformer See Wiring Diagram Perform the CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o 8 2 2 EIS 2 1 Return to Section TOC Return to Master TOC
20. Return to Section TOC Return to Master TOC o 7 5 F 41 F 41 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT continued FIGURE F 17 INPUT CONTACTOR CLEANING AND REMOVAL Li LJ sd T3 212 El AX J Je 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL CLEANING PROCEDURE 1 Remove the main input supply power to the machine 1 2 Locate and get access to the input contac tor CR1 in the input box See Figure F 17 2 3 Remove the input contactor cover plate using a phillips head screwdriver 3 WARNING Y e Do not apply input power to the machine with the input contactor cover plate re moved 4 5 4 Blow out any dirt or dust in or around the contacts with a low pressure air stream 6 5 Inspect the contacts for signs of excessive wear pitting or contacts fused stuck together 7 a If any of these conditions are present replace the input contactor assembly 6 Replace the input contactor cover plate 8 CONTACTOR REPLACEMENT PROCEDURE Disconnect main input supply power to the machine Locate and get access to the input contac tor CR1 in the input box See Figure F 17 Disconnect the main input supply power leads L1 L2 and L3 to the input contactor
21. 9 0 Eg 10 290 990 690 gt 90 290 o 290 190 090 690 8S0 490 mi 950 990 50 esa 250 160 090 6v0 0 Sra vO zea 950 Sea 50 EEQ ZEO trea 620 820 220 920 vz 620 SS 10 10 210 110 ord VOOFNI 1 661211 14 20 90 50 za 10 08 1 11 89991 5 1 952 ME 8 09 091 Z LLGTLL 1 2 Os 008 6 0111 1 Ora SELLY 99 06715 1 gt 09 89 0 06 615 I SEI 227 82 7 0111 922 001 7270 201 06 1 8 8 2 2 629 DL 801129492 05 0 407 04 0111 2 27 22 cco 002 55 6 06 15 1 223 ob 02 81 61 06 15 y 2627222 022 6 00717900 49 2700 25 0111 2 152712 892 99 199 099 690 893 ZSI OEI 610 812 712 9 09 220 5 899919 12 912 ZI2 112 012 69 82 3 001791 801 067215 o SE L v GZ O6 EIS 9 occ NOILVOIJILN3QI ON 0 038 WALI 5 20 O0 3 c gt m ul G gt i N 2 BO 9 m z he 6 8 DOL 49159 0 DOL 49159 0 901 49159 0
22. Return to Section TOC Return to Master TOC 74 REMOVAL OF CHOKE AND IRON ASSEMBLY 1 Remove the two left and right glastic stiffen 6 Using a hoist carefully lift the choke and top ers connecting the negative rectifier plate iron assembly out and clear of the trans and choke assembly to the main transformer former coils ope NOTE The coils may be stuck to the top iron 2 Remove the top and center choke leads from and may require some careful prying to the mode selector switch dislodge them Depending upon which coils are to be replaced it may be advantageous to remove some of the stuck coils with the top iron 3 Remove the bottom choke lead from the neg ative rectifier plate O10 Fle 515 5 2 2 1 4 Label and cut desolder choke control coil leads that are soldered to the arc control switch Cut any necessary cable ties 7 The leads from the coils that are to be removed and or replaced must be discon nected See the Wiring Diagram 5 Using the 9 16 deep well socket wrench remove the four thru bolts that clamp the top E iron and choke assembly to the bottom E iron NOTE for easier reassembly clean the threads When aluminum leads are re connected apply a thin layer of Dow Corning 340 Heat Sink Compound Lincoln E1868 to mating surfaces Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5
23. birth defects or other reproductive harm The Above For Diesel Engines 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 The Above For Gasoline Engines Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS Return to Master TOC o 7 E Return to Master TOC FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing
24. process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National El
25. 4 a St 2091 00 615 y GEI H vel Y 06H 5015 91 1 08 815 644 8 H 082 05 00761 5 2 H Q 265 5265 00515 1 H 2 92 92 00 615 VOLH z u MZ I 01 1y Z18011 2 14H 198 Gc WI 001 00 615 EOT H 084 994 22 00 615 y 888 S94 1 G v 2627 007615 L 821 Y 901 Y 66H 68H 694 29 gt I8 9 1189 00615 1 198 5 mysi 007615 1 09H tc MI ZZ 2122 00515 y OET Y GZT H SeH GSH o 96 o OSI 007615 S vO H 6H vGH mo 2EE gt S 2 8 My l 1122 007615 2 OSH gt 5 LvlH E lt BETY 86H G8H ESY OLY 894 gt OI 2001 007615 12 EGY BPH Lry Iry gt 5 7 00 0001 00615 ZS1 4 oo ML 9Z 2 92 00 515 SZI Y LOIA vvH YZ EL 2161 007615 9 ZOEY 00 H 801 96H 5 Mv l 672 6 2 007615 1 o Mg l 295 0299 00615 9 LIEY ZEH 5 5 e MZ I OS 65 21801 1 928 OR 5 ot 1001 007615 y E94 1
26. 8 SEMIAUTOMATIC WIRE FEEDER To use the LN 8 Semiautomatic Wire Feeder with the Idealarc DC 400 1 Set the Idealarc DC 400 welding MODE switch to either CV FCAW GM AW mode or CV Submerged Arc mode depending on the welding process being used Set the Idealarc DC 400 OUTPUT CONTROL switch to Remote Setthe OUTPUT TERMINALS switch to Remote Set the ARC CONTROL to midrange 3 Set the LN 8 Welding Mode switch to the CV posi tion The LN 8 Welding Mode switch is located on the variable voltage CC board Refer to the LN 8 Operator s Manual for instruc tions on how to use the LN 8 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 7 5 OPERATION LN 7 AND LN 9 SEMIAUTOMATIC WIRE FEEDERS OR OTHER CONSTANT SPEED WIRE FEEDERS To use the LN 7 LN 9 or other constant wire feed speed semiautomatic wire feeders with the Idealarc DC 400 l Setthe Idealarc DC 400 welding MODE switch to either CV FCAW GMAW mode or CV Submerged Arc mode depending on the welding process being used NOTE These semiautomatic wire feeders cannot be used in the CC mode 2 Set the Idealarc DC 400 OUTPUT CONTROL switch a LN 7 Use either an optional K775 Remote Control Box Assembly or set the Idea
27. Check to make sure the output choke control coil is not open or grounded See Wiring Diagram Check resistor R1 resistance is 15 ohms Normal A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o ci PEN 2 EIS 2 1 Return to Section TOC Return to Master TOC F 11 F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The output terminals are always electrically hot Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make certain the Output Terminals switch 53 is in the position Remove any external leads hooked to the 14 pin amphenol and or the terminal strip If the problem disappears the fault is in the control cable or wire feeder RECOMMENDED COURSE OF ACTION 1 Check for an internal short between leads 2 and 4 See Wiring Diagram Check the Output Terminals switch 53 for proper opera tion Also check associated leads See Wiring Diagram Remo
28. Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC INSTAL 7 LATION FIGURE A 5 INPUT CONNECTION DIAGRAM FOR 230 460 575 VOLTS AC 60 HZ HIGH VOLTAGE CAN KILL WARNING Do not operate with covers Do not touch electrically live parts remove e Disconnect input power before Only qualified persons should install servicing use or service this equipment IDEALARC 230 460 575 INPUT SUPPLY CONNECTION DIAGRAM IMPORTANT CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 575V PILOT 5 Daa Beal CONNECTION FOR 575 VOLTS 60 HZ ow o L3 7108 8 RECONNECT LINES FS 1 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H4 PILOT 2 7 H wO PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN L1 olor 0 e 2 INSULATE UNUSED H2 H3 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION H1 H2 e eee 3 CONNECT TERMINAL MARKED C TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES GND 4 CONNECT TRANSFORMER LEADS 16 17 18 4 8 13 5 amp 14 6 8 15 TO RECONNECT PANEL PILOT 5 SEPERATELY TO PR
29. Remove the control transformer primary leads H1 H2 or H3 dependent on input volt age from L1 and L3 terminals on the input side of the contactor Disconnect the output leads T1 T2 and T3 from the input contactor Identify and label the leads connected to the input contactor coil See the Wiring Diagram Disconnect the leads from the input contac tor coil leads X1 232 and 233 See the Wiring Diagram Remove the three self tapping mounting screws using a 5 16 socket wrench See Figure F 17 Remove the input contactor 9 Insert the replacement input contactor and IDEALARC DC 400 LINCOLN 5 install it following the procedures in reverse order NOTE Be sure to reconnect all leads cor rectly F 42 F 42 TROUBLESHOOTING amp REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting as
30. Return to Master TOC Return to Section TOC Return to Master TOC O o 515 PEN mlt 5 5 1 Return to Section TOC Return to Master TOC F 47 F 47 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 20 SCR DETAILS GATE ANODE CATHODE OUTER METAL RING SPECIAL INSTRUCTIONS NOTE Before disassembling the existing recti fier note toward which heat sink the outer metal ring of the power SCR is mounted Also note the positioning of the gate lead of the SCR Failure to reinstall the new SCR in the same ori entation as the original may result in subsequent damage to the new SCR and other components of the welder See Figure F 20 A CAUTION The unclamping and clamping procedure out lined below is critical for the prevention of inter nal SCR damage Failure to follow this proce dure may result in subsequent damage of the SCR Handle all SCRs with care PROCEDURE 1 Remove the main input supply power to the machine the SCR Diode Rectifier 2 Perform Assembly Removal and Replacement pro cedure 3 Alternately loosen nuts 1 2 turn each until heat sinks are loose Remove nuts and leaf spring IT IS RECOMMENDED THAT NEW HARDWARE LEAF SPRING AND HOUSING BE USED FOR REASSEMBLY 4 Remove the old SCR IDEALARC DC 400 LINCOLN 5 Clean the area on the heat sink around the SCR mounting surface using
31. Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 40 F 40 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD Return to Section TOC o 5 DESCRIPTION o E The following procedure will aid the technician in inspecting cleaning and replacing the input 9 contactor E 2 o MATERIALS NEEDED Phillips head screwdriver 5 16 socket wrench Flat heat screw driver Low pressure air source O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 3
32. TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 7 5 B 3 OPERATION GENERAL DESCRIPTION The Idealarc DC 400 is an SCR controlled three phase input DC output power source for welding and cut ting It uses a single range potentiometer control The welders unique combination of transformer three phase semiconverter rectifier capacitor bank arc con trol choke and solid state control system deliver out standing arc characteristics in the constant voltage mode For stick welding an Arc Force Control enables the Idealarc 400 to perform much like the R3R 500 RECOMMENDED PROCESSES The Idealarc DC 400 is recomended for all open arc processes including Innershield and all solid wire and gas procedures within its capacity of 60 to 500 amps It also can perform stick and TIG welding and air car bon arc gouging up to 5 16 8 mm diameter A mode switch on the front control panel selects CV FCAW GMAW CV Submerged Arc or CC stick TIG The Idealarc DC 400 can be connected to wire feed ing equipment including Automatic wire feeders NA 3 NA 5 and NA 5R Requires the DC 400 Diode Kit option to use the cold start and cold electrode sensing features of these feeders Semi automatic wire feeders LN 7 LN 7 GMA LN 8 LN 9 LN 9 GM
33. TRANSFORMER MAIN TRANSFORMER INPUT CONTACTOR 115VAC REMOTE CONTROL TO CONTROL BOARD GENERAL DESCRIPTION The DC 400 is a multiprocess welder power source capable of both constant voltage and constant current operation Its power system is SCR controlled with solid state electronic circuitry Minimum to maximum output is obtained with a single potentiometer control INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER The desired three phase input power is connected to the DC 400 through an input contactor located in the input box at the rear of the machine Two phases of the input line are also connected to the control trans former which through the power switch supplies power to activate the input contactor A reconnect panel allows the user to configure the machine for the desired input voltage This AC input voltage is applied to the primary of the main trans former CR DIODE STN HYBRID BRIDGE SWITCH FEEDBACK NEGATIVE OUTPUT TERMINAL gt POSITIVE OUTPUT TERMINAL aE Q REED SWITCH The transformer changes the high voltage low current input power to a lower voltage higher current output The finishes or neutrals of the main secondary coils are connected together and the three starts of the secondary windings are connected to the rectifier bridge assembly In addition the main transformer has separate and
34. The following procedure will aid the technician in mounting stud type diodes to the aluminum heat sinks on the DC 400 Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 1 2 Open end wrench Lincoln E1868 Dow Corning 340 Heat Sink Compuond Slip type torque wrench No 000 fine steel wool O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B F 53 F 53 TROUBLESHOOTING amp REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM 5 5 HEAT SINKS continued PROCEDURE E 1 Remove the main input supply power to the DIODE STUD FOOT INCH 2 With the 5 16 nut driver remove the case 3 4 16 25 21 300 324 top and sides 1 104 5 3 Loosen the appropriate diode nut and remove the diode that is to be replaced 4 Clean the area on the heat sink around the diode mounting surface using a putty knife or similar tool DO NOT SCRATCH THE DIODE MOUNTING SURFACE 5 Polish each heat sink s mounting surface using No 000 fine steel wool Wipe the sur face clean with a lint free cloth or paper towel 6 Inspect the mounting surfaces of each new diode Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the diode mounting surface 7 Apply a thin 0 003 to 0 007 uniform layer of E1868 Dow Corning 340 heat sink com pound t
35. Waveform Constant Voltage Subarc F 39 9 Replacement Procedures tli deen nav inch F 40 Input Contactor CR1 1 F 40 Fan Motor and Blade Removal and F 42 SCR Diode Rectifier Assembly Removal and F 44 SCR Removal and Replacement 1 4 10 00 0 eene F 46 Mounting of Stud Type Diodes to Aluminum Heat Sinks F 52 Main Transformer Removal and F 54 Retest After Repair F 61 o 7 E Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 3 Return to Section TOC Return to Master TOC o 7 5 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will i
36. Weal WH3l E 50401 O3NOL WH3LOL Py MEI 5 f HO o 30084190713 5 STYNINYAL m KINO 30010 1ndlno o NO 1N3S3Hd T s 9 ze 5 700 HOLIMS j 5 NE IVNOILdO c LON cE ANY LE 2 E D L Q3INZT00 99 7 2183 09 05 081NO9 NO nd 25 5 g3xvduya LINDYIO ANY u3Xv3ug TOYLNOD 39804 _ O N s 9 2 VOL 9 MYWO MNO3 NO di NOLLVINSNI A 009 5 19721 LV OL 2 Le oe ay T avs D 1 436 3dY1 8 N AINO g HOLIOYdVO ouv ans A9 STS a NO 1N3S3ud AWLINOUIO V N 29 CIIAN LMYWO MYO3 AO Oo SALON 95 1ndino HOLIMS ws 5 quvog 10 1 00 640 O d JO 3415 IN3NOdNOO ans Ao 4 99 c 32 3103 ONIH3SRN 5 a c QuvO8 10 1 009 SNV9 S HOLIMS NidZ Nid Ok 9 Eo HOLIMS udMOd 6 1 9 D 15 8 NOLLO3108d 6 4 TVINH3HL o 8 9 lt 16948 5108445 71901919373 oc 30010 o 1 463844 LON 0737 _ o lt 522 5 MOS 0 2 zu Quv
