Lincoln Electric IDEALARC SVM 122-A Service Manual
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Lincoln Electric IDEALARC SVM 122-A Service Manual

Lincoln Electric IDEALARC SVM 122-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN INDEX
SVM 122-A
Oct. 1996
TM
IDEALARC DC-400
For use with machine code numbers 9847, 9848 and 9850
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.

SERVICE MANUAL

LINCOLN
®
ELECTRIC
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

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Summary of Contents for Lincoln Electric IDEALARC SVM 122-A

  • Page 1: Service Manual

    RETURN TO MAIN INDEX SVM 122-A Oct. 1996 IDEALARC DC-400 For use with machine code numbers 9847, 9848 and 9850 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 .

  • Page 2: Safety

    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.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING SPARKS can 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc Protegez-vous contre la secousse électrique: Les circuits à...

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Installation Section Table of Contents ...A-1 Technical Specifications ...A-2 Safety Precautions...A-3 Select Suitable Location (Stacking, Tilting, Lifting) ...A-3 Input Connections...A-4 Reconnect Procedure ...A-6 Output Connections...A-7 Operation...Section B Safety Instructions ...B-2 General Description ...B-3 Controls and Settings ...B-4 Welding Operation ...B-6...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation Technical Specifications Idealarc DC-400 ...A-2 Input and Output Specifications ...A-2 Cable and Fuse Sizes...A-2 Physical Dimensions ...A-2 Safety Precautions...A-3 Select Suitable Location ...A-3 Lifting ...A-3 Tilting ...A-3 Stacking...A-3 Input Connections...A-4 Ground Connection ...A-4 Input Supply Connections...A-4 Input Wire and Fuse Size ...A-5 Reconnect Procedure ...A-6...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - IDEALARC DC-400 INPUT - THREE PHASE ONLY Standard Voltage 208V 230V 460V 575V Duty Cycle 100% Current Mode Range Constant Current 60 to 500 Amps Constant Voltage 60 to 500 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage / Fuse Frequency...

  • Page 9: Safety Precautions

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

  • Page 10: Input Connections

    FIGURE A.1 – RATING PLATE LOCATION 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 (...

  • Page 11: Input Wire And Fuse Size

    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 ®...

  • Page 12: Reconnect Procedure

    LINES INPUT CONTACTOR PILOT TRANSF. THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. INSTALLATION 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.

  • Page 13: Output Connections

    INPUT CONTACTOR PILOT TRANSF. THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. OUTPUT CONNECTIONS The output (welding) cables are connected to the output terminals marked “+” and “-”. See Table A.1 for recom- mended cable sizes for the combined lengths of elec- trode and work cables.

  • Page 14: Wire Feeder Connections

    Output Connections. A TIG torch is connected to the electrode (+) terminal of the welder. Select cable size according to Table A.1. Do not connect a TIG torch and stick electrode cable at the same time. They will both be electrically HOT.

  • Page 15: Operation Section

    Section B-1 - OPERATION SECTION - Operation...Section B Safety Instructions ...B-2 General Description ...B-3 Recommended Processes ...B-3 Operational Features and Controls ...B-3 Design Features and Advantages ...B-3 Welding Capability...B-3 Limitations ...B-3 Controls and Settings ...B-4 Welding Operation ...B-6 Operating Steps ...B-6 Local Control...B-6 Remote Control ...B-6 Welding Procedure Recommendations ...B-6...

  • Page 16: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not weld on containers that have held com- bustibles.

  • Page 17: General Description

    DC output power source for welding and cut- ting. It uses a single range potentiometer control. The welder’s unique combination of transformer, three- phase semiconverter rectifier, capacitor bank, arc con- trol choke, and solid state control system deliver out- standing arc characteristics in the constant voltage mode.

  • Page 18: Controls And Settings

    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 1. Power Source Pilot Light 2. ON/OFF Power Toggle Switch 3. Output Control Potentiometer 4.
  • Page 19 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.

