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troubleshooting & repair - Red-D

1. AUTOMATIC CONTROL BOX NEGATIVE POSITIVE ELECTRODE TO CABLE TO work AUTOMATIC EQUIPMENT NOTE If using a K215 contr ol cable connect control cable leads 75 76 and 77 to the matching 75 76 and 77 terminals on the terminal strip of the Idealar c DC 400 4 Connect the wir e feeder contr ol cable gr ound lead to the frame terminal marked NOTE The Idealar DC 400 must be properly grounded IDEALARC DC 400 ACCESSORIES Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AVG 14 or larger insulated wire Tape the bolted connec tion with insulating tape An S 16586 X remote voltage sensing work lead is available for this purpose NOTE For proper NA 5 operation the 7 cables must be secured under the clamp bar on the left side of the NA 5 Contol Box Set the DC 400 OUTPUT CONTROL switch to the ORemoteO position and the OUTPUTERMINALS switch to the ORemote position CONNECTING THE NA 3 OR NA 5 TO THE IDEALARC DC 400 14 PIN AMPHENOL Keep the 21 lead electrically separate from the work cable circuit and connection 1 Disconnect main AC input power to the Idealac d Tape the 21 lead to work cable for ease of DEA use 2 Set the Idealarc DC 400 POWER switch to the OFF Connect NA 5 wire
2. 1 5 1 CAPACITOR 040 OVER VOLTAGE tN4004 PROTECTION PY sw T P lw CURRENT SWITCH gt 013 016 104004 144004 267 ee R124 e 04 6810 CC CURRENT 1N4004 3 047 LIMITER 1N4004 LIMITER MAS CURRENT AMP gt d CONTROL X6 9 i m e e R6 Hep 1 00M 046 1N4004 Dt 1N4004 037 144004 017 14004 1 4004 049 1N4004 045 1N4004 043 144004 n CC LOW VOL
3. 2 0 E 2 Output Mode and Control Rectification and Feedback E 3 Protective Devices and 2 E 4 SCR niece E 5 OUTPUT FORCE CONTROL CONTROL CONTROL TRANSFORMER FEEDBACK NEGATIVE OUTPUT TERMINAL CONTROL BOARD MAIN TRANSFORMER C D B N N K E T OUTPUT TERMINAL O REED INPUT SWITCH CONTACTOR 115VAC REMOTE TO CONTROL CONTROL BOARD FIGURE E 1 IDEALARC DC 400 BLOCK LOGIC DIAGRAM IDEALARC DC 400 LINCOLN B 2 2 THEORY OF OPERATION FIGURE 2 D INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER OUTPUT ARC FORCE CONTROL CONTROL CONTROL BOARD CONTROL TRANSFORMER FEEDBACK NEGATIVE OUTPUT TERMINAL MAIN TRANSFORMER zo o R F E E D K E POSITIVE T TERMINAL 1 SCR DIODE SHUNT SE INPUT CONTACTOR HYBRID BRIDGE 115VAC REMOTE CONTROL TO CONTROL BOARD GENERAL DESCRIPTION The DC 400 is a multipr ocess welder power sour ce The transformer changes the high voltage low curr ent capable of both constant voltage and constant curr ent input power to a lower voltage higher curr ent output operation power system is SCR contr olled with The
4. 210 010 1 661211 14 60 20 90 ea 2010 08 1 11 899915 1 953 09 091 2 6111 1 2 09 009 6 LLGllL 1 96 18 99 06715 1 655 00 89 0 06 15 1 955 001 22 82 11511 O01 201 0 5 801129492 AOS 0 407 09 19111 002 6 0 5 1 22 02 8 1 06v 1S y 260 222 025 S19 00717500 40 v00 25 0111 2 15212 892 92 1 99 099 650 892 50 162 OES 610 812 712 0S 220 899915 12 912 Z12 119 012 62 82 3 001791 801 05 615 9270272 S L v 0 15 9 9 212 NOILVOISILNAGI 1 G 03H er er 1 888909 10 1 09 007949 128 279 000 E zog 288 298 199 25 is s 0 EON o 920 820 gt 188 it Board Components are not ircu dual Printed Ci ivi t may comprom lidate your factory warranty Ind inva board level troubleshoot in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Irs WI PC Board repai ing Iting from board level troubleshoot
5. 1001 00761 S L OZY ASL 19 7 009615 S EGH 28H 1 192 0792 007615 YET 8 GOTH TGH My l 7001 2001 007615 91 OEY ETH 21 TTY 1 GLb 09 7 00761 9 L84 988 ZEN 9EY OTY Mp l 2 9 2 1 92 00 615 IP14 6 SY rH 12 vl 1 11 zu lu LZO9NZ v L0LZIL zno TNO 10 2 89 0 211 50 SS 133 13NNVH2 N 5 0 211 20 98 70211 5 80 90 vO 50 10 80191051 0140 01 000915 1 1130 872815 1 er ZI 872815 1 H30v3H Ol 872815 Le 30010 H3N3Z 1 20 211 1 7120 62 20 211 1 5120 GELPNI 0 20 211 1 2170 8 vCGNI 6 20 211 1 0120 Sv GEGNI 09 20 211 1 620 LG PNI 86 20 211 1 970 81 ZGNI SI 20 211 1 170 62 20 2 1 9 970 570 770 570 270 120 40 2 0 110 30010 SOO0 NI 66 211 6 0 0 690 890 OZO 280 080 6 0 8 0 10 6 0 10 290 990 990 90 590 290 1 90 090 650850 250 990 950 esa 290 150 6 0 8v0 LHO gra vO zea 950 SEG 550 250 150 620 820 320 2 220 910