37. a remote location In the Remote position a wire feeder with remote control capabilities or a remote control device such as a K775 must be connected to the DC 400 Refer to the Accessories section for wire feeder installation infor mation WELDING PROCEDURE RECOMMENDATIONS Select Mode Switch position based on type of welding to be done 1 FCAW GMAW Welding Other Open Arc Processes Use the CV FCAW GMAW mode 2 Submerged Arc Welding Use the CV Submerged Arc mode f performing high speed welding switch between the CV Submerged Arc and the CV FCAW GMAW mode and use the mode that pro duces the best welding results 3 Air Carbon Arc Cutting Stick Welding High Current Large Puddle Submerged Arc Welding Use the CC mode When the Idealarc DC 400 is used for Air Carbon Arc cutting the OUTPUT CONTROL potentiometer should be set to 9 ini tially Based on the size of the carbon being used or the process turn the potentiometer to a lower setting as required by the process You can use carbon rods up to 5 16 8 mm in diameter at cur rents as high as 450 amps with excellent arc con trol The welder protection circuit protects the machine from extremely high short circuiting pulses SEMIAUTOMATIC AND AUTOMATIC WIRE FEEDING WITH AN IDEALARC DC 400 When using the Idealarc DC 400 with semiautomatic or automatic wire feeding equipment and for stick welding or air carbon arc cutting it is recommended that the optional
38. and proper opera tion Normal resistanace is 10 000 ohms Check the continuity of leads 204 208 and 209 from the Arc Force control to the control board The control board may be faulty Replace The welding arc is variable and sluggish Check the input voltage at the DC 400 making sure the cor rect voltage and all three phases are being applied to the machine Make sure welding process is correct for machine settings Check welding cables for loose or faulty connections Also make sure cables are sized cor rectly for welding current 2 3 4 Check the welding Mode switch 54 the microswitches and the associated wiring Perform the SCR Diode Rec tifier Bridge Test Perform the Main Transformer The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 7 5 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST
39. at approximately 0 5 when the switch is closed the SCR is volts or 0 10 volts defective 10 Test the voltage level of the battery Short NOTE Be sure the battery is function leads A and C Close switch SW 1 ing properly A low battery can affect the Battery voltage should be 4 5 volts or higher results of the test Repeat Battery Test If lower replace the battery Procedure in Step 10 if needed 11 Connect the tester to the SCR 1 as shownin 16 Open switch SW 1 Figure F 16 a Connecttester lead A to the anode 17 Reconnect the tester leads See Figure F 16 a Connect tester lead A to the cathode b Connect tester lead C to the cathode b Connect tester lead C to the anode c Connect tester lead to the gate 12 Close switch SW 1 NOTE Switch SW 2 should be open 13 Read meter for zero voltage c Disconnect test lead from the gate 18 Close switch SW 1 19 Read meter for zero voltage O10 Fle 515 5 2 1 a If the voltage is zero SCR is func a Ifthe voltage reading is higher than zero tioning the SCR is shorted b If the voltage is higher than zero the 14 Close or keep closed switch SW 1 SCR is shorted 15 Close switch SW 2 for 2 seconds Release 20 Perform the Active Test Procedure outlined and read meter in Steps 11 19 for SCRs 2 and 3 a Ifthe voltage is 3 6 volts while the switch 21 Replace all SCR assemblies that do no
40. back to gain clearance to 3 2 remove the fan See Figure F 18 Resplice any motor leads cut for removal n x cm 4 Ifthe fan motor is to be removed the leads Reattach the fan blade if it was removed earlier using the Allen head wrench to tighten it to the motor shaft 10 Install the case top and sides Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 44 F 44 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in the removal and replacement of the SCR diode assembly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 7 16 Wrench 1 2 Wrench 9 16 Wrench 3 8
41. cable 12 inches 30 m long is available for easy connection of standard K812 Hand Amptrol or K870 Foot Amptrol The cable has a 6 pin MS style connector which connects to the Amptrol and termi nals which connect to 75 76 and 77 on the machine terminal strip and to the case grounding screw The Amptrol will control the same range of output as the current control on the welder If a smaller range of control is desired for finer adjustment a K775 Remote may be used in conjunction with the Amptrol Adapter Cable Kit Connection information is included with the Amptrol Adapter Cable Kit The Amptrol arc start switch does not function in this application K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS X ELECTRIC SHOCK can kill Turn the input supply power OFF before installing plugs or cables or when connecting or disconnecting plugs to the welder This K843 adapter is used to connect Amptrol K812 K813 K870 remote control K775 and Hi Freq K799 accessories to the DC 400 The OUTPUT CONTROL switch must be in Remote for Amptrol to control current Accessories may be combined and connected in four different ways as shown on the fol lowing page FIGURE C 3 REMOTE CONTROL ADAPTER CABLE K864 STRAIGHT PLUG 14 PIN TO POWER SOURCE CABLE RECEPTACLE 6 SOCKET IE 1 K857 REMOTE CONTROL 2 K812 HAND AMPTROL 3 K870 FOOT AMPTROL CABLE RECEPTACLE 14 SOCKET TO L 7 WIRE FEEDER IDEALARC D
42. compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine IDEALARC DC400 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo o c 515 gt ele 5 5 oO 1 Return to Section TOC Return to Master TOC G 6 Snubber PC Board M15370 Layout ELECTRICAL DIAGRAMS ITEM REQD 1 02 03 DESCRIPTION C4 C5 68 400 H1 R2 R3 05 600 TPTTP2 TPS 10 2W 4 5 38J TP6 Cd Gd lt 160 NOTE Lincoln Electric assumes no responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result LINCOLN in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine 80J G 6 IDEALARC DC400 G 7 ELECTRICAL DIAGRAMS G 7 Control PC Board G2588 Schematic
43. from the mini mum of the power source to a maximum set by the remote limit control K775 Remote Y Limit Control K812 K813 K870 Amptrol K843 Adapter Bolt and nut connection te ago ccs dnsulate e 2 ET and tape 2 Arc start cable included with K799 SWITCH and connect black lead to black and K843 white lead to white 799 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o E S9 PEN 2 mlt 5 5 1 Return to Section TOC Return to Master TOC C 6 C 6 ACCESSORIES CAPACITOR DISCHARGE CIRCUIT K828 1 Mounts inside the DC 400 Recommended when DC 400 is used in conjunction with any LN 23P or older LN 8 or LN 9 semiautomatic wire feeder Eliminates possible arc flash re start of weld when trigger interlock is used Not required with current LN 8 above Code 8700 or LN 9s with serial num bers above 115187 manufactured after 12 83 or any LN 9 having an L6043 1 Power PC Board DC 400 is used with an LN 22 equipped with an older K279 Contactor Voltage Control Option Eliminates electrode overrun when gun trigger is released Not required when later K279 above Code 8800 is used DC 400 is used with any semiautomatic wire feeder and possible small spark is objectionable if elec trode touches work just after gun trigger is released Install
44. isolated 115VAC and 42VAC auxiliary windings The 115VAC winding supplies power to the cooling fan and also offers 10 amps of auxiliary power at the terminal strip and 14 pin amphenol to operate wire feeding equipment The 42VAC auxiliary power is available at the 14 pin amphenol only and is protected by a 10 amp circuit breaker The three 21VAC phase angle windings are also housed in the main trans former assembly These windings provide power and timing for the control board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fie ci 915 ele 2 1 Return to Section TOC Return to Master TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 OUTPUT MODE AND CONTROL RECTIFICATION AND FEEDBACK OUTPUT ARC FORCE CONTROL CONTROL CONTROL TRANSFORMER ale Ina 9 nna v INPUT CONTACTOR 115VAC REMOTE TO CONTROL CONTROL BOARD OUTPUT MODE AND CONTROL RECTIFICATION AND FEEDBACK The three phase AC output from the main transformer secondary is rectified and controlled 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 control board The control board compares the commands of the Mode Switch the Arc Force Cont
45. per M 17060 instructions included with the kit HI FREQ KIT K799 FOR CODES 8634 AND ABOVE ONLY Kit supplies the high frequency plus gas valve for DC TIG welding The DC 400 is shipped with proper R F bypass circuitry installed to protect the control circuit when welding with a HI FREQ unit K844 Water Valve Option Kit can be used with K799 when TIG welding with water cooled torches AMPTROL ADAPTER FOR K799 HI FREQ KIT K915 REQUIRES K864 ADAPTER OR K843 ADAPTER A V cable to connect a K799 Hi Freq kit 5 pin con nector with either a K812 Hand Amptrol or a K870 Foot Amptrol 6 pin connector and the machine The cable going to the machine has a 6 pin connector which requires either a K864 adapter to connect with the 14 pin connector on the machine or a K843 adapter to connect to terminals 75 76 77 and the case grounding screw on the machine UNDERCARRIAGES K817 K817R K841 For easy moving of the machine optional undercar riages are available with either steel K817 or rubber tired K817R wheels or a platform undercarriage K841 with mountings for two gas cylinders at the rear of the welder Installation instructions are included with each kit CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS A WARNING e ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance Turn the input power OFF atthe dis connect switch or fuse box before working o
46. power to the machine With the 5 16 nut driver remove the case top and the reconnect panel cover Locate the two leads connected to the input contactor coil 233 and X1 232 top See Figure F 1 for location Connect an AC voltmeter to the leads WARNING Electric Shock can kill e With the input power on there are high voltages inside the machine Do not reach the machine or touch any internal part of the machine while the power is on 5 6 IDEALARC DC 400 LINCOLN 5 Apply the correct voltage to the machine and turn the power switch S1 ON Check for 120VAC at the contactor coil leads If the 120VAC is NOT present with the power switch S1 on check the power switch 51 and associated circuitry See the Wiring Diagram Also perform Control Transformer T2 Voltage Test If the 120VAC is present and the contactor does NOT activate then the input contactor is faulty Replace the input contactor F 17 F 17 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F2 INPUT CONTACTOR TEST CONNECTIONS X1 232 Return to Section TOC Return to Master TOC APPLY EXTERNAL 120 VAC HERE X1 4232 AND 233 Return to Section TOC Return to Master TOC TEST FOR CONTACT CONTINUITY 1 Disconnect the main input supply power to 4 With the contactor activated check the con the machine tinuity acros
47. starts observing the NA 3 voltmeter When the voltmeter pointer swings smoothly up to the desired arc voltage without undershooting or overshooting the desired arc voltage the Open Circuit Voltage Control is set properly If the voltmeter pointer overshoots the desired voltage and then returns to the desired voltage the Open Circuit Voltage Control is set too high This can result in a bad start where the wire tends to blast off If the voltmeter pointer hesitates before coming up to the desired voltage the Open Circuit Voltage Control is set too low This can cause the elec trode to stub 4 Start and make the weld a Cold starts For cold starts be sure the work piece is clean and the electrode makes posi tive contact with the work piece b Hot On the Fly starts For hot starts travel should begin before the wire contacts the work piece ARC STRIKING WITH THE NA 3 START BOARD When electrical stickouts exceed 1 3 4 44 4 mm an NA 3 Start Board may be required to improve arc strik ing When the NA 3 Start Board is used to improve arc striking use the following procedures 1 Setstart time at 0 2 Set NA 3 start current and start voltage at mid range 3 Set the NA 3 output current and voltage to the proper settings for the welding procedure to be used IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
48. the Accessories section of this manual for spe cific instructions on connecting and using the Multiprocess Switch 960CT IDEALARC DC 400 LINCOLN 5 Section B 1 Section B 1 OPERATION SECTION 3 Operation ecclesia ERE Section B Safety 2 5 General SS MPG adi UN UE dd bla B 3 Recommended 5 cine cutis i sees cie ta ged uate ner Ha d RE UR es n B 3 Operational Features and 2 3 Design Features and B 3 Welding Capability rote ettet a E Cre REOR M RI AER RD ER Y RA ERR B 3 ITE B 3 Controls arid Settings E n dr B 4 Welding Operation E B 6 T Operating Steps oco ome bie become ad ee B 6 Local OCI UU a a B 6 5 Remote T B 6 Welding Procedure Recommendations B 6 Semiautomatic and Automatic Wire Feeding with an Idealarc 400 B 6 5 NA 3 Automatic Wire Feeder nennen nnne B 7 Good Arc Striking Guidelines for the 3 B 7 Arc Striking with the NA 3 Start Board em memes B 7 NA 5 Automatic Wire 2 4 0 222244 eene B 8 LN 8 Semiautomatic Wire
49. the front panel Remove the three heavy aluminum sec ondary leads from the SCR finned heat sinks Remove the four nuts and associated wash ers that hold the SCR diode assembly to the mounting brackets Carefully lift and remove the SCR diode heat sink assembly from the machine Note It may be necessary to loosen the six sheet metal screws that hold the front panel to the base Carefully lift and pull out the front 11 19 IDEALARC DC 400 LINCOLN 5 panel to allow clearance for SCR diode assembly removal Clear any necessary leads that might hinder removal For reassembly carefully place the SCR diode assembly into position on the mount ing bracket and reinstall the washers and nuts Tighten the front panel to base if it was loosened earlier Replace and tighten the four nuts and lock washers that hold the SCR diode assembly to the mounting brackets Reattach the three heavy aluminum sec ondary leads to the SCR finned heat sinks Apply a thin coating of Dow Corning 340 heat sink compound Lincoln E1868 to con nection points Connect the green ground lead to the front panel lead 225 to the negative output lead and lead 224 to the positive output lead Connect plug P5 to the snubber board and plug P3 to the control board Connect the choke and mode switch lead to the left side of the negative heat sink plate See Figure F 19 Connect the positive capaci
50. the machine is in opera tion 10 THERMAL PROTECTION INDICATOR LIGHT This amber light indicates that either of the two protective thermostats has opened Output power is removed but input power is still being applied to the machine 11 DC AMMETER Displays output current when welding 12 DC VOLTMETER Displays output voltage when welding 13 VOLTMETER ELECTRODE ELEC TRODE SWITCH Selects the electrode polarity forthe remote work sensing lead 21 when using automatic or semiautomatic wire feeders Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 E Return to Section TOC Return to Master TOC o 42 5 OPERATION WELDING OPERATION OPERATING STEPS LOCAL CONTROL The following procedures are for using the Idealarc DC 400 in the local control mode of operation For remote control of the machine see the REMOTE CONTROL section Before operating the machine make sure you have all materials needed to complete the job Be sure you are familiar with and have taken all possible safety pre cautions before sta
51. well socket wrench reassemble the four thru bolts that clamp the top E iron to the bottom E iron Lightly tap on the top of the iron with a hammer before tightening Tighten the nuts and thru bolts to 19 25 Ib ft FIGURE F 29 COIL INSULATION PRIMARY COILS TOP LEFT TOP CENTER TOP RIGHT SECONDARY COIL ASSEMBLY INSULATION PRIMARY COIL BOTTOM SHIMS IDEALARC DC 400 LINCOLN 5 F 59 F 59 TROUBLESHOOTING amp REPAIR olo MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued og 5 2 FIGURE F 30 PRIMARY THERMOSTAT LOCATION gt 22 5 25 TOP VIEW o THERMOSTAT olo ae 55 FRE 2 FRONT VIEW 22 Sis cm 10 Mount the primary thermostat to the lead 11 If necessary trim off excess secondary lead end coil nose See Figure F 30 Place a stickout and TIG weld the leads together small amount of Lincoln Electric E1603 See Figure F 31 Epoxy between the coil nose and the coil insulation and between the insulation and the thermostat Hold the thermostat in place with E2381 375 wide tape If nec essary after assembly protect the thermo stat terminals with E2547 terminal boots FIGURE F 31 SECONDARY LEAD TRIM AND WELD DETAIL O o 515 o PEN 9 gt g 8 5 2 aja Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN
52. 0 gt 2 1 SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Internal Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 36 F 36 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED 81 CONSTANT VOLTAGE FCAW GMAW MODE 2 2 CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 5 milliseconds in time The machine was loaded with a resistance grid bank The DC 400 meters read 400 amps at 36 VDC O10 Fle 515 gt 2 1 Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Internal Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 37 F 37 TROUBLESHOOTING amp REPAIR 3 TYPICAL OUTPUT V
53. 0 CONTROL Q CABLE 2 Set the Idealarc DC 400 POWER toggle switch to the OFF 0 position gt AUTOMATIC 3 Connect the wire feeder control cable leads to the Idealarc DC 400 terminal strip as shown in Figure C5 Return to Section TOC Return to Master TOC FIGURE C 5 NA 5 WIRE FEEDER CONNECTION TO THE IDEALARC DC 400 NA 5 WIRE FEEDER Ee CONTROL ES CABLE o S O j E AUTOMATIC NEGATIVE POSITIVE ELECTRODE 515 CABLE TO E 5 ORE AUTOMATIC EQUIPMENT 5 Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape e b An S 16586 X remote voltage sensing work O lead is available for this purpose c NEGATIVE POSITIVE E 8 Keep the 21 lead electrically separate from 16 CET 9 5 the work cable circuit and connection work AUTOMATIC 2 EQUIPMENT 3 d Tape the 21 lead to work cable for ease of c odd NOTE If using a K215 control cable connect E NOTE T
54. 1 Return to Section TOC Return to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine has minimum welding output and no control POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 If remote control is being used set the Output Control switch S2 in the OUTPUT CONTROL LOCAL position and control the weld output with the machine Control potentiometer R4 If the problem is solved check the remote control unit or wire feeder and associated control cable Make certain the remote control leads 75 76 and 77 are not grounded to the positive weld ing output Make certain the three phase input voltage is correct and matches the machine rating and the reconnect panel TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check the Output Control potentiometer R4 and associ ated wiring See Wiring Diagram Check the welding Mode switch 54 the microswitches and the associated wiring Check the Output Control switch 52 and associated wiring See Wiring Diagram 4 Perform the Main Transformer 5 Perform the SCR Diode Rec tifier Bridge Test 6 The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service D
55. 1 UuunjeH 901 49159 01 uunjeH DOL uonoes oj DOL uonoes uumeg DOL uonoes uumeg DOL uonoes oj Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 o 2 Return to Section TOC Return to Master TOC o O o 9 c 2 tc G 5 Starting PC Board M14520 Layout ELECTRICAL DIAGRAMS 1 UC 4l bw STARTING 14520 2 REQ D G 5 IDENTIFICATION C1 50 50 01 D1 D2 03 04 05 06 07 1N4007 mE Ri R2 1N4004 9W 2500 OHM RESISTOR s pe R3 5 dp R4 1K 1 4W R6 1 5 1 4W SCR1 100 10W SCR2 4A 400V SCR 5851 SCR HEAT SINK AS BLY TP1 SILICON BILATERAL SWITCH TP2 38J 4 4 4 po po 160 NOTE Lincoln Electric assumes no responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not LINCOLN available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may
56. 14520 G 8 Snubber PC Board M15370 Schematic G 9 Return to Master TOC o 7 c E Return to Master TOC IDEALARC DC400 LINCOLN NOTES IDEALARC DC400 LINCOLN 5 NOL 0 901 49159 901 J91Se N uunjeH 901 J91Se N 01 UuunjeH DOL uonoes oj DOL uonoes uumeg DOL uonoes oj uumeg DOL uonoes y 5 o a tc lt d lt a o E lt E 2
57. 40 39019 p 222 LN3S3Hd LON 021 g 922 MOSS 07 S lt 702 Quvog O 702 u388nNs M 2 i o 90 502 8 gt O 09 2 p 9 8398 2808 T 11085 A HOV3 AOS 5 4331 11933 E o tS E HOJSNVHL NIVIN LL 5 g NOlldO 4 FOUVHOSIC 2 HOLIOVdvO i d 1 uOllovdvall FT S NAZI gt 406 8 SIVISOWYSHL J c Le Leg AHVWIHd AHVONOO3S gt S YH IET HERE 5 3 YANYOSSNVYL SH Vee S E 1081000 un NOUSONNOD e 1105 m e NO NMOHS gt SY SLVINSNI jg c 193NNOO 2 2 1109 2 AuviIHd I 50199109 SON HOLOW o 3009 7191819373 D TVNOLLVN H3d OL z ot za 2 ZH INT E AMdnsol pH A 085 HOS Q3103NNOO NMOHS o 1825 097 062 io E ceo 9 o amp a E a B 5 NOL 49 59 0 DOL 49159 0 901 49159 01 UuunjeH 901 49159 01 uunjeH DOL uonoes oj DOL uonoes uumeg DOL uonoes uumeg DOL uonoes oj G 4 1 8892 o XT8IN3SSV 0808 24 TOHINOO 007 00 t Board Components not ise the quality of the design and may result IDEALARC DC400
58. 400 NA 3 NA 5 14 PIN AMPHENOL CONNECTION 14 PIN AMPHENOL TO WORK TO NA 3 or NA 5 INPUT CABLE PLUG K597 XX INPUT CABLE ASSEMBLY ELECTRODE CABLE TO WIRE FEED UNIT IDEALARC DC 400 LINCOLN 5 ACCESSORIES o E e FIGURE C 7 5 5 IDEALARC DC 400 LN 7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM ola oz 9 515 2 2 TO LN 7 INPUT 14 PIN CABLE PLUG AMPHENOL K584 XX INPUT CABLE ASSEMBLY o o 2 3 Return to Section TOC Return to Master TOC o 5 Input Cable Assembly to the terminal of the welder and to the LN 7 wire feeder Connect the work cable to the terminal of the welder Reverse this hookup for negative polarity NOTE Welding cable must be sized for the current and duty cycle of the application ELECTRODE CABLE B TO WIRE FEED UNIT RE TO WORK 918 FRE gt 5 5 8 9 SEMIAUTOMATIC WIRE FEEDERS CONNECTING THE LN 7 TO THE IDEALARC 4 Connect K584 XX Input Cable between the DC DC 400 14 PIN AMPHENOL 400 and the LN 7 See Figure 7 l Disconnect main AC input power to the Idealarc Set the welder VOLTMETER toggle switch to the DC 400 desired polarity either DC or DC 2 Setthe POWER toggle switch to the OFF 0 posi Set the MODE switch to a CV constant voltage tion position at the welder 3 Connect the electrode c
59. 5 F 60 F 60 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued REASSEMBLING THE MAIN REASSEMBLE THE LIFT BAIL TRANSFORMER INTO THE MACHINE 1 NOTE The following procedure assumes you have completely reassembled the transformer coils as described in the procedure above The lower iron has remained in place in the 2 machine See Figures F 25 and F 26 Carefully position the lift bail onto the machine base Using the 9 16 socket wrench attach the lift bail to the base of the machine with four bolts flat washers and lock washers Using the 9 16 socket wrench attach the lift bail to the transformer top and bottom irons with four Return to Section TOC Return to Master TOC Resolder the choke control coil leads to the arc control switch Attach the bottom choke lead to the negative recti bolts Attach the sheet metal screw that holds the capacitor bank assembly to the case back fier plate 4 Connect leads 204 and 227 to resistor R3 3 Attach the top and center choke leads to the mode 5 Connect lead 204 to resistor R2 selector switch 6 Connect the negative capacitor strap to the mode selector switch 7 Connectthe positive capacitor strap to the output shunt 8 Attach the two leads to resistor R1 9 Attach the fiber baffle to the left side of the choke 10 Attach the two fiber baffles to the left and right sides of the lift bail adjacent t
60. A LN23P LN 25 LN 742 Tractors LT 56 LT 7 OPERATIONAL FEATURES AND CONTROLS The following operational controls are standard on the Idealarc DC 400 Power Source Pilot Light ON OFF Power Toggle Switch Output Control Potentiometer Output Control Switch with Local or Remote posi tions Output Terminals On or Remote Switch Arc Force Selector for CC stick or TIG processes only Auxiliary Power Connections for Wire Feeder and Other Equipment 115V and 42V Mode Switch Arc Control Thermal Protection Indicator Light DC Ammeter DC Voltmeter Voltmeter Electrode or Electrode Switch DESIGN FEATURES AND ADVANTAGES Input line voltage compensation keeps output con stant for fluctuations of 10 SCR control extends life of mechanical contactors Hinged front control panel provides easy access to printed circuit boards and other control circuitry Fully enclosed fan motor with permanently lubri cated sealed ball bearings needs no maintenance Fully recessed control panel protects controls and minimizes accidental contact Recessed output terminals and hinged terminal cover reduce chance of accidental contact Low profile case permits installation under a work bench Removable rear access panel provides easy access to input contactor and input lead connections Removable case sides provide easy access for ser vice or inspection even when m
61. Adapter Cable 857 2 1 0 2201 24 12 0 9 91 42 018 00000 nnns C 4 Remote Control Adapter Cable 864 C 4 9 Amptrol Adapter Cable 843 C 4 E Capacitor Discharge Circuit 828 1 C 6 2 6 Amptrol Adapter for K799 015 C 6 Undercarriages K817 K817R 841 C 6 5 Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders C 6 Automatic Wire Feeders eee cie tad he e d ei i cc a d E eiie Edd C 6 NA 3 Terminal Strip a C 6 5 Terminal Strip tan rrr ntn rer th ot E C 7 NA 3 or NA 5 14 Pin C 8 Semiautomatic Wire 44 2 2040 nennen enne nennen nennen nnn C 9 9 LN 7 14 tern eta ek ra kd exa enda oie Rn a Rene C 9 E LN 7 Terminal 2 nemen nennen nnne C 10 2 LN 8 or LN 9 Terminal C 11 LN 8 or LN 9 14 s ncc aser dac rn t ntn 6 12 LN 742 14 Pin 13 Q 0 5 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TO
62. C o HE o 2 3 Return to Section TOC Return to Master TOC 7 5 ACCESSORIES OPTIONS ACCESSORIES FACTORY INSTALLED OPTION DIODE OPTION This factory installed option allows use of the cold start i cold oe 22 2 of the E FIELD INSTALLED OPTIONS The following options accessories are available for your Idealarc DC 400 from your local Lincoln Distributor COVER FOR 14 PIN AMPHENOL LINCOLN ELECTRIC PART NUMBER 517062 3 Protects the amphenol from dirt and moisture when the amphenol is not being used MULTIPROCESS SWITCH K804 1 ALSO AVAILABLE AS A FACTORY INSTALLED OPTION Required when using the DC 400 for both automat ic semiautomatic and stick air carbon arc This field or factory installed kit mounts on the front of the DC 400 It includes hinged covers over its output studs The switch has three positions Wire Feeder Positive Wire Feeder Negative Stick Air Carbon Arc FIGURE C 1 MULTIPROCESS SWITCH POSITIVE STICK OR AR CARBON ARC NEGATIVE STICK OR AIR CARBON ARC CABLES WIRE FEEDER CABLES The Multiprocess Switch gives you the ability to e Switch between Stick Welding Air Carbon Arc Cutting or Positive Wire Feeder or Negative Wire Feeder Change the polarity of a semi automatic or auto matic wire feeder without changing any electrical cabl
63. C 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o ci PEN 2 2 a Return to Section TOC Return to Master TOC C 5 5 ACCESSORIES K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS Continued Amptrol Only The Amptrol provides remote current control through the full range of the power source POWER SOURCE K812 K813 or K870 Amptrol Power source terminal 3 EF I IF Black and white leads not used Tape and insulate Amptrol Plus Remote Limit Control The Amptrol provides remote current control from the minimum of the power source to a maximum set by the remote limit control K812 K813 or K870 Amptrol SOURCE Bolt and nut connection Insulate and tape Black and white leads not used Tape and insulate Amptrol and Hi Freq Kit The Amptrol will start the Hi Freq kit to turn on gas and high frequency starting for DC TIG welding The Amptrol controls current through the full range of the power source POWER SOURCE K812 K813 870 Amptrol K799 Hi Freq Kit Arc start cable included with ARC START SWITCH and connect black lead to black and white lead to white Amptrol and Hi Freq Kit Plus Remote Limit Control The Amptrolswitch will start the Hi Freq kit to tum on gas and high frequency starting for DC TIG welding The Amptrol controls current
64. C DC 400 LN 742 CONNECTION DIAGRAM O10 515 10 gt 2 1 TO LN 742 INPUT 14 PIN CABLE PLUG AMPHENOL 592 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 Section D 1 Section D 1 TABLE OF CONTENTS O MAINTENANCE 8 Maintenance 2 44 000 Section D gt Safety Precautions 5 ei e a T n ease dna we d D 2 Routine and Periodic D 2 General Component 5 1 eene enne nennen D 3 Return to Master Q 7 E Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC Return to Master TOC D 2 MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this mainte nance Turn 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 six months
65. CEEDING TO THE ASSEMBLY PROCEDURE Two different designs of leaf springs and housings have been used to clamp the SCR to the rectifier The two different designs can be identified by the size of the leaf spring One design uses a 1 2 inch wide leaf spring and the other uses a 5 8 inch wide spring The different designs require different assembly and clamping procedures The assem bly procedure will be different depending upon the thread on the cap screws 1 4 28 thread requires a different tightening procedure than a 1 4 20 thread PROCEDURE FOR THE 1 2 INCH WIDE SPRING 1 Place a piece of sleeving around each cap screw 2 Insert cap screws through the leaf spring Orient the leaf spring so that its ends are curved upward toward the cap screw heads See Figure F 21 Pressing on the cap screw heads should produce a rocking motion of the spring in its housing If the spring does NOT rock it is installed upside down Remove the spring and turn it over Check for rocking motion See Figure F 21 3 Insert cap screws and leaf spring into the plastic housing 4 Insert clamp assembly through heat sinks Install nuts Tighten clamp nuts equally on cap screws until fingertight See Figure F 22 Heat sinks may not be exactly as pictured 5 Reinspect the SCR for proper seating FIGURE F 22 CLAMP ASSEMBLY HEX NUT ff HEAT SINK SCR HEAT SINK HOUSING LEAF SPRING CAP SCREW IDEALARC DC 400 LI
66. DEALARC DC 400 LINCOLN 5 a Reverse the meter leads and measure the resistance from cathode to anode probe of diode D1 The resistance should be high See Figure F 11 b Ifa low resistance is measured in both meter polarities diode D1 is shorted Replace diode D1 c high resistance is measured in both meter polarities diode D1 is open Replace diode D1 12 Test diodes 02 D3 and 04 for proper oper ation using the same procedure described in Step 11 13 Reconnect all leads and molex plugs 14 If this test did not identify the problem or to further test the SCRs go to the F 29 F 29 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD olo 5 5 DESCRIPTION mio 2 E This test will help determi
67. EH 0 volts Return to Section TOC Return to Master TOC 20 volts 2ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal O10 Fle 515 gt 2 1 SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling tenete DC Trigger Internal Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 35 F 35 TROUBLESHOOTING amp REPAIR 3 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 5 5 CONSTANT VOLTAGE SUBARC 8 3 MAXIMUM OUTPUT SETTING NO LOAD o 9 CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 5 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal O10 515 1