  • Page 20: Welding Operation

    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...
  • Page 21 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 in the CV or CC mode posi- tion. Some earlier models are capable of cold starting only in the CC mode position.
  • Page 22 4. Turn the Start Board Timer to maximum. 5. 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. Set the Start Board voltage control equal with the NA-3 voltage control setting.

  • Page 23: Overload Protection

    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: 1. Set the Idealarc DC-400 welding MODE switch to either CV FCAW/GMAW mode or CV Submerged Arc mode, depending on the welding process being used.
  • Page 24 Capacitor Discharge Circuit (K828-1) ...C-6 Hi-Freq Kit (K799) ...C-6 Amptrol Adapter for K799 (K915) ...C-6 Undercarriages (K817, K817R, K841) ...C-6 Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders ...C-6 Automatic Wire Feeders...C-6 NA-3 (Terminal Strip) ...C-6 NA-5 (Terminal Strip) ...C-7 NA-3 or NA-5 (14-Pin Amphenol) ...C-8...

  • Page 25: Accessories

    OPTIONS/ACCESSORIES FACTORY INSTALLED OPTION DIODE OPTION This factory installed option allows use of the cold- start and cold electrode sensing features of the NA-3, NA-5, or NA-5R automatic wire feeders. See the topic, Connecting the NA-3 [NA-5] to the Idealarc DC-400 in this section of the manual.
  • Page 26 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.

  • Page 27: Remote Control Adapter Cable (K864

    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.
  • Page 28 K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS (Continued) Amptrol Only: The Amptrol provides remote current control through the full range of the power source. K812, K813 or K870 Amptrol K843 Power source Adapter terminal strip Black and white leads not used. Tape and insulate.

  • Page 29: Capacitor Discharge Circuit (K828-1

    (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. ACCESSORIES CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS WARNING ELECTRIC SHOCK can kill.
  • Page 30 FIGURE C.4 – NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC DC-400 5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece. a. Make a bolted connection using AWG #14 or larger insulated wire. Tape the bolted connec- tion with insulating tape.
  • Page 31 Input Cable Assembly to the “+” terminal of the welder and to the wire feeder. Connect the work cable to the “-” terminal of the welder. Reverse this hookup for negative polarity. See Figure C.6. NOTE: Welding cable must be sized for the cur- rent and duty cycle of the application.

  • Page 32: Semiautomatic Wire Feeders

    3. Connect the electrode cable from the K584-XX 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.
  • Page 33 C-10 FIGURE C.8 - LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC DC-400 CONNECTING THE LN-7 TO THE IDEALARC DC-400 (TERMINAL STRIP) 1. Disconnect main AC input power to the Idealarc DC-400. 2. Set the Idealarc DC-400 POWER toggle switch to the OFF (0) position.
  • Page 34 C-11 FIGURE C.9 - LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC DC-400 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.
  • Page 35 3. Connect the electrode cable from the LN-8 or LN-9 to the “+” terminal of the welder. Connect the work cable to the “-” terminal of the welder. Reverse this hookup for negative polarity. See Figure C.10. FIGURE C.10 – IDEALARC DC-400/LN-8 OR LN-9 WITH K595-XX CABLE...
  • Page 36 2. Set the POWER toggle switch to the OFF (0) posi- tion. 3. Connect the electrode cable from the LN-742 to the “+” terminal of the welder. Connect the work cable to the “-” terminal of the welder. Reverse this hookup for negative polarity. See Figure C.11.

  • Page 37: Routine And Periodic Maintenance

    Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Safety Precautions...D-2 Routine and Periodic Maintenance ...D-2 General Component Locations...D-3 IDEALARC DC-400 LINCOLN ® ELECTRIC...

  • Page 38: Safety Precautions

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified 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...
  • Page 39 FIGURE D.1 – GENERAL COMPONENT LOCATIONS 1. CONTROL PANEL 2. SCR/DIODE BRIDGE 3. MAIN TRANSFORMER 4. CHOKE 5. RECONNECT PANEL (LOCATION) 6. INPUT CONTACTOR (LOCATION) 7. FAN ASSEMBLY 8. CONTROL TRANSFORMER 9. CAPACITORS 10. PC BOARDS (LOCATION) 11. CASE FRONT 12.
  • Page 40 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Input Line Voltage, Contactor and Main Transformer ...E-2 Output Mode and Control, Rectification and Feedback ...E-3 Protective Devices and Circuits ...E-4 SCR Operation...E-5 CONTROL TRANSFORMER POWER SWITCH MAIN TRANSFORMER...