6. e 2 SCR2 KE x A BBA d 2 400V 3 1 gt e D4 05 J 38 130V TP D6 A e J6 6 218 IDEALARC DC400 START SCHEMATIC o 19686 G 8 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 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 Improper PC board repairs could result in damage to the machine IDEALARC DC400 ELECTRICAL DIAGRAMS G 9 Snubber PC Board M15370 Schematic 28961 28960 8 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 57 221 204 222 223 220 225 rH 224 2 8 3 4 1 5 7 6 N J5 J5 J5 J5 J5 J5 J5 J5 e e e 1 C2 1 5 552068 2513088 068 2 400V 2 400V 400 alll n 1600 Poy
7. 4 Turn the Start Board Timer to maximum 5 Set Start Board current and voltage contol 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 contol equal with the NA 3 voltage contol 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 6 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 start where the wire tends to Oblast df If the voltmeter pointer hesitates befoe coming up to the desired voltage the Open Circuit Voltage Control is set too low T
8. G 7 Starting PC Board M14520 G 8 Snubber PC Board M15370 5 G 9 IDEALARC DC400 LINCOLN G 1 NOTES IDEALARC DC400 LINCOLN ELECTRICAL DIAGRAMS G 2 G 2 Diagram Codes 9847 9848 iring 90161 34 6 6 1 PO A INO NOILdO 30010 NO 1 353959 AYLINDYID lt NO 1 LON LE 8HdQ 13M 21 09 05 NO AINO 1N3S3Hd 38V LINDYID AOZZ NOILVINSNI A 009 15937 OL 131 3 3435 JdVL KINO JDYVHISIG YOLIDVdVD 1 35384 AYLINDYID VN SALON 24 30 3415 LNINOdWOD 5 ONIYIGWNN ALIAVO YOLIANNOD Lf sf 9r Nid OL 8 9 v 334 SIOSWAS 1 21812313 NOILdO JGOIG 1N3S38d LON QV31 7504 01 Waal OL 91915 Wadi OL P 12313 5532034 HDLIMS 4 WN IWNOILdO 1081NO2 indino ML AOL TI 112 i o HILIMS 10 1 2 LNdLNO ts 1 112 012712 94 e 90 50 sc 15 3313 u3MOd N 211 5 STV
9. 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 NOTE IDEALARC DC400 LINCOLN E 6 4 ELECTRICAL DIAGRAMS Control PC Board G2588 Layout 1 8892 AT8N3SSV 7274 IOHLINOO 007 94 9uv 1V3adi 339 399170 01 821515 1 LX U3IdITdAV 02 821915 1 9x 933 AG 5 821515 1 SX dAV dO vZZW1 821515 y vX EX ZX TX 825 79 6 191615 25 2825 1435 Mg l 0 2 00 615 21 1 002 0002 00 615 ZOEY JOEY mz 01 2 21 2 vGlH MOI 091 LI 6t9p1 L 119 SWHO 0051 1 009 1 2 OSIY MOL 052 89 00 211 1 61 8 9 11 Mb l azz 2122 007615 9ST GETH 7928 2928 007615 1 2619 92 u G2EH vetu zeeu ozeu 89 2189 007615 vi 9I EH 19 2619 007615 1 2218 2119 007615 1 2912 007615 1 MZ l 2180 1 1118
10. 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 29 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 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 device can be gated ON and conduct current from anode to cathode MATERIALS NEEDED An SCR tester as specified in this procedure 5 16 Nut driver Idealarc DC 400 Wiring Di
11. 3 B 7 Arc Striking with the NA 3 Start B 7 NA 5 Automatic Wire B 8 LN 8 Semiautomatic Wire Feeder eee B 8 LN 7 and LN 9 Semiautomatic Wire Feeders mee B 9 tee p e ee ea rie ERA ee d B 9 Auxiliary POWet REP reda er ue REPRE B 9 IDEALARC DC 400 LINCOLN B OPERATION ais 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 or explosion Keep flammable material away Do not weld on containers that have held com bustibles ARC RAYS can burn 24 Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual IDEALARC DC 400 LINCOLN B 3 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 use
12. 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 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 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 4 turn Tighten first cap screw 1 8 turn