68. EPERATELY TO PROVIDE AT LEAST 600V INSULATION 13 14 15 16 17 18 TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 1 15666 OUTPUT CONNECTIONS The output welding cables are connected to the output terminals marked and 1 mended cable sizes for the combined lengths of trode and work cables They are located at the lower right and lower left corners of the front panel Strain relief for the cables is provided by routing them through the rectangular holes in the base before connecting them to the output terminals Lift the output terminal cover to access the output terminals Lower the cover after making the connections See Figure A 6 FIGURE A 6 OUTPUT TERMINAL CONNECTIONS 1 NEGATIVE WELDING CABLE CONNECTION 2 POSITIVE WELDING CABLE CONNECTION 3 CABLE STRAIN RELIEF HOLE LOCATION IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o 515 PEN 9 gt 818 5 5 1 Return to Section TOC Return to Master TOC A 8 INSTALLATION TABLE A 1 CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE AND WORK CABLES ese BET 50 1006 100 150ft 150 2008 200 2508 Machine Size 15 30 m 30 46 m 46 61 m 67 76
69. ER The Idealarc DC 400 can provide nominally 115 volt AC and 42 volt AC auxiliary power for operating wire feeding equipment and other accessories This power is available at the 14 pin amphenol on the control panel and or at the terminal strip behind the hinged control panel on the case front On the amphenol 115 volts AC is available at pins A and J Domestic and Export models only 42 volts AC is available at pins and K On the terminal strip 115 volts AC is available at terminals 31 and 32 42 volts AC is not available The two circuits 115 volts AC and 42 volts AC are iso lated and each is protected by a 10 amp circuit break er On European and export models a Continental European receptacle is provided on the rear panel for supplying 220 volts AC to a water cooler A 2 amp cir cuit breaker also located on the rear panel protects this circuit from overloads or short circuits IDEALARC DC 400 LINCOLN 5 Section C 1 Section C 1 TABLE OF CONTENTS o 5 ACCESSORIES 5 ACCeSSOLIGS nihili utt rum Section C Optlons ACCessOrl8S asia ree oh ce er e EEG i ER eat dle EE DR RF i EE a o Ren C 2 5 Factory Installed Optlon iei ERE M ege e d ra nde C 2 Field Installed ODEIOns d e v bs 2 Cover for 14 Pin 2 Multiprocess Switch 804 0 C 2 Remote Output
70. MULTIPROCESS switch be used This switch permits you to easily change the polarity of the connected wire feeding equipment or switch to stick welding or air carbon arc cutting IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 42 5 OPERATION NA 3 AUTOMATIC 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 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 the work automatically stop and automatically energize the flux hopper valve The cold start feature requires the factory installed diode option See the Accessories section 2 Set the DC 400 welding MODE switch for the desired process CV Submerged Arc CV FCAW GMAW mode or CC mode 3 Set the NA 3 mode switch position to either CV or CC to match the DC 400 mode selected in step 2 4 Set the OUTPUT CONTROL switch to Remote 5 Set the OUTPUT TERMINALS switch to Remote 6 For CC welding set the ARC FORCE CONTROL to midrange 5 6 After welding starts adjust as nec essary 7 For CV FCAW GMA
71. Master TOC o 7 5 TERMINAL STRIP Es Co 65 14 AMPHENOL 2 2 2 Terminal Strip Terminal Strip Lead 31 Lead 32 Uu 75 76 77 Expected VAC Amphenol Pi n Lead 41 Pin K Lead 42 12 Test for 115VAC between leads 31 and 32 on the terminal strip Also test for 42VAC between pin lead 42 and pin lead 41 in the 14 pin amphenol a Remove the sheet metal screws from the control box cover with the 5 16 nut driver and flip the cover down It does not have to be completely removed to perform the tests b If the above voltage checks are incor rect check for loose or faulty wiring Check continuity c the wiring is good then the main transformer may be faulty Replace the main transformer 13 IDEALARC DC 400 LINCOLN 5 Test with an AC voltmeter for 21VAC for each phase angle winding at plug P1 on the control board as shown in Figure F 8 and the accompanying table NOTE f the main input supply voltage varies the main transformer voltages will vary proportionately a If the voltage is low remove plug P1 and recheck the voltage for 21VAC If the reading is normal the control board may be faulty Replace the control board b If one or more of the voltage t
72. NCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC F 49 F 49 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREWS NOTE This procedure can only be used with 1 4 28 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 4 turn Stop Ui A W N Assembly now has the proper clamping force 8 Perform the Active SCR Test CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten sec
73. OFF power switch to OFF 5 Connect main input supply power to the a 2 8 2 Disconnect main input supply power from meer 2 5 the machine 6 Setthe ON OFF power switch to ON 3 3 With the 5 16 nut driver remote the case a Make sure the input contactor CR1 top and sides and the reconnect panel energizes and the fan runs d E 7 Test with AC voltmeter for proper main 4 Inspect the input contactor reconnect input supply voltage to the line side of the panel and primary leads to the main trans input contactor CR1 See the Wiring former for loose or faulty connections See Diagram a L1to L2 a Confirm that the reconnect panel is b 121013 connected properly for the three phase main input supply power supplied to L1to L3 olo the machine See the reconnect panel E o connection diagram located on the 5 inside of the input box assembly 8 access door a gt g 2 5 5 5 IDEALARC DC 400 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC F 23 F 23 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 6 MAIN SECONDARY LEAD TEST POINTS MAIN TRANSFORMER SECONDARY LEADS 8 Read the meter a 11 Test with an AC voltmeter for approximate If proper
74. OLTAGE WAVEFORM MACHINE LOADED 5 5 CONSTANT VOLTAGE SUBARC MODE 2 2 CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 5 milliseconds in time The machine was loaded with a resistance grid bank The DC 400 meters read 400 amps at 36 VDC O10 Fle 515 gt 2 1 Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Internal Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC F 38 F 38 TROUBLESHOOTING amp REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM CONSTANT VOLTAGE SUBARC MAXIMUM OUTPUT SETTING NO LOAD CH1 0 volts 2 volts 5 ms This is the typical SCR gate pulse voltage waveform Th
75. OTE For proper NA 5 operation the electrode 7 cables must be secured under the clamp bar on the left side of the NA 5 Control Box Set the DC 400 OUTPUT CONTROL switch to the Remote position and the OUTPUT TERMINALS switch to the Remote position CONNECTING THE NA 3 OR NA 5 TO THE IDEALARC DC 400 14 PIN AMPHENOL the work cable circuit and connection 1 Disconnect main AC input power to the Idealarc d Tape the 21 lead to work cable for ease of use 2 Idealarc DC 400 POWER switch to the OFF 0 position Connect NA 5 wire feeder control jumpers on Voltage Control Board See NA 5 Operators 3 Connect the electrode cable from the K597 XX Manual Input Cable Assembly to the terminal of the NOTE The connection diagram shown in Figure C 5 E e 4 2 shows the electrode connected for positive hook n for n gative polarity See Fi 6 polarity To change polarity 9 y g a Set the Idealarc DC 400 POWER toggle NOTE 2 4 Hue switch to the OFF 0 position y b Move the electrode cable to the negative 5 T to the desired output terminal p y c Move the work cable to the positive output 3 Set the MODE switch to a CV constant voltage position terminal 6 Setthe DC 400 OUTPUT CONTROL switch to the d the VOLTMETER toggle switch to negative Remote position and the OUTPUT TERMINALS switch to the Remote position FIGURE C 6 IDEALARC DC
76. OVIDE AT LEAST 600V INSULATION 1 2 3 7 8 9 TRANSF TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS L3 p w R1 5 6 CONNECTION FOR 460 VOLTS 60 HZ cp 29 RECONNECT LINES 8 1 CONNECT L1 L2 amp 13 INPUT SUPPLY LINES AND H1 amp PILOT 2 7 uer 20 PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF 1 CONTACTOR AS SHOWN Li _ o 5e 2 INSULATE UNUSED H2 H4 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION H1 H2 e 99 3 CONNECT TERMINAL MARKED SYSTEM GROUND PER NATIONAL ELECTRIC CODES GND H4 4 CONNECT TRANSFORMER LEADS 1 2 8 4 amp 7 5 amp 8 6 amp 9 RECONNECT PANEL aA PILOT 5 TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13 14 15 16 17 18 TRANSF TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS lo w o on o CONNECTION FOR 230 VOLTS 60 HZ 195 O RECONNECT LINES 1 CONNECT 11 12 amp L3 INPUT SUPPLY LINES AND H1 amp H2 PILOT INPUT 2 7 uen PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF CONTACTOR AS SHOWN Li 4 s 2 INSULATE UNUSED H3 H4 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION H1 eso ooo 3 CONNECT TERMINAL MARKED SYSTEM GROUND PER NATIONAL ELECTRIC CODES GND H2 4 CONNECT TRANSFORMER LEADS 18 7 2 amp 8 8 9 4 amp 5 amp 6 RECONNECT PANEL TRANSF 5 TAPE S
77. RETURN TO MAIN INDEX SVM 122 A 400 _ For use with machine code numbers 9847 9848 and 9850 Return to Master TOC View Safety Info i d SSS 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 SANA d 4 Return to Master TOC View Safety Info o 9 gt 9 o z 2 gt o O HE i o s 5 tc SERVICE MANUAL LINCOLN ELECTRIC Sales and Service through subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors Return to Master TOC View Safety Info SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known to the State of California to cause cancer
78. TPUT CONTROL switch in the Remote position and the OUTPUT TERMINALS switch in the Remote position FIGURE C 10 IDEALARC DC 400 LN 8 OR LN 9 WITH K595 XX CABLE 14 PIN AMPHENOL TO WORK TO LN8 LN9 INPUT CABLE PLUG K595 XX INPUT CABLE ASSEMBLY ELECTRODE CABLE TO WIRE FEED UNIT IDEALARC DC 400 LINCOLN 5 ACCESSORIES Qjo e CONNECTING THE LN 742 TO THE 5 IDEALARC DC 400 14 PIN AMPHENOL 5 9 8 dd RR 5 Setthe welder VOLTMETER switch to the desired S i polarity either DC or DC Set the POWER toggle switch to the OFF 0 posi 6 Set the MODE switch to a CV constant voltage 2 3 Hen position c 3 Connect the electrode cable from the LN 742 to 7 Adjust wire feed speed at the LN 742 and set the the terminal of the welder Connect the work welding voltage with the output ARC CONTROL to cable to the terminal of the welder Reverse this hookup for negative polarity See Figure C 11 NOTE optional remote control is used set the NOTE 2 2 n be od for the current OUTPUT CONTROL switch to the Remote ane Guy Cycler position and the OUTPUT TERMINALS switch 4 Connect the K592 Control Cable to the 14 pin to the Remote position amphenol on the IDEALARC DC 400 and to the input cable plug on the LN 742 See Figure C 11 Return to Section TOC Return to Master TOC FIGURE C 11 IDEALAR
79. W welding set the ARC CON TROL to midrange 3 After welding starts adjust as necessary 8 Referto the NA 3 operator s manual for instructions on how to use the NA 3 in conjunction with the DC 400 9 Follow the guidelines for good arc striking detailed below for each welding mode GOOD ARC STRIKING GUIDELINES FOR THE NA 3 WITH THE IDEALARC DC 400 IN THE CV FCAW GMAW CV SUBMERGED ARC OR STICK TIG CC WELDING MODES Following are some basic arc striking techniques that apply to all wire feed processes Using these proce dures should provide trouble free starting These pro cedures apply to single solid wires and Innershield wires 1 Cut the electrode to a sharp point 2 Set the NA 3 Open Circuit Voltage Control to the same dial setting as the Arc Voltage Control If this is a new welding procedure good starting point is to set the Open Circuit Voltage Control to 76 NOTE The open circuit voltage of the Idealarc DC 400 varies from apporximately 12 volts to 45 volts in the CV FCAW GMAW or CV Submerged Arc modes The open circuit voltage is constant in the CC mode 3 Runa test weld Set proper current voltage and travel speed a For the best starting performance the NA 3 Open Circuit Voltage Control and Voltage Control setting should be the same Set the Inch Speed Control for the slowest inch speed possible b To adjust the Open Circuit Voltage Control to get the best starting performance make repeated
80. WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the input contactor is receiving the correct coil voltage and if the contacts are functioning correctly MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver Idealarc DC 400 Wiring Diagrams See the Electrical Diagrams section of this manual External 120VAC supply IDEALARC DC 400 LINCOLN B F 15 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o 515 o PEN 5 5 1 Return to Section TOC Return to Master TOC F 16 F 16 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F 1 INPUT CONTACTOR CONNECTIONS X1 4232 TEST PROCEDURE 1 4 Disconnect the main input supply
81. WG 14 or larger insulated wire Tape the bolted connec tion with insulating tape ELECTRODE CABLE TO AUTOMATIC EQUIPMENT NOTE work cable length is less than 25 feet and the connections to the work piece are secure then wire feeder control cable lead 3221 can be connected directly to the DC 400 terminal strip b An S 16586 X remote voltage sensing work lead is available for this purpose Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 21 lead to work cable for ease of use NOTE The connection diagram shown in Figure C 8 shows the electrode connected for positive polarity To change polarity a Set the IDEALARC DC 400 POWER toggle switch to the OFF 0 position b Move the electrode cable to the negative output terminal c Move the work cable to the positive output terminal d Set the VOLTMETER toggle switch to nega tive IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o He o 2 3 Return to Section TOC Return to Master TOC 5 ACCESSORIES FIGURE C 9 LN 8 OR LN 9 WIRE FEEDER CONNECTION TO THE IDEALARC DC 400 LN 8 OR LN 9 WIRE FEEDER CONTROL CABLE
82. Wrench Slot head screw driver 1 2 Socket and extension O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 7 5 F 45 F 45 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT continued FIGURE F 19 SCR DIODE ASSEMBLY DETAILS GLASTIC CHOKE MODE STIFFENERS SWITCH LEAD CONNECTION LEADS PLUG G3 BRACKETS SCR DIODE ASSEMBLY MOUNTING FASTENERS PROCEDURE 1 10 Remove the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Remove the glastic stiffeners one on each side left and right See Figure F 19 Remove the positive capacitor lead and shunt from the positive heat sink plate See Figure F 19 Remove the choke and mode switch lead from the left side of the negative heat sink plate See Figure F 19 Remove the gate leads from the control board plug P3 Remove plug P5 from the snubber board Also remove lead 224 from the positive output lead Remove lead 225 from the negative output lead Remove the green ground lead from
83. a putty knife or similar tool DO NOT SCRATCH THE SCR MOUNTING SURFACE Polish each heat sink s mounting surface using NO 000 fine steel wool Wipe surface clean with a lint free cloth or paper towel Inspect the mounting surfaces of each new SCR a Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the SCR mounting surfaces Apply a thin 0 001 to 0 003 layer of PEN 13 Lincoln Electric 2529 or PENETROX A heat sink compound to each heat sink s SCR mounting surface a Care must be used to prevent foreign material contamination of the SCR to heat sink junction Place the new SCR between the heat sinks Be sure that the outer metal ring of the SCR is facing toward the same heat sink as the old SCR s metal ring Be sure that the roll pin of the heat sink engages the hole in the SCR The SCR contact surfaces must sit flat against both heat sink surfaces Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC F 48 F 48 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 21 1 2 WIDE LEAF SPRING SPRING CURVATURE EXAGGERATED 1 2 lt 10 Go to the procedure below that matches your machine s cap screws NOTE WHICH THREAD IS ON YOUR CAP SCREWS BEFORE PRO