  • Page 41: Theory Of Operation

    BOARD 14 PIN AMPHENOL 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.

  • Page 42: Output Mode And Control, Rectification And Feedback

    THEORY OF OPERATION FIGURE E.3 – OUTPUT MODE AND CONTROL, RECTIFICATION AND FEEDBACK CONTROL TRANSFORMER POWER SWITCH MAIN TRANSFORMER INPUT CONTACTOR 115VAC REMOTE CONTROL CONTROL BOARD 42VAC 14 PIN AMPHENOL 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.

  • Page 43: Protective Devices And Circuits

    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.

  • Page 44: Scr Operation

    THEORY OF OPERATION 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.
  • Page 45 Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide...F-4 - F-14 Test Procedures Input Contactor Test...F-15 Control Transformer (T2) Voltage Test...F-18 Main Transformer (T1) Voltage Test...F-21 Static SCR/Diode Rectifier Bridge Test ...F-26 Active SCR Test...F-29 Oscilloscope Waveforms ...F-33...

  • Page 46: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 47: Pc Board Troubleshooting Procedures

    • If the PC Board uses protective shorting 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.

  • Page 48: Troubleshooting Guide

    – no pilot light. 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.

  • Page 49: Troubleshooting Guide

    – the pilot light is lit. 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.
  • Page 50 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. POSSIBLE AREAS OF...
  • Page 51 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.
  • Page 52 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.
  • Page 53 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. detailed in the beginning of this manual.
  • Page 54 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. POSSIBLE AREAS OF...
  • Page 55 “hot.” 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. detailed in the beginning of this manual.
  • Page 56 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. detailed in the beginning of this manual.
  • Page 57 (CV) mode. 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. POSSIBLE AREAS OF...
  • Page 58 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. detailed in the beginning of this manual.

  • Page 59: Input Contactor Test

    F-15 TROUBLESHOOTING & REPAIR 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.
  • Page 60 F-16 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.1 – INPUT CONTACTOR CONNECTIONS TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and the reconnect panel cover. 3.
  • Page 61 F-17 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.2 – INPUT CONTACTOR TEST CONNECTIONS TEST FOR CONTACT CONTINUITY 1. Disconnect the main input supply power to the machine. 2. Remove the two leads connected to the input contactor coil, #233 and X1/#232. See Figure F.1 for location.

  • Page 62: Control Transformer (T2) Voltage Test

    TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST 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-...
  • Page 63 F-19 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.3 – CONTROL TRANSFORMER AND LEAD LOCATIONS TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the top, case sides, and lower the front control panel.
  • Page 64 F-20 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.4 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS RIGHT SIDE VIEW 6. 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.

  • Page 65: Main Transformer (T1) Voltage Test

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST 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 man- ual.
  • Page 66 F-22 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS TO MAIN TRANSFORMER LOCATIONS TEST PROCEDURE 1. Set the ON/OFF power switch to OFF. 2. Disconnect main input supply power from the machine.
  • Page 67 F-23 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS 8. Read the meter. a. If proper voltage is present for all three phases, proper main input supply volt- age is being supplied. b.
  • Page 68 F-24 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.7 – PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION 12. Test for 115VAC between leads #31 and #32 on the terminal strip. 42VAC between pin K (lead #42) and pin I (lead 41) in the 14 pin amphenol.
  • Page 69 F-25 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION Plug P3 From Lead # DC-400 CONTROL G2588-X #204 #203 Plug P1 PHASE ANGLE WINDING VOLTAGES To Lead # IDEALARC DC-400 LINCOLN ®...