13. 1 328 1 1281 007615 SILLY 89 1 Mp l 25 00 515 1 1 229 1299 00615 1 AZOT 2201 007615 001 4 Mp l ST 2091 007615 y GEL H vETH PSY HOLS 214 085815 1 8H 6 3 Mr l 092 009 007615 SO H 224 265 5265 007615 1 2 92 2192 00 615 ZLY H3AWIHl 2 1 1 218011 2 1 4 9H 1 WI 001 007615 084 994 2268 00615 Y IZI Y ZOI Y 884 a9u mm Mg l G v 007615 L 901 Y 66 68H 694 zau 1 4879 1189 007615 1 194 11 02 007615 09H ZZ 2122 007615 v OET Y ezTH Mb l XG l 091 007615 5 My l ZEE 2 00 615 2 2GH 1122 007615 OSH CvTH SITY 86H I 6H OLY 8984 1 2001 007615 v9u 998 Lry gry gt 1 001 0001 007615 S 721879218 94 1 2792 2192 007615 5 1 2161 007615 9 2085 0068 96H 1 6772 00 615 1 1 295 0299 007615 9 LIEH OIl EH C H 1 65 21801 1 9zu
14. Extend wir e feeder contr ol cable lead 421 so it can be connected dir ectly to the work piece a Make a bolted connection using 14 or larger insulated wir e Tape the bolted connec tion with insulating tape b An 5 16586 X remote voltage sensing work lead is available for this purpose Keep the 21 lead electrically separate fr om the work cable cir cuit and connection d Tape the 21 lead to work cable for ease of use NOTE The connection diagram shown in Figur C 4 shows the electr ode connected for positive polarity To change polarity a Set the Idealarc DC 400 POWER toggle Switch to the OFF 0 position b Move the electr ode 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 Set the DC 400 OUTPUT CONTROL switch to the ORemoteO position and the OUTPUT TERMINALS switch in the ORemote position CONNECTING THE NA 5 TO THE IDEALARC DC 400 TERMINALSTRIP 1 Disconnect main AC input power to the DC 400 2 Set the c DC 400 POWER toggle switch to the OFF 0 position 3 Connect the wir e feeder contr ol cable leads to the Idealar c DC 400 terminal strip as shown in Figur e C 5 FIGURE C 5 D NA 5 WIRE FEEDER CONNECTION TO THE IDEALARC DC 400 NA 5 WIRE FEEDER CONTROL CABLE
15. automatic wire feeding equipment and for stick trol is for CV FCAW GMAW welding only Adjust welding or air carbon arc cutting it is recommended as necessary for best pinch control that the optional MULTIPROCESS switch be used 8 Set the ON OFF POWER toggle switch to the ON Mis permis du easily change tie 2 Br position 1 the connected wire feeding equipment or switch to stick welding or air carbon arc cutting Y The power source pilot light glows Y The fan starts 9 Set OUTPUT CONTROL potentiometer to desired voltage or current 10 Make the weld IDEALARC DC 400 OPERATION NA 3 AUTOMATIC WIRE FEEDER 1 Set the DC 400 OUTPUT CONTROL switch to ORemote O NOTE Later model NA 3 automatic wire feeders are capable of cold starts when the NA 3 Mode switch is in the CV or CC mode posi tion Some earlier models are capable of cold starting only in the CC mode position Cold starting enables you to inch the wire down to the work automatically stop and automatically energize the flux hopper valve The cold start feature requires the factory installed diode option See the 2 Set the DC 400 welding MODE switch for the desired process CV Submerged Arc 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 ORemote 5 Set the OUTPUT TERMINALS switch to ORemote 6 For CC welding set the
16. 5 LON Waal Waal 41815 504 01 OL W431 OL ME E o 290912313 0 HILIMS SSIDOUdILINW ot UN v E Ede 45 LEZ 211 5 2 LNdLNO 2 55 1indino 1 lic 0 AOL 94 IZ oL L 2 LLELZ 5 HDILIMS sivNiWwuaL Fu indino t 9 9 5 ES LL 9 SL ZE Ie Zz A Iit BeAr Lu DU 1 2 2 222 A00v1 04WZv00 95 HOLIMS 9313W110A 9 95 TOYLNOD 32304 la su sec 602 TEL E AINO 22 NI MVW9 MV23 A2 3345 x galvnlov 275 anis nou5 AINO 1 12 5 avs 2 Cu 912 od we QNI avs 2 ANS AD 4 MOOLS 51 an S QNI 95 1194110 SudliWwW 902 DNILYVLS 59 soz 902 TOYLNOD WA CT 15 EET 354 2 cec Scc 10 LNOD 1H9I1 NOIL2310Ud MVW5 MV23 AO vrs