84. able from the K584 XX Adjust wire feed speed at the LN 7 and set the welding voltage with the OUTPUT CONTROL NOTE optional remote control is used place the OUTPUT CONTROL and the OUTPUT TERMI NALS switch in the Remote position IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 5 o 2 3 Return to Section TOC Return to Master TOC o 7 5 ACCESSORIES FIGURE C 8 LN 7 WIRE FEEDER CONNECTION TO THE IDEALARC DC 400 LN 7 WIRE FEEDER CONTROL CABLE 3 LN 7 INPUT CABLE PLUG 2 gt i 77 NEGATIVE POSITIVE TO WORK CONNECTING THE LN 7 TO THE IDEALARC DC 400 TERMINAL STRIP Disconnect main AC input power to the Idealarc DC 400 Set the Idealarc DC 400 POWER toggle switch to the OFF 0 position Connect the wire feeder control cable leads to the Idealarc DC 400 terminal strip as shown in Figure C 8 Connect the wire feeder control cable ground lead to the frame terminal marked m NOTE The DC 400 must be properly 5 grounded PERFORM THIS STEP ONLY IF THE LN 7 IS EQUIPPED WITH A METER KIT Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using A
85. achines are stacked Dripproof enclosure design permits outdoor operation Double dipped transformer SCR bridge and choke resist corrosion WELDING CAPABILITY The Idealarc DC 400 has the following duty cycle ratings If the duty cycle is exceeded a thermal pro tector will shut off the machine output until it cools to normal operating temperature The amber thermal protection indicator light will turn on until the machine cools Duty Cycle Amps Volts 100 400 36 60 450 38 50 500 40 Based on a 10 minute time period For example a 60 duty cycle means 6 minutes on and 4 minutes off LIMITATIONS The Idealarc DC 400 has no provisions for paralleling IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC Return to Master TOC B 4 OPERATION CONTROLS AND SETTINGS All operator controls and settings are located on the case front assembly See Figure B 1 for their loca tions FIGURE B 1 CASE FRONT CONTROLS 8 1 lt 5S Of gt CA gt 400 1 Power Source Pilot Light 8 Mode Switch 2 ON OFF Power Toggle Switch 9 Arc Control 3 Output Control Pote
86. anual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The machine has high welding out 1 If remote control is being used 1 Check the Output Control put and no control set the Output Control switch switch 52 and associated 52 in the OUTPUT CONTROL wiring 2 Check feedback leads 225 the weld output with the negative output terminal 205 machine Output Control poten and 4206 output shunt for tiometer R4 If the problem is f loose or faulty connections solved check the remote con See Wiring Diagram trol unit or wire feeder and Return to Section TOC Return to Master TOC associated control cable 3 Perform the SCR Diode Rec tifier Bridge Test 4 The control board may be faulty Replace Return to Section TOC Return to Master TOC o cy 8 2 2 2 1 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o PEN 2 EIS 2
87. ble from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine IDEALARC DC400
88. control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o E ci PEN 2 2 21 Return to Section TOC Return to Master TOC F 13 F 13 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Poor arc characteristics when welding in the constant voltage CV mode POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS 1 Make sure the correct weld pro cedures are being used Electrode Gas Etc 2 Check the welding cables for loose or faulty connections TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check reed switch CR3 for proper operation Switch should be normally open until weld current is established Remove plug P6 from the start board If problem is resolved the start board may be faulty Replace See Wiring Diagram Check the welding Mode switch S4 the microswitches and the associated wiring Check the output capacitors and connections A capacitor failure is indicated if the smal
89. crews with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn Tighten first cap screw 1 8 turn Tighten second cap screw 1 8 turn STOP wu gt Assembly now has the proper clamping force 9 Perform the Active SCR Test IDEALARC DC 400 LINCOLN 5 F 52 F 52 TROUBLESHOOTING amp REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS Return to Section TOC Return to Master TOC WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION
90. debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispostifis de s ret leur place IDEALARC DC 400 LINCOLN 5 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety ssi tiene ie Maddie ade reise ann el addled aes i iv Installation ial nen e E Section A Installation Section Table of lt A 1 Technical Speciications s irae o ea me t Pda d ne rd D nd bns A 2 Safety Precautiors diee ed ee he pe RC RR D a E e e A 3 Select Suitable Location Stacking Tilting m A 3 PU COMMOC HONS isis estes A 4 Reconnect Procedure iersinii xoa el pa e ER RU REOR He REA FERE A 6 Output uie Udo e aa e Foe ua HE or v dae A 7 Operation Section B Safety pbi Eta e Ea dad M pede a dE ERR Ld a e D E a pa B 2 General DeSCnptON sete sein hii td ted EN e ae e v d e e e b do eben B 3 Controls and 0 nennen enne nennen nnne nnne nennen enn nnns B 4 Welding OperdtiOnz ias veda d Fa B 6 Overload Protection e to Y aec ded e e ae Poe ada Ede P Pec o d B 9 E B 9 500 6
91. e arc will be softer and have 4 OUTPUT CONTROL SWITCH WITH LOCAL OR less spatter but may be more prone to sticking At REMOTE POSITIONS Selects the mode of con trol In the Local position control is by the machine control panel In the Remote position control is by either a wire feeder unit or through an optional remote control device maximum setting the arc will be more forceful and less prone to sticking but will produce more spat ter IDEALARC DC 400 LINCOLN 5 OPERATION 7 AUXILIARY POWER AND REMOTE CONTROL CONNECTIONS FOR WIRE FEEDER AND OTHER EQUIPMENT 115V AND 42V The 14 pin amphenol receptacle provides either 115 or 42 volts AC as well as remote control connec tions Terminal strips with screw connections are located behind the hinged control panel for hard wired control Only 115 volts AC is available on the terminal strip A strain relief connector is pro vided for cable entry 8 MODE SWITCH Selects between Constant Voltage FCAW GMAW and Constant Voltage Submerged Arc Red range on dial and Constant Current Stick TIG Blue range on dial 9 CONTROL five position switch that changes the pinch effect of the arc when in the CV FCAW GMAW mode It allows control of spatter fluidity and bead shape The Arc Control is set to provide optimum welding depending on the process position and electrode Pinch effect is increased by turning the control clockwise It can also be adjusted while
92. e connections See Figure C 1 The Multiprocess Switch has two sets of output termi nals You connect the wire feeder unit cables to the set of terminals on the left side of the box facing the front of the machine and the stick or air carbon arc cables to the set of terminals on the right side as shown in Figure C 1 When the Multiprocess Switch is in the Stick Welding Air Carbon Arc position only those terminals are energized The wire feeder nozzle or gun and elec trode are not electrically hot when in this mode Refer to installation instructions M17137 included with Multiprocess Kit for installation IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC Return to Master TOC C 3 C 3 ACCESSORIES Multiprocess Switch Operation The operation of the Multiprocess Switch is as follows A semiautomatic or automatic wire feed unit electrode and work cables are connected to the terminals on the left side of the box Stick or air carbon arc electrode and work cables are connected to the terminals on the switch With the switch in the left position the wire feed terminals are electrode negative In the center position the wire feeder terminals are electrode posi tive In both the left and center switch position the right side stick terminals are disconnec
93. e machine was in an open circuit condition no load and operating properly Note that each vertical division represents 2 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at SCR gate and cathode probe to gate probe to cathode SCOPE SETTINGS Volts Div 2V Div Horizontal Sweep 5 ms Div Coupling es DC Trigger Internal IDEALARC DC 400 LINCOLN 5 F 39 F 39 TROUBLESHOOTING amp REPAIR olo O 5 ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 8 5 CONSTANT VOLTAGE SUBARC ONE OUTPUT SCR NOT FUNCTIONING glg CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms This is NOT the typical DC output voltage waveform One output SCR is not functioning Note the gap in the waveform One SCR gate is dis connected to simulate an open or non functioning output SCR Each vertical division represents 20 volts and each horizontal division repre sents 5 milliseconds in time O10 Fle 515 5 2 1 Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling n DC Trigger Internal
94. ear louvers Keep dust dirt and other foreign materials that can be drawn into the machine to a min imum Failure to observe these precautions can lead to excessive operating temperatures and nuisance shut downs accessory such as a trailer or a gas cylinder Lift only with equipment of adequate lifting capacity Be sure the machine is stable when lifting Do not stack more than three high Do not stack the DC 400 on top of any other machine The Idealarc DC 400 weighs 473 pounds 215 kilo grams A permanent lift bail is located at the top of the machine positioned at the center of gravity for sta ble lifting TILTING Place the machine on a secure level surface Any sur faces you place it on other than the ground must be firm non skid and structurally sound STACKING Idealarc DC 400s may be stacked three high bottom machine must be on a stable hard level sur face capable of supporting the weight of up to three machines 1419 pounds 645 kilograms Be sure that the two pins in the roof of the bottom machine fit into the holes in the base of the machine above The lift bail is positioned so that it fits without interference under the base of the second machine IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE o 2 3 Return to Section TOC Return to Master TOC Q
95. eas of Block Logic Diagram are the subject of discussion IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 Fle 515 5 2 2 1 Return to Section TOC Return to Master TOC Return to Master TOC E 4 E 4 THEORY OF OPERATION PROTECTIVE DEVICES AND CIRCUITS Two thermostats protect the DC 400 from 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 coil will activate if the machine is overloaded The machine will not have output the amber thermal protection light will glow and the fan will continue to run The secondary thermostat located on the lead con necting the secondary coils together will open either with an excessive overload or insufficient cooling The machine will not have output the amber protection light will be on and the fan should continue to oper ate When the thermostats reset the amber protec tion light will be off Upon restart if the fan does not turn or the air intake louvers are obstructed the input power must be removed and the fan problem or air obstruction cor rected The DC 400 is also protected against overloads on the SCR diode bridge assembly through an electronic pro
96. ectrical Code and the manufacturer s recommendations IDEALARC DC 400 LINCOLN 5 Return to Master TOC Return to Master TOC Q 7 E Return to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Lescircuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter tou jours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un planch er metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat defonctionnement d jamais plonger le porte lectrode dans l eau pour le refroidir e jamais toucher simultan ment les parties sous ten Sion des porte lectrodes connect s deux machines so
97. epartment for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o ci PEN 2 EIS 2 1 Return to Section TOC Return to Master TOC F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine does not have maxi mum output Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make certain the correct three phase input voltage is being applied to the machine If remote control is being used set the Output Control switch S2 in the OUTPUT CONTROL LOCAL position and control the weld output with the machine Control potentiometer R4 If the problem is solved check the remote control unit or wire feeder and associated control cable RECOMMENDED COURSE OF ACTION 1 Check the Output Control potentiometer R4 Normal resistance is 10 000 ohms Also check associated wiring for loose or faulty connections See Wiring Diagram Check the welding Mode switch 54 the microswitches and the associated wiring Check the Output Control switch S2 and associated wiring See Wiring Diagram Perform the Main Transformer 5 Perform the SCR Diode Rec tifie
98. erminal c Move the work cable to the positive output terminal d Setthe VOLTMETER toggle switch to negative C 7 Set the OUTPUT CONTROL switch to the Remote position and the OUTPUT TERMINALS switch to the Remote position IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 7 5 ACCESSORIES 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 Set the POWER toggle switch to the OFF 0 posi tion 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 this hookup for negative polarity See Figure C 10 NOTE Welding cable must be sized for the current and duty cycle of the application 4 Connect the input cable K595 XX between the 14 pin amphenol on the DC 400 and the input cable plug on the LN 8 or LN 9 See Figure C 10 5 Set welder VOLTMETER switch to the desired polarity either DC or DC 6 Set the MODE switch to a CV constant voltage position 7 Adjust wire feed speed at the LN 8 or LN 9 and set the welding voltage with the WIRE FEEDER VOLTAGE CONTROL Place the OU
99. ermine to the best of your technical ability that the PC board is the most likely component caus ing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shield ing bag Wear an anti static wrist Aa ATTENTION strap For safety use a 1 Meg Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame ae If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Reusable Keep touching the frame to pre Container vent static build up Be sure not Do Not Destroy to touch any electrically live parts at the same time Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag f the PC Board uses protective s
100. es and precautions detailed throughout this man ual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will determine if the correct voltages are being applied to the primary windings of the Main Transformer T1 and induced on the secondary winding auxiliary windings and phase angle windings Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver IDEALARC DC 400 Wiring Diagram See Electrical Diagrams section of Manual O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B F 22 F 22 TROUBLESHOOTING amp REPAIR olo MAIN TRANSFORMER T1 VOLTAGE TEST continued 5 5 olg gt FIGURE 5 INPUT RECONNECT PANEL AND PRIMARY LEADS TO MAIN TRANSFORMER LOCATIONS c 5 2 INPUT SUPPLY INPUT RECONNECT CABLE ENTRY CONTACTOR PANEL OPENING CR1 ASSEMBLY LINCOLN 5 MAIN TRANSFORMER d LEADS d olo e o H 55 a gt 2 FRONT VIEW SIDE VIEW 5 Ld 2 8 olo TEST PROCEDURE O E 1 Set ON