  • Page 70: Static Scr/Diode Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST 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-...
  • Page 71 F-27 TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS DC-400 CONTROL G2588-X Plug P3 TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides.
  • Page 72 F-28 TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.11 – HEAT SINK AND SCR TEST POINTS 8. Remove the red insulating paint from the heat sink test points. See Figure F.11. NOTE: Do not disassemble the heat sink. 9.

  • Page 73: Active Scr Test

    F-29 TROUBLESHOOTING & REPAIR 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-...
  • Page 74 F-30 TROUBLESHOOTING & REPAIR FIGURE F.12 – CONTROL BOARD PLUG P1 AND P3 LOCATIONS DC-400 CONTROL G2588-X Plug P3 TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides.
  • Page 75 F-31 F-31 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (continued) FIGURE F.15 – HEAT SINK TEST POINTS 8. Remove the red insulating paint from the heat sink test points. See Figure F.15. NOTE: Do not disassemble the heat sinks. IDEALARC DC-400 LINCOLN ®...
  • Page 76 F-32 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (continued) FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS 9. Construct the circuit shown in Figure F.16. One 6-volt lantern battery can be used., Set voltmeter scale low, at approximately 0-5 volts or 0-10 volts. 10.

  • Page 77: Normal Open Circuit Voltage Waveform-Constant Current Mode

    F-33 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE – NO LOAD 2 ms 50 volts 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.

  • Page 78: Normal Open Circuit Voltage Waveform-Constant Voltage Fcaw/Gmaw

    F-34 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE FCAW/GMAW MAXIMUM OUTPUT SETTING – NO LOAD 2 ms 20 volts 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.

  • Page 79: Normal Open Circuit Voltage Waveform-Constant Voltage Subarc

    F-35 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE SUBARC MAXIMUM OUTPUT SETTING – NO LOAD 5 ms 20 volts 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.
  • Page 80 F-36 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED CONSTANT VOLTAGE FCAW/GMAW MODE 5 ms 20 volts 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.
  • Page 81 F-37 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED CONSTANT VOLTAGE SUBARC MODE 5 ms 20 volts 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.

  • Page 82: Typical Scr Gate Voltage Waveform-Constant Voltage Subarc

    F-38 TROUBLESHOOTING & REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM CONSTANT VOLTAGE SUBARC MAXIMUM OUTPUT SETTING – NO LOAD 5 ms 2 volts This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no load) and operating properly.

  • Page 83: Abnormal Open Circuit Voltage Waveform-Constant Voltage Subarc

    F-39 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE SUBARC ONE OUTPUT SCR NOT FUNCTIONING 5 ms 20 volts This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “gap” in the waveform.

  • Page 84: Input Contactor (Cr1) Cleaning/Replacement

    TROUBLESHOOTING & REPAIR INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT 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-...

  • Page 85: Replacement Procedures

    F-41 TROUBLESHOOTING & REPAIR INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL 1. INPUT SUPPLY LINE 2. INPUT CONTACTOR CR1 3. RECONNECT PANEL CLEANING PROCEDURE 1. Remove the main input supply power to the machine. 2.

  • Page 86: Fan Motor And Blade Removal And Replacement

    TROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT 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-...
  • Page 87 F-43 TROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – FAN MOTOR MOUNTING DETAILS PROCEDURE 1. Remove the main input supply power to the machine. 2. Using the 5/16” nut driver, remove the case top and sides. 3.

  • Page 88: Scr/Diode Rectifier Assembly Removal And Replacement

    SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT 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-...
  • Page 89 F-45 TROUBLESHOOTING & REPAIR SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.19 – SCR/DIODE ASSEMBLY DETAILS PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. 3.