17. E 3 E 3 THEORY OF OPERATION FIGURE E 3 D OUTPUT MODE AND CONTROL RECTIFICAION AND FEEDBACK OUTPUT ARC FORCE CONTROL CONTROL CONTROL PART OF TRANSFORMER SWITCH FEEDBACK NEGATIVE OUTPUT TERMINAL MAIN TRANSFORMER R F 5 B K POSITIVE OUTPU TERMINAL Ae SCR DIODE INPUT CONTACTOR HYBRID BRIDGE 115VAC REMOTE CONTROL TO CONTROL BOARD OUTPUT MODE AND CONTROL RECTIFICATION AND FEEDBACK The thr ee phase AC output fr om the main transformer The heavy curr ent carrying portion of the Mode secondary is r ectified and contr olled thr ough the SCR Switch is connected between the output choke diode bridge Output curr ent and voltage is sensed at which stor es ener gy and pr ovides curr ent filtering the shunt and output terminals This feedback infor and the negative output terminal Depending upon mation is pr ocessed in the contr ol board The contr ol the mode selected dif ferent portions of the choke e board compar es the commands of the Mode Switch needed In the constant curr ent mode the the Arc Force Contr ol constant curr ent mode only entire choke is connected into the welding output cir and the Output Contr ol or remote contr ol with the cuit When constant voltage is equired only feedback information and sends appr opriate gate part of the choke is utilized fring signals
18. TABLE A 1 CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE AND WORK CABLES 50 1006 100 150ft 150 2008 200 2508 Machine Size 15 30 m 30 46 m 46 61 m 67 76 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 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 A WARNING Do not connect a 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 TI
19. 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 OVO cable to connect a K799 Hi f amp q 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 843 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 Y Only qualified personnel should perform this maintenance Y Turn the input power OFF at the dis connect switch or fuse box before working on this equipment Y 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 locate
20. or de engergizes the input contactor which is pow ered by the 115 volt auxiliary transformer The switch turns the machine ON or OFF Position OI is ON position is OFF OUTPUT CONTROL trols voltage in CV mode and current in CC mode OUTPUT CONTROL SWITCH WITH LOCAL OR REMOTE POSITIONS Selects the mode of con trol In the OLocalO position conti is by the machine control panel In the ORemote position control is by either a wire feeder unit or through an optional remote control device 5 OUTPUT TERMINALS OR SWITCH When in the ORemote position leads 2 and 4 have to be jumpered externally to ener gize the output terminals When in the OON posi tion this switch internally jumpers leads 2 and 4 which energizes the output terminals 6 ARC FORCE SELECTOR Allows you to select the ideal arc force according to the procedure and electrode being used for CC stick or TIG welding It controls the amount of current added to the welding current when the electrode shorts to the work At minimum setting no extra short circuit current is added The arc will be softer and have less spatter but may be more prone to sticking At maximum setting the arc will be more forceful and less prone to sticking but will produce more spat ter IDEALARC DC 400 7 10 11 12 13 OPERATION AUXILIARY POWER AND REMOTE CONTROL CONNECTIONS FOR W
21. 1 resu ility for liablilit lable from Lincoln Electric This informat ic assumes no responsi In Electr inco L NOTE d may result LARC DC400 ign an the quality of the desi 15 ir since i d repa ing an Iscourages ic d In Electr ided for reference only L lon IS prov gt G 5 Starting PC Board M14520 Layout ELECTRICAL DIAGRAMS PS P MP ITEM C 1 01 02 D3 D4 D5 D6 D7 R2 R5 R 4 R 6 SCR1 REQ DIDENTIFICATION 1 50 50 2 1 4007 5 1N4004 2 5W 2500 OHM RESISTOR 2 1K 1 4W 1 1 5K 1 4W 1 100 10W SCR2 400 SCR 5851 SCR HEAT SINK AS BLY TP1 SILICON BILATERAL SWITCH TP2 38 LINCOLN 160 NOTE Lincoln Electric assumes responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are 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 resulb e ALARC DC400 in danger to the Machine Operator Technician Improper PC board repairs cou