101. ests incorrect check for loose or faulty wiring the wiring is good then the main transformer may be faulty Replace the main transformer Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fie E S9 FEE ele mlt 5 2 1 Return to Section TOC Return to Master TOC F 25 Plug P3 F 25 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 8 CONTROL BOARD PLUG P1 LOCATION Plug P1 DC 400 CONTROL G2588 X 201 Plug P1PHASE ANGLE WINDING VOLTAGES From Lead To Lead Expected VAC 201 204 21 VAC 202 204 21 VAC 203 204 21 VAC IDEALARC DC 400 LINCOLN 5 F 26 F 26 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Serv
102. ft side of the choke Remove the two leads from resistor R1 15 ohms 100 watts Remove the positive capacitor strap from the output shunt Remove the negative capacitor strap from the mode selector switch lead 204 from resistor R2 40 ohms 50 watts located on case back Remove leads 204 and 227 from resistor R3 7 5 ohms 100 watts located on case back 10 11 12 CAPACITOR BANK CASE BACK MOUNTING SCREW LIFT BAIL TRANSFORMER IRON MOUNTING BOLTS 4 Remove the sheet metal screw that holds the capacitor bank assembly to the case back This should enable the capacitor bank to be removed with the lift bail assem bly Using the 9 16 socket wrench remove the four bolts left and right mounting the lift bail to the transformer top and bottom irons Using the 9 16 socket wrench remove the four bolts flat washers and lock washers mounting the lift bail assembly to the base of the machine WARNING The transformer and choke assembly is now loose and free to slide or tip on the base ofthe machine 13 IDEALARC DC 400 LINCOLN 5 Remove the lift bail by lifting straight up and clear from the machine F 56 F 56 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 26 CHOKE REMOVAL CHOKE Return to Section TOC Return to Master TOC CHOKE LEADS GLASTIC STIFFENERS THRU BOLTS
103. g products 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 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 Also see item 1 b IDEALARC DC 400 LINCOLN 5 Return to Master TOC Return to Master TOC o 0 E Return to Master TOC WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheat
104. he connection diagram shown in Figure C 4 control cable leads 75 76 and 77 to shows the electrode connected for positive the matching 75 76 and 77 terminals polarity To change polarity on the terminal strip of the Idealarc DC a Set the Idealarc DC 400 POWER toggle m switch to the OFF 0 position 4 Connectthe wire feeder control cable ground lead b Move the electrode cable to the negative 1o the frane terminal manken output terminal NOTE The Idealarc DC 400 must be properly c Move the work cable to the positive output terminal d Set the VOLTMETER toggle switch to nega tive 6 Setthe DC 400 OUTPUT CONTROL switch to the Remote position and the OUTPUT TERMINALS switch in the Remote position Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 7 5 ACCESSORIES Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connec tion with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpose Keep the 21 lead electrically separate from N
105. horting jumpers don t remove them until installation is complete If you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Testthe machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all elec trical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o ci PEN 2 EIS 2
106. ice Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if an SCR or diode is shorted or leaky See the Machine Waveform Section in this manual for normal and abnormal output waveforms Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Volt Ohmmeter Multimeter 5 16 Nut driver Idealarc DC 400 Wiring Diagrams See the Electrical Diagrams section of this manual O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC O o Fie 91 5 ele 2 1 Return to Section TOC Return to Master TOC F 27 F 27 TROUBLESHOOTING amp REPAIR the machine With the 5 16 nut driver remove the case top and sides STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE F 9 CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS olo P P 55 514 DC 400 CONTROL oz G2588 X M15370 X SNUBBER 2 2 5 2 2 8 TEST PROCEDURE 1 Disconnect the main input supply power to Locate and remove molex plug P5 from the snubber board See Figure F 9 Rotate the mode switch S4 to the constant current CC position 3 Discon
107. in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo o 5 5 o PEN 9 gt g 8 mlt 5 5 1 Return to Section TOC Return to Master TOC Return to Master TOC F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure l Det
108. ing and create a fire hazard 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode i If damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the
109. ing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when
110. l vent plug on top of a capacitor is raised or blown out WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body Clean up vented electrolyte using rubber gloves and a water damped cloth Any elec trolyte which gets on skin clean with soap and water CAUTION If for any reason you not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o ci PEN 2 2 EIS 2 cc 1 Return to Section TOC Return to Master TOC F 14 F 14 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The Arc Force control R5 has no effect on the arc Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS The Arc Force control is active only in the Stick Mode The effect of the Arc Force con trol will be less noticeable at high welding currents Weld at low currents less than 150 amps and check the Arc Force control function RECOMMENDED COURSE OF ACTION Check the Arc Force control potentiometer R5 for correct resistance
111. larc DC 400 OUTPUT CONTROL switch in the Local position b LN 9 Refer to the LN 9 Operator s Manual for instructions on how to use the LN 9 C LN 25 Refer to the LN 25 Operator s Manual for instructions on how to use the LN 25 d LN 742 Refer to the LN 742 Operator s Manual for instructions on how to use the LN 742 OVERLOAD PROTECTION The power source is thermostatically protected with proximity thermostats against overloads or insufficient cooling One thermostat is located on the nose of the center bottom primary coil A second thermostat is attached to the lead connecting the secondaries If the machine is overloaded the primary thermostat opens the output becomes zero and the amber thermal pro tection light comes on The fan will continue to run The secondary thermostat opens with either an exces sive overload or insufficient cooling The output becomes zero and the amber thermal protection light comes on When the machine cools the thermostats reset and the thermal protection light goes off The power source is also protected against overloads on the SCR bridge asssembly through an electronic protection circuit This circuit senses an overload on the power source and limits the output to 550 amps by phasing back the SCRs The Idealarc DC 400 also has self restoring fusing to prevent damage to the machine in the event of an accidental grounding of the remote control leads 75 76 or 77 AUXILIARY POW
112. ld consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source IDEALARC DC 400 LINCOLN B Return to Master TOC Return to Master TOC o 7 E Return to Master TOC SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wear
113. m 400 Amp 100 Duty Cycle WIRE FEEDER CONNECTIONS See the Accessories section of this manual for spe cific instructions on connecting the following semi automatic and automatic wire feeders to the Idealarc DC 400 Automatic Wire Feeders NA 3 NA 5 Semi automatic Wire Feeders LN 7 LN 8 LN 9 LN 25 LN 742 CONNECTIONS FOR STICK TIG OR AIR CARBON ARC CUTTING OPERA TIONS WARNING The output terminals are energized at all times when the Idealarc DC 400 is used for stick TIG or air car bon arc cutting 3 0 3 0 85 mm 85 mm 2 0 2 0 67 mm 67 mm 3 0 3 0 4 0 85 mm 85 mm 107 mm 3 0 3 0 4 0 85 mm 85 mm 107 mm The work and electrode cables for stick TIG or air carbon arc cutting are connected as described ear lier under the heading Output Connections A TIG torch is connected to the electrode terminal of the welder Select cable size according to Table A 1 WARNING Do not connect TIG torch and stick electrode cable at the same time They will both be electrically HOT If the Idealarc DC 400 is already set up for wire feeder operation all wire feeder unit control electrode and work cables must be disconnected first before you can connect the cables for stick TIG or air carbon arc operation However the Idealarc DC 400 can be used for both wire feeder operation and stick TIG air carbon arc operation if a K804 1 Multiprocess Switch is used See
114. n arc torch User supplied 4 0 107 mm jumper IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o He o 2 3 Return to Section TOC Return to Master TOC 7 5 ACCESSORIES REMOTE OUTPUT CONTROL K857 WITH K864 ADAPTER PLUG OR K775 The K857 has a 6 pin MS style connector The K857 requires a K864 adapter cable which connects to the 14 pin connector on the machine An optional remote output control is available This is the same remote control that is used on the Lincoln and DC 600 power sources 775 The K775 consists of a control box with 28 ft 8 5m of four con ductor cable This connects to terminals 75 76 and 77 on the terminal strip and the case grounding screw marked with the symbol 77 the machine These terminals are located behind the control panel on the front This device will give the same control as the out put control on the machine REMOTE CONTROL ADAPTER CABLE K864 A V cable 12 inches 30 m long to connect a K857 Remote Control K812 Hand Amptrol or K870 Foot Amptrol 6 pin connector with a wire feeder 14 pin connector and the machine 14 pin connector If a remote control or amptrol is used alone the wire feed er connection is not used See Figure C 3 AMPTROL ADAPTER CABLE K843 A five wire
115. n this equipment Do not touch electrically hot parts Auxiliary power for wire feeder operation is available at both a 14 pin amphenol and at terminal strips with screw type connections located behind the hinged control panel on the front of the machine The 14 pin amphenol can provide both 115 VAC pins A and J and 40 42 VAC pins and The terminal strip pro vides 115 VAC only terminals 31 and 32 The two cir cuits are isolated and each is protected by a 104A cir cuit breaker The following descriptions show how to connect the wire feeders using either the 14 pin amphenol or the terminal strip NOTE The LN 742 wire feeder because it operates on 42 VAC can be connected only to the 14 pin amphenol AUTOMATIC WIRE FEEDERS CONNECTING THE NA 3 TO THE IDEALARC DC 400 TERMINAL STRIP l Disconnect main AC input power to the Idealarc DC 400 2 Set DC 400 POWER toggle switch to the OFF 0 position 3 Connectthe wire feeder control cable leads to the Idealarc DC 400 terminal strip as shown in Figure Connect the wire feeder control cable ground lead to the frame terminal marked 777 NOTE DC 400 must be properly grounded IDEALARC DC 400 LINCOLN 5 ACCESSORIES FIGURE C 4 NA 3 WIRE FEEDER CONNECTING THE NA 5 TO THE CONNECTION TO THE IDEALARC DC 400 IDEALARC DC 400 TERMINAL STRIP NA 3 WIRE l Disconnect main AC input power to the Idealarc FEEDER DC 40
116. name suggests the SCR is a rectifier so it passes current only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more pos itive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state The amount of time spent in the ON state is controlled by the gate I LATER IN THE CYCLE I THE SCR OUTPUT I IS DECREASED 1 An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard PN junc tion between gate and cathode the voltage between these terminals must be slightly greater than 0 6V Once the SCR has fired it is not necessary to contin ue the flow of gate current As long as current contin ues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC sup ply voltage passes through zero into the negative por tion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output IDEALARC DC 400 LINCOLN 5 Sec
117. ne IDEALARC DC400 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 0 gt 22 1 Return to Section TOC Return to Master TOC G 9 Snubber PC Board M15370 Schematic ELECTRICAL DIAGRAMS G 9 18961 5 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED DIODES 1 AMP 400 VOLT UNLESS OTHERWISE SPECIFIED OP AMPS LM124 UNLESS OTHERWISE SPECIFIED V COMMON CONNECTION 221 204 222 223 220 225 rH 224 2 8 3 4 1 5 7 6 J5 J5 Ns J5 lis J5 J5 ar e 1 C1 1 C2 1 J 068 1 068 068 d 2 400V 2 400V 400V 2 160 600V 164 05 e e J 2 ow ow Zlow VL 160 10 10 10 150V 05 320V TP6 C5 TP5 e N e T2 130 130V 38 38 130V 38J 3 8 91G MISC USE SNUBBER SCHEMATIC S 19687 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not availa
118. ne if the device can be gated ON and conduct current from anode to cathode ala ec MATERIALS NEEDED An SCR tester as specified in this procedure 5 16 Nut driver Idealarc DC 400 Wiring Diagrams See the Electrical Diagrams section of this manual O10 515 gt 2 oO 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B F 30 F 30 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 13 SNUBBER BOARD PLUG P5 LOCATION FIGURE F 12 CONTROL BOARD PLUG P1AND P3 LOCATIONS Return to Section TOC Return to Master TOC DC 400 CONTROL G2588 X M15370 X SNUBBER Return to Section TOC Return to Master TOC FIGURE F 14 RESISTOR R2 LOCATION O o e 91 5 9 9 2 1 TEST PROCEDURE 1 Disconnect the main input supply power to the machine from the control board See Figure F 12 Locate and remove molex plug P5 from the snubber board See Figure F 13 2 With the 5 16 nut driver remove the case Rotate the mode switch S4 to the constant olo top and sides Remove the screws holding current CC position Locate and remove lead 204 from resistor 55 3 Disconnect the welding cables from the R2 40 ohms 50 Watts See Fig
119. nect the welding cables from the Locate and remove lead 7204 from resistor welding output terminals R2 40 ohms 50 Watts See Figure F 10 4 Locate and remove molex plugs P1 and P3 from the control board See Figure F 9 FIGURE F 10 RESISTOR R2 LOCATION IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 10 gt 2 1 Return to Section TOC Return to Master TOC F 28 F 28 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE F 11 HEAT SINK AND SCR TEST POINTS INSULATING PAINT 8 Remove the red insulating paint from the 10 11 heat sink test points See Figure F 11 NOTE Do not disassemble the heat sink Measure the resistance from the anode to the cathode of SCR 1 using an analog volt ohmmeter multimeter set at R x 1000 scale See Figure F 11 a Reverse the meter leads and measure the resistance from the cathode to the anode of SCR 1 See Figure F 11 b If a low resistance is measured in either meter polarity SCR1 is faulty Replace SCR 1 Test the resistance of SCR 2 and SCR 3 using the same procedure described in Step 9 Measure the resistance of diode D1 from anode probe to cathode probe using an analog ohmmeter set at R x 1000 scale The resistance should be low See Figure F 11 I
120. ng is not cocked in the housing See Figure F 24 Heat sinks may not be exactly as pictured HOUSING LEAF SPRING CAP SCREW IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 gt elg 1 Return to Section TOC Return to Master TOC F 51 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREWS NOTE This procedure can only be used with 1 4 28 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn STOP A W Assembly now has the proper clamping force 9 Perform the Active SCR Test AFTER REPLACING THE SCRs Follow the steps in the SCR Diode Rectifier Removal and Replacement procedure to reassemble the machine CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap s