  • Page 90: Scr Removal And Replacement

    TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT 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-...
  • Page 91 SCR mounting surfaces. 8. Apply a thin (0.001” to 0.003”) layer of PEN- ETROX A-13 (Lincoln Electric #E2529) or PENETROX A, heat sink compound, to each heat sink’s SCR mounting surface.
  • Page 92 F-48 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – 1/2” WIDE LEAF SPRING 10. Go to the procedure below that matches your machine’s cap screws. NOTE WHICH THREAD IS ON YOUR CAP SCREWS BEFORE PROCEEDING TO THE ASSEMBLY PROCEDURE. Two different designs of leaf springs and housings have been used to clamp the SCR to the rectifier.
  • Page 93 F-49 TROUBLESHOOTING & 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.
  • Page 94 F-50 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING STEEL PRESSURE PAD PROCEDURE FOR THE 5/8 INCH WIDE SPRING 1. Place a piece of sleeving around each cap screw.
  • Page 95 F-51 TROUBLESHOOTING & 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.

  • Page 96: Mounting Of Stud Type Diodes To Aluminum Heat Sinks

    TROUBLESHOOTING & REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM 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-...
  • Page 97 F-53 TROUBLESHOOTING & REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. 3. Loosen the appropriate diode nut and remove the diode that is to be replaced.

  • Page 98: Main Transformer Removal And Replacement

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT 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-...
  • Page 99 F-55 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) REMOVAL OF LIFT BAIL 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. 3. Remove the two fiber baffles from the left and right sides of the lift bail adjacent to the main transformer.
  • Page 100 F-56 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) REMOVAL OF CHOKE AND TOP IRON ASSEMBLY 1. Remove the two (left and right) glastic stiffen- ers connecting the negative rectifier plate and choke assembly to the main transformer thru-bolts. See Figure F.26. 2.
  • Page 101 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.
  • Page 102 Place the coils so that the leads come out at the back of the machine. See Figure F.28 for proper positioning. 4. Place insulation (Lincoln Electric part number S20728) on top of each of the three primary coils. The longer side of the insulation should be placed toward the front of the machine.
  • Page 103 FIGURE F.30 – PRIMARY THERMOSTAT LOCATION INSULATION 10. Mount the primary thermostat to the lead end coil nose. See Figure F.30. Place a small amount of Lincoln Electric E1603 Epoxy between the coil nose and the coil insulation and between the insulation and the thermostat.
  • Page 104 F-60 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE 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 machine.

  • Page 105: Retest After Repair

    F-61 TROUBLESHOOTING & REPAIR Retest a machine: • If it is 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. Input volts/Phase/Hertz 200/3/60 208/3/60...
  • Page 106 F-62 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR (continued) MAXIMUM ACCEPTABLE OUTPUT VOLTAGE- Mode Constant Current Constant Voltage (FCAW/GMAW) MINIMUM ACCEPTABLE OUTPUT VOLTAGE- AT MAXIMUM OUTPUT SETTINGS Mode Constant Current Constant Voltage (FCAW/GMAW) Constant Voltage (SUB ARC) AT MINIMUM OUPUT SETTINGS Control Settings Output Control and Arc Force Control at Minimum...
  • Page 107 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagram Section ....... . . Section G Wiring Diagram (Codes 9847, 9848) .
  • Page 108 NOTES IDEALARC DC400...

  • Page 109: Wiring Diagram (Codes 9847, 9848

    Wiring Diagram (Codes 9847, 9848) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ELECTRICAL DIAGRAMS IDEALARC DC400...

  • Page 110: Wiring Diagram (Code 9850

    ELECTRICAL DIAGRAMS Wiring Diagram (Code 9850) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. IDEALARC DC400...

  • Page 111: Control Pc Board (G2588) Layout

    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 in danger to the Machine Operator or Technician.

  • Page 112: Starting Pc Board (M14520) Layout

    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 in danger to the Machine Operator or Technician.

  • Page 113: Snubber Pc Board (M15370) Layout

    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 in danger to the Machine Operator or Technician.

  • Page 114: Control Pc Board (G2588) Schematic

    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 in danger to the Machine Operator or Technician.

  • Page 115: Starting Pc Board (M14520) Schematic

    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 in danger to the Machine Operator or Technician.

  • Page 116: Snubber Pc Board (M15370) Schematic

    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 in danger to the Machine Operator or Technician.

This manual is also suitable for:

Idealarc dc-400

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