121. ntiometer 10 Thermal Protection Indicator Light 4 Output Control Switch with Local or Remote positions 11 DC Ammeter 5 Output Terminals Switch with On or Remote positions 12 DC Voltmeter 6 Arc Force Selector for CC stick or TIG processes only 13 Voltmeter Electrode or Electrode Switch 7 Auxiliary Power Connections for Wire Feeder and Other Equipment 115V and 42V 1 POWER SOURCE PILOT LIGHT This light indi 5 OUTPUT TERMINALS ON OR REMOTE cates that the power source input contactor is SWITCH When in the Remote position leads energized closed This also means that the main 2 and 4 have to be jumpered externally to ener power transformer and all auxiliary control trans gize the output terminals When in the ON posi formers are energized tion this switch internally jumpers leads 2 and 4 2 ON OFF POWER TOGGLE SWITCH Energizes 1e output or de engergizes the input contactor which is pow 6 ARC FORCE SELECTOR Allows you to select ered by the 115 volt auxiliary transformer The the ideal arc force according to the procedure and switch turns the machine ON or OFF Position I electrode being used for CC stick or TIG welding is ON position 0 is OFF It controls the amount of current added to the 3 OUTPUT CONTROL POTENTIOMETER Con when the electrode to the trols voltage in CV mode and current in CC mode ni Mannu Seng WO Extra circuit current is added Th
122. nvalidate 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 malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into two main categories Output Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJ USTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to
123. o Master TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC A 6 INSTALLATION RECONNECT PROCEDURE Multiple input voltage welders are shipped connected for the highest voltage listed on the machine s rating plate Before installing the welder be sure the recon nect panel is connected for the proper voltage CAUTION Failure to follow these instructions can cause immedi ate failure of components in the welder To reconnect a multiple voltage machine to a different voltage remove input power Follow the input con nection diagram located on the inside access panel cover appropriate for your machine s input voltage These same connection diagrams are shown below For 208 208 230 amp 230 460 volts AC see Figure A 4 For 230 460 575 volts AC see Figure A 5 FIGURE INPUT CONNECTION DIAGRAM FOR 208 208 230 and 230 460 VOLTS 50 60 HZ A WARNING HIGH VOLTAGE CAN KILL Do not operate with covers Do not touch electrically live parts remove e Disconnect input power before e Only qualified persons should install on t servicing use or service this equipmeni DUAL VOLTAGE MACHINE INPUT SUPPLY CONNECTION DIAGRAM IMPORTANT CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS CONNECTION FOR HIGHEST RATING PLATE VOLTAGE 50 OR 60 HZ
124. o the heat sink mounting surface Return to Section TOC Return to Master TOC a Do not apply compound to the diode stud or mounting threads b The diode threads must be clean and free of defects so that the nut can be fin ger tightened before applying torque A slip type torque wrench must be used to tighten the diode nut 8 Tighten the diode nuts to the specifications in the following table O10 Fle 515 5 2 1 a Startthe nuts for diodes with steel studs by hand and then torque them accord ing to the following table b Run the nuts for diodes with copper studs on all the way by hand then torque them according to the following table c Turn the nuts a minimum of 1 2 turn more while torquing 9 Install the case top and sides Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 54 F 54 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test proced
125. o the main trans former Return to Section TOC Return to Master TOC 11 Install the machine case top and sides O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B F 61 F 61 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine fitis rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR If you repair or replace any electrical components Return to Section TOC Return to Master TOC INPUT IDLE AMPS AND WATTS Input volts Phase Hertz Maximum Idle Amps Maximum Idle KW 200 3 60 208 3 60 220 3 60 230 3 60 380 3 60 400 3 60 415 3 60 440 3 60 460 3 60 500 3 60 575 3 60 Return to Section TOC Return to Master TOC 200 3 50 220 3 50 230 3 50 380 3 50 400 3 50 415 3 50 440 3 50 500 3 50 Constant Current 54 58 Constant Current 51 55 olo o 5 5 PEN 9 gt g 8 mlt 5 2 1 Constant Voltage 42 5 46 5 FCAW GM AW 42 5 46 5 Constant Voltage 43 5 47 5 SUB ARC 43 5 47 5 Auxiliary Output 431 3332 114 124 Auxiliary Output 31 32 109 119 Auxiliary Output 241 342 43 8 47 5 Auxiliary Output 241 342 42 0 45 6 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 62 F 62 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR c
126. obes Be sure that neither the alligator clip nor the meter probe touches any metal surfaces c Connect the other meter probe to the 3231 connection top lead at the power switch See Figure F4 d Apply input power to the DC 400 Read the meter for 115VAC a If 115VAC is present the control trans former is functioning properly b If 115VAC is NOT present go to Step 8 8 IDEALARC DC 400 LINCOLN 5 FIGURE F 4 CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS INSULATED ALLIGATOR CLIP CABLE INPUT CONTACTOR CASE BACK If 115VAC is not present between leads X1 and 7231 check the spliced connection between 231 and X2 Test for correct main input supply power to the control transformer primary windings H1 H2 H3 etc Check the main input supply power hookup to the machine See the Wiring Diagram If the correct main input supply power to the control transformer primary windings is present AND the secondary voltage is not correct the control trans former may be faulty Replace F 21 F 21 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety not
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128. on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 6 some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot a ELECTRIC AND MAGNETIC FIELDS N may 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 EMF fields may interfere with some pacemakers and welders having a pacemaker shou
129. ond cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn STOP A W Assembly now has the proper clamping force 7 Perform the Active SCR Test IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC F 50 PROCEDURE FOR THE F 50 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 23 HOUSING AND PRESSURE PAD FOR 5 8 WIDE LEAF SPRING STEEL PRESSURE PAD HOUSING FIGURE F 24 CLAMP ASSEMBLY 5 8 INCH WIDE SPRING 1 Insert cap screws through the leaf spring Place the steel pressure pad in the housing Insert cap screws and leaf spring into plastic Insert the clamp assembly through the heat Reinspect the SCR for proper seating Place a piece of sleeving around each cap HEX NUT screw The leaf spring is flat so the orientation of the leaf spring does not matter HEAT SINK with the 1 8 inch wide standoff facing up See Figure F 23 housing being sure that the steel pressure pad remains in position Pressing on the cap screw heads should produce a rocking action of the spring in its housing HEAT SINK sinks Install nuts Tighten the clamp nuts equally on the cap screws until finger tight Be sure that the leaf spri
130. ontinued MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MINIMUM OUPUT SETTINGS Mode Control Settings Load Constant Current Output Control and Arc Force Under 70 Amps 0 to 3 Volts Control at Minimum Return to Section TOC Return to Master TOC Constant Voltage Output Control at Minimum 120 Amps 6 to 12 Volts FCAW GM AW MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT SETTINGS Mode Control Settings Load Constant Current Output Control at Maximum 525 Amps 9 41 5 Volts Min Constant Voltage Output Control at Maximum 525 Amps 9 41 5 Volts Min FCAW GM AW Return to Section TOC Return to Master TOC Constant Voltage Output Control at Maximum 525 Amps 9 41 5 Volts Min SUB ARC O o 5 5 o PEN 9 gt 818 5 5 cc a Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Su TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION o 5 o Electrical Diagram Section Section G Wiring Diagram Codes 9847 9848 G 2 Wiring Diagram Code 9850 G 3 Control PC Board 22588 4 Starting PC Board M14520 Layout G 5 Snubber PC Board M15370 G 6 Control PC Board G2588 Schematic G 7 Starting PC Board M
131. r Bridge Test 6 The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o E E cy PEN 2 EIS 2 a Return to Section TOC Return to Master TOC F 10 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine will not shut off when the power switch is put in the OFF position POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 Make sure the three phase input lines are connected cor rectly to the DC 400 TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the Input Power switch 51 and the associated leads See Wiring Diagram 2 Perform the Input Contactor The Arc Control switch 55 has no effect in CV FCAW GMAW mode when welding with the short circuit transfer process 1 Make sure the correct process and gas are being used Check the Arc Control switch 5 for proper operation Check the welding Mode switch 54 the microswitches and the associated wiring
132. ram NOTE Unused leads should be taped a Inspect for broken or incorrect con nections IDEALARC DC 400 LINCOLN 5 LEAD X1 CONNECTION Locate control transformer leads X1 top and X2 a Lead X1 is connected to the input con tactor CR1 coil located on the input side of the contactor See Figure F 3 b Lead X2 is spliced into lead 231 See the Wiring Diagram Lead 231 is connected to the power switch S1 Remove five machine screws holding the control panel to the case front and tilt the panel forward to access the power switch and Lead 231 connec tion See Figure 4 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to Master TOC o 7 5 F 20 F 20 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continued MACHINE FRONT CONTROL PANEL 6 7 LEAD 231 CONNECTION METER PROBE RIGHT SIDE VIEW Test for 115VAC between leads X1 and 231 NOTE If the main AC input supply voltage varies the control transformer voltage will vary by the same percentage a Connectone end of an insulated alliga tor clip to the X1 connection at the input contactor CR1 coil See Figure FA b Connect the other end of the alligator clip to one of the meter pr
133. rimary coils one on each of the three legs of the bottom iron 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 520728 on top of each of the three primary coils The longer side of the insulation should be placed toward the front of the machine See Figure F 29 for the location of this insulation 5 Place the three secondary coils on top of the insu lation installed in Step 4 The leads should come out at the front of the machine with the short leads on top See F 28 for proper positioning 6 Insert shims Lincoln Electric part number C1001250 or C1000317 between the secondary coil sides and the iron assembly on either side of the legs See Figure F 29 PRIMARY COIL LEADS 7 Place insulation Lincoln Electric part number 520728 top of each of the three secondary coils The longer side of the insulation should be placed toward the front of the machine where the secondary start and finish leads come out See Figure F 29 8 Install the three top primary coils noting which is right left and center Leads should come out at the back of the machine See Figure F 28 for prop er positioning The coils must be in correct position left center right 9 Install the top iron lamination and choke assem bly With the 9 16 deep
134. rol constant current mode only and the Output Control or remote control with the feedback information and sends the appropriate gate firing signals to the SCR diode bridge A dry closure of leads 2 and 74 either at the termi nal strip or the 14 pin amphenol signals the control board to apply gate firing signals to the SCR Diode Bridge which creates a DC voltage at the output of the bridge assembly If the Mode Switch is in the constant voltage FCAW GMAW mode this DC voltage is fil tered by the Output Capacitors SCR DIODE HYBRID BRIDGE FEEDBACK NEGATIVE OUTPUT TERMINAL gt POSITIVE TERMINAL REED SWITCH The heavy current carrying portion of the Mode Switch is connected between the output choke which stores energy and provides current filtering and the negative output terminal Depending upon the mode selected different portions of the choke are needed In the constant current mode CC the entire choke is connected into the welding output cir cuit When constant voltage CV is required only part of the choke is utilized The starting circuit board function is to momentarily change the inductance effect that the choke has on the welding circuit This is accomplished by changing the amount of pinch or arc control windings that are active in the output choke When weld current is established the reed switch closes and the start board becomes inactive NOTE Unshaded ar
135. rting work It is important that you follow these operating steps each time you use the machine 1 Turn on the main AC input power to the machine 2 Set the VOLTMETER or switch to the appropriate position Set toggle to Electrode Negative position if the electrode is connected to the negative output terminal Settoggle to Electrode Positive position if the electrode is connected to the positive output terminal 3 Setthe welding MODE switch to welding process being used CV FCAW GMAW CV Submerged Arc CC Stick Tig 4 Set the OUTPUT CONTROL switch to Local Exception when using an LN 9 LN 9 GMA or NA 5 wire feeder set the switch to Remote Otherwise the wire feeder may automatically shut down 5 Set the OUTPUT TERMINALS switch to the desired mode 6 Setthe ARC FORCE CONTROL to midrange 5 6 This control is for CC stick or TIG welding only Adjust for best characteristics as necessary 7 Setthe ARC CONTROL to midrange 3 This con trol is for CV FCAW GMAW welding only Adjust as necessary for best pinch control 8 Set the ON OFF POWER toggle switch to the ON position 1 The power source pilot light glows The fan starts 9 SetOUTPUT CONTROL potentiometer to desired voltage or current 10 Make the weld REMOTE CONTROL The toggle switch on the control panel labeled Output Control Remote gives you the option of controlling the machine output from
136. s the contacts Zero ohms or very low resistance is normal See Figure Remove Me F 2 If the resistance is high the input con input contactor coil 233 and X1 232 See Figure F 1 for location tactor is faulty Replace the input contactor 5 When the contactor is NOT activated the resistance should be infinite or very high across the contacts Ifthe resistance is low the input contactor is faulty Replace the input contactor 3 Using the external 120VAC supply apply 120VAC to the terminals of the input con tactor coil If the contactor does NOT acti vate the input contactor is faulty Replace the input contactor O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 18 F 18 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Depar
137. sistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in gaining access to the fan blade and fan motor for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 8 Wrench Allen head type wrench O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Q O 2 3 tc Return to Master TOC F 43 F 43 TROUBLESHOOTING amp REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continued FIGURE F 18 FAN MOTOR MOUNTING DETAILS to the motor must be disconnected This will require cutting the wires or breaking the splice SHROUD ATTACHED TO CASE BACK olo ae 55 a gt 2 2 dO MOUNTING BRACKETS PROCEDURE 1 Remove the main input supply powerto the Remove the four mounting nuts and associ machine ated flat and lock washers that hold the olo 2 Using the 5 16 nut driver remove the case ibn aee Figure gie top and sides e 5 5 3 The fan blade can be removed using the 9 8 Allen head wrench To replace the fan motor mount the motor to 2 es NOTE You may need to loosen the its mounting bracket using the four nut and associated flat and lock washers ele machine case
138. t pass is closed and after the switch is open the above tests 22 Replace all molex plugs onto the control board and snubber board Reconnect lead 3004 to resistor R2 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 33 F 33 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE NO LOAD Return to Section TOC Return to Master TOC CH1 0 volts Return to Section TOC Return to Master TOC 50 volts 2ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal divi sion represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal O10 515 10 gt 2 1 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN 5 F 34 F 34 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE FCAW GMAW MAXIMUM OUTPUT SETTING NO LOAD Return to Section TOC Return to Master TOC CH1
139. t un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de la faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fum es toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment roxique ou autres produits irritants PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFOR MATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la
140. t where the wire tends to blast off If the voltmeter pointer hesitates before coming up to the desired voltage the Open Circuit Voltage Control is set too low This can cause the elec trode to stub C Set NA 3 Start Board current and voltage as close to the welding procedure current and voltage as possible NOTE The Start Board current and voltage should be as close as possible to the welding procedure current and voltage while still getting satisfactory starts d Setthe start time to as low a time as possible while still getting satisfactory starts Start and make the weld NA 5 AUTOMATIVE WIRE FEEDER When using the Idealarc DC 400 with the NA 5 wire feeder set the controls on the Idealarc DC 400 as fol lows for the best performance 1 Turn OFF main AC input powerto the Idealarc DC 400 Connect the electrode cables to the terminal polarity to be used Set the VOLTMETER or switch to the same polarity as the electrode cable connection Set the OUTPUT CONTROL switch to Remote Setthe OUTPUT TERMINALS switch to Remote Set the Idealarc DC 400 welding MODE switch to the position that matches the welding process being used a For submerged arc welding set welding MODE SWITCH TO CV SUBMERGED ARC position b Forall open arc welding processes set weld ing MODE switch TO CV FCAW GMAW posi tion Set the ARC CONTROL to midrange 3 welding starts adjust as necessary After LN
141. tant Current 60 to 500 Amps 57 VDC 115 VAC 10 Amps Constant Voltage 60 to 500 Amps 45 5 VDC 42 VAC 10 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Input Wire Size Ground Wire Size Input Voltage Fuse Input Ampere Type 75 Type 75 Frequency Super Lag Rating on Copper Wire in Copper Ground or Breaker Size Nameplate Conduit AWG Wire in Conduit Volts Hz Sizes AWG IEC Sizes 208 60 230 60 460 60 220 50 60 230 50 60 380 50 60 400 50 60 440 50 60 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o He o 2 3 Return to Section TOC Return to Master TOC o 5 3 A 3 INSTALLATION Read this entire installation section before you LIFTING start installation WARNING SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury A WARNING Do not lift this machine using the e ELECTRIC SHOCK can kill lift bail if it is equipped with a heavy 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 equipment SELECT SUITABLE LOCATION Place the Idealarc DC 400 where clean cooling air can flow freely in through the front louvers and out through the r
142. tection circuit located on the control board This circuit senses an overload on the power source and limits the output to 550 amps by phasing back the SCRs A circuit is also provided to protect the circuitry from accidental grounds If the external remote control leads 75 76 or 77 are accidentally connected to the positive output welding lead the DC 400 output will be reduced to a low level thus preventing damage to the machine If an erroneous connection is made between the remote control leads and the negative output welding lead the control board self restoring fuses will blow preventing damage to the machine IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 Fle 515 5 1 Return to Section TOC Return to Master TOC Return to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 4 SCR Operation INPUT PULSE IS APPLIED OUTPUT 1 NOTE AS THE GATE ANODE SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large currents 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 from anode to cathode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cathode thus the device acts like an open switch As the
143. ted In the right switch position the wire feed terminals are discon nected from the DC 400 and the stick terminals con nected The polarity of the stick terminals is marked on the end of the box To change polarity the elec trode and work cables must be interchanged In the stick position the stick terminals are energized at all times Connections For those applications where it is not necessary to have separate work cables for stick and semiautomat ic welding If both stick and semiautomatic welding is done on the same workpiece only one work cable is required To do this connect a 4 0 107 mm jumper from the work terminal on the semiautomatic side to the terminal to be used for work on the stick side The work cable from the semiautomatic side then serves as the work cable for both semiautomatic and stick welding See Figure 2 To change stick polarity reverse the leads at the and terminals on the right side of the Multiprocess S witch NOTE When a DC 400 equipped with Multiprocess Switch is mounted on an undercarriage the undercarriage handle in the resting position can hit the case of the Multiprocess Switch This does no harm but if the user desires a 1 4 or 3 8 bolt and nut may be placed in the hole in the undercarriage tow bar to limit the travel of the undercarriage handle FIGURE C 2 SINGLE WORK CABLE WITH JUMPER To semi auto or auto equipment To stick electrode holder or air carbo
144. tion F 1 Section F 1 TABLE OF CONTENTS 3 TROUBLESHOOTING amp REPAIR SECTION 5 3 Troubleshooting amp Repair 01 meme Section F e How to Use Troubleshooting F 2 PC Board Troubleshooting Procedures eene enne F 3 9 Troubleshooting GUIE screena F 4 F 14 Test Procedures TESE ale Fanaa F 15 Control Transformer T2 Voltage F 18 Main Transformer T1 Voltage Test eem emen F 21 Static SCR Diode Rectifier Bridge 5 emen F 26 Active SCR hte lied ele et beri Ene t n a dn F 29 Oscilloscope Waveforms mene nnne enne F 33 gt Normal Open Circuit Voltage Waveform Constant Current F 33 Normal Open Circuit Voltage Waveform Constant Voltage FCAW GMAW F 34 5 Normal Open Circuit Voltage Waveform Constant Voltage 5 F 35 a Typical Output Voltage Waveform Constant Voltage F 36 Typical Output Voltage Waveform Constant Voltage F 37 2 Typical SCR Gate Voltage Waveform Constant Voltage F 38 Abnormal Open Circuit Voltage
145. tment for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will determine if the correct voltage is being applied to the primary of the control transformer and induced on the secondary winding of the control transformer MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver IDEALARC DC 400 Wiring Diagrams See the Electrical Diagrams section of this manual Return to Section TOC Return to Master TOC O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 gt 2 1 Return to Section TOC Return to Master TOC F 19 F 19 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continued FIGURE F 3 CONTROL TRANSFORMER AND LEAD LOCATIONS INPUT CONTACTOR LEAD X2 CONNECTION SPLICED TO LEAD 231 TEST PROCEDURE 1 Disconnect the main input supply power to the machine With the 5 16 nut driver remove the top case sides and lower the front control panel Locate the control transformer T2 on the left side of the input box facing the back of the machine See Figure F 3 Locate the control transformer primary leads H1 H2 etc See the Wiring Diag
146. tor lead and shunt to the positive heat sink plate See Figure F 19 Install the glastic stiffeners to the left and right sides See Figure F 19 Install the case top and sides F 46 F 46 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the SCRs from the output rectifier heat sink for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED NO 000 Fine Steel Wool Penetrox A 13 Lincoln E2529 or Penetrox A 7 16 Open end wrench Allen head type wrenches O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Return to Section TOC
147. ud MEDIE E ME Section C Maintenance eT Section D Safety Precautloris deco conet reda dr edt c eaa ed a cie dd RP Rd D 2 Routine and Periodic Maintenance eene nennen nnns D 2 General Component nennen nens D 3 Theory of Operation 0 2202 n d cat ied ad Section E Troubleshooting and 0 Section F How To Use Troubleshooting F 2 EE F 4 cingere F 15 Oscilloscope Baie dee eae th aioe F 33 Replacement ote F 40 Retest After R pall n de a ba F 61 Electrical Diagrams deron doeet rei sd Poi a de Wa d eh i EE aad Section G Parts Manual ee iei Doa eda ED hd ee CU ere reb deae rid P 234 IDEALARC DC 400 LINCOLN 5 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION o O 5 i Installation 3 Technical Specifications Idealarc 02 400 uscite A 2 2 9 Input and Output Specifications 1 eee ee eee eene A 2 Cable and Fuse 512 eene enne enne nnne nennen nennen nnne A 2 Physical DIMENSIONS
148. uder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enroule le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc C Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie d tincelles 10 Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement e
149. ure F 14 9 welding output terminals 4 Locate and remove molex plugs P1 and ele 82 dc IDEALARC DC 400 LINCOLN 5 F 31 IDEALARC DC 400 LINCOLN 5 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 15 HEAT SINK TEST POINTS INSULATING REMOVE PAINT NOTE Do not disassemble the heat sinks 8 Remove the red insulating paint from the heat sink test points See Figure F 15 F 31 NOL 0 901 49159 0 901 J91Se N uunjeH 901 J91Se N 01 UuunjeH DOL uonoes oj DOL uonoes DOL uonoes oj uumeg DOL uonoes F 32 F 32 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 16 SCR TESTER CIRCUIT AND SCR CONNECTIONS ANODE Return to Section TOC Return to Master TOC swi R2 OE pe 6VOLT LANTERN R1 4 ohms 10 watts CATHODE BATTERY sch X e R2 3 ohms 10 watts UNDER c TEST To test SCRs construct the circuit outlined above Resistor values are plus or minus LEADS ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC 912 eT AE lt gt gt gle 9 Construct the circuit shown in Figure F 16 b Ifthe voltage is 3 6 volts only when the One 6 volt lantern battery can be used Set switch is closed or if there is no voltage voltmeter scale low
150. ures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main transformer for mainte nance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 9 16 Socket wrench 9 16 Box end wrench 1 2 Socket wrench 1 2 Box end wrench 3 8 Nut driver or socket wrench 9 16 Deep well socket wrench O10 515 gt 2 oO 1 Return to Section TOC Return to Master TOC IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC F 55 F 55 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 25 LIFT BAIL REMOVAL TRANSFORMER MOUNTING BOLTS 4 REMOVAL OF LIFT BAIL 1 Remove Remove the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Remove the two fiber baffles from the left and right sides of the lift bail adjacent to the main transformer See Figure F 25 Remove the fiber baffle from the le
151. ve plug P3 SCR gate leads from the control board If the problem disappears the control board may be faulty Replace If the output terminals are still electrically hot per form the SCR Diode Rectifier Bridge Test 4 The snubber board may be leaky Check or replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o ci 91 5 2 2 EIS 2 1 Return to Section TOC Return to Master TOC F 12 F 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Poor arc striking when using semi automatic or automatic wire feeders Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS 1 Make sure the correct weld pro cedures are being used Electrode Gas Etc 2 Check the welding cables for loose or faulty connections RECOMMENDED COURSE OF ACTION 1 Check reed switch CR3 for proper operation Switch should be normally open until weld current is established 2 The start board may be faulty Replace 3 The
152. voltage is present for all three phases proper main input supply volt age is being supplied If proper voltage is not present in any or all of the three phases check input fuses and leads 9 Test with an AC voltmeter for proper main input supply voltage from the output side of the input contactor CR1 See the Wiring Diagram T1to T2 b T2to T3 T1to T3 10 Read the meter a If proper voltage is present for all three phases the input contactor is working properly If the proper voltage is not present for any or all of the three phases the input contactor may be faulty Replace the input contactor IDEALARC DC 400 LINCOLN 5 ly 42VAC across each of the three main secondary start leads located at the SCR Diode Rectifier Bridge Remove the red insulating paint to achieve good con tact if necessary See Figure F 6 See the Wiring Diagram If one or more of the above voltage tests are incorrect check for loose or faulty connections b If the connections are good then the main transformer may be faulty Re place the main transformer F 24 F 24 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 7 PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section TOC Return to
153. welding or observing open arc welding Headshield and filter lens should conform to ANSI 787 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 irritatin
154. wer off at the fuse box before working on this equipment Do not touch electrically hot parts Insulate yourself from the work and ground Always wear dry insulating gloves IDEALARC DC 400 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 1 Return to Section TOC Return to Master TOC A 5 INSTALLATION FIGURE A 3 INPUT POWER SUPPLY CONNECTIONS 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL 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 with the super lag fuses recom mended on the Technical Specifications use delay type circuit breakers Choose an input and grounding wire size according to local or national codes also see thel Technical Specifications page Using fuses or circuit breakers smaller than recom mended may result in nuisance shut offs from welder inrush currents even if you are not welding at high currents IDEALARC DC 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return t
155. x X o sani cH Mu rd ZH aa 25220 3Nvd 103NNO03U 790905 TANVd 109 14415 OL H e EN 2 103NNOO3U Sao PM 193NNOO3H 144408 OL o amp H BN H 9 2 ad G9Y170A 08 08 5 3909 101619319 3000 790119373 3909 190119373 031534409 NMOHS 5 022 303 C3LO3NNOO NMOHSI TWNOILWN 93 3193 09 NMOHS 934 031984400 NMOHS 699 1 976 Y30NN 2 1 10 077 086 022 OL 005 088 OL 39V 10A 007 062 OL 39V110A 319 591 00 8 ui O E 9 2 A S a e g 12 NOL 49 59 0 DOL 49159 0 DOL uonoes uumeg NOL Je1se N uunjeH DOL uonoeg 0 901 Je1se N uunjeH DOL uonoeg oj uunjeg DOL uonoes oj

Lincoln Electric 122-A User's Manual

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