22. 1 2 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 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 l 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
23. 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 disconnected 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 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 Switch N
24. Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 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 Remove 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 F 12 F 12 TROUBLESHOOTING am
25. QO eS lo o 1 C 400 LJ 1 RATING PLATE GROUND CONNECTION The frame of the welder must be grounded An earth grounding lead must be connected to the gounding terminal marked on the input box floor with the sym bol 27 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 though 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 thee line terminals on the input contactor See Figure A 2 FIGURE 2 D REAR PANEL 4 J J 1 INPUT SUPPLY LINE ENTR Y HOLE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL A WARNING ELECTRIC SHOCK can kill e YHave a qualified electrician install and service this equip ment YTurn the input power of at the fuse box before working on this equipment YDo not touch electrically hot parts Y Insulate yourself fiom the work and ground Y Always wear dry insulating gloves IDEALARC DC 400 5 5 INSTALLATION FIGURE A 3 INPUT POWER SUPPLY CONNECTIONS OO 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL Have a qualified
26. See Figure F 28 for proper secondary start and finish leads come out See positioning Figure F 29 4 Place insulation Lincoln Electric part number 8 Install the three top primary coils noting which is 520728 on top of each of the three primary coils right left and center Leads should come out at The longer side of the insulation should be placed the back of the machine See Figure F 28 for prop toward the front of the machine See Figure F 29 er positioning The coils must be in corect position for the location of this insulation left center right 5 Place the three secondary coils on top of the insu 9 Install the top iron lamination and choke assem lation installed in Step 4 The leads should come bly With the 9 160 deep well socket wench out at the front of the machine with the short leads reassemble the four thru bolts that clamp the top on top See 28 for proper positioning to the bottom Lightly tap on the 6 Insert shims Lincoln Electric part number 001250 or 1000317 between the secondary top of the iron with a hammer before tightening Tighten the nuts and thru bolts to 19 25 Ib ft coil sides and the iron assembly on either side of the legs See Figure F 29 FIGURE F 29 D COIL INSULATION PRIMARY COILS M Pp m LEFT CENTER RIGHT SECONDAR Y COIL ASSEMBLY INSULATION PRIMARY COIL BOTTOM SHIMS IDEALA
27. 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 50 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 PROCEDURE FOR THE 5 8 INCH WIDE SPRING 1 Place a piece of sleeving around each cap screw Insert cap screws through the leaf spring The leaf spring is flat so the orientation of the leaf spring does not matter Place the steel pressure pad in the housing with the 1 8 inch wide standoff facing up See Figure F 23 Insert cap screws and leaf spring into plastic housing being sure that the steel pressure pad remains in position Pressing on the cap screw heads should produce rocking action of the spring in its housing Insert the clamp assembly through the heat sinks Install nuts Tighten the clamp nuts equally on the cap screws until finger tight Be sure that the leaf spring is not cocked in the housing See Figure F 24 Heat sinks may not be exactly as pictured Reinspect the SCR for proper seating IDEALARC DC 400 LINCOLN B FIGURE F 24 CLAMP ASSEMBLY HEAT SINK HOUSING LEAF SPRING CAP SCREW F 51 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued
28. Tighten second cap screw 1 8 turn STOP Q9 CET d eu a9 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 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 The following procedure will aid the technician in mounting stud type diodes to the aluminum heat sinks on the DC 400 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 IDEALARC DC 400 LINCOLN B 53 TROUBLESHOOTING amp REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS continued PROCEDURE 1 Remove the main input supply power to the machine With the 5 16 nut
29. ans A5 MVW5 MVO2d A2D 1 043 HILIMS MO 5 T cu MOO H2V3 AOS 000716 ELECTRICAL DIAGRAMS a voc uvos 88nNS zd EuD HILIMS A18Wi3SSV 3313112393 QUAS uOLll2VdV2O L NOILdO sz NOILdO 51 uOll2VdV2O voc lv Ly SIVISOWHWU3HI 12 Lex vH 3WHOdSNVHL 2 agit zu Marr 1 J NO NMOHS LX SV 1 105 51102 Wvubvia 235 a ivt 0 4 5 NIVW L1 AYVWIYd AYYWIYd 401 51102 108 LIN dad L23NNOOD AYWWIYd OL 182 OL YOLIVLNOD EEZ gt ON 1 51312313 OL N 11 TANVd 123NNO23H Aldd CAOEZ 804 GALDINNOD NMOH 5 ASLS 09v 0 C Diagram Code 9850 iring G 3 TT ET S3NI1 ns 01 ix gt gt YOLOW
30. 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 10 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 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
31. 32 RATED OUTPUT Volts at Rated Amps OUTPUT Current Maximum Open Mode Range Circuit Voltage Auxiliary Power Constant 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 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 B A 3 A 3 INSTALLATION 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 SELECT SUITABLE LOCATION Place the Idealarc DC 400 where clean cooling air can flow freely in through the front louvers and out through the rear 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 LIFTING WARNING FALLING EQUIPMENT
32. ARC FORCE CONTROL to midrange 5 6 After welding starts adjust as nec essary 7 For CV FCAW GMAW welding set the CON TROL to midrange 3 After welding starts adjust as necessary 8 Refer to the NA 3 operator 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 a good starting point is to set the Open Circuit Voltage Control to 6 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 possi
33. F 36 Typical Output Voltage Waveform Constant Voltage F 37 Typical SCR Gate Voltage Waveform Constant Voltage F 38 Abnormal Open Circuit Voltage Waveform Constant Voltage F 39 Replacement Procedures ec E a uli ecd F 40 Input Contactor CR 1 Cleaning Replacement F 40 Fan Motor and Blade Removal and F 42 SCR Diode Rectifier Assembly Removal and F 44 SCR Removal and Replacement F 46 Mounting of Stud Type Diodes to Aluminum Heat Sinks F 52 Main Transformer Removal and F 54 Retest After Repair eee be HER E p F 61 IDEALARC DC 400 LINCOLN B 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 invalidate your factory warranty For your safety and to avoid Electrical Shock please Observe all safety notes and precautions detailed throughout this manual T
34. FIGURE F 22 CLAMP ASSEMBLY HEX NUT HEAT SINK E HEAT SINK HOUSING LEAF SPRING CAP SCREW IDEALARC DC 400 LINCOLN B 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 second cap screw 1 2 turn Tighten first cap screw 1 2 turn
35. RA UR EHE ER E UR CUERO PR s A 7 edocet niei dete e cet a Section B Safety Instr ctioris alluit e ERA OI pd en epe B 2 General Descriptio 2 Lb d tr ed ur b uw Pb dare dv B 3 Controls arid Settirigs ettet ee e p e Ergo aee B 4 Welding Operation hab B 6 Overload Protection trt etta cc na e e t da B 9 POW B 9 onec baie es Be E teg dale t e ades Section C Maintenance Section D Safety Precautions be bau eet DR ed RO ROO a eae D 2 Routine and Periodic Maintenance D 2 General Component 1 5 0 3 Theory of Operation 3 e a e e PH E E Section E Troubleshooting and sss emen Section F How To Use Troubleshooting eene F 2 Troubleshooting Guid esam ac tette ber F 4 Test Procedures oo dero edite EP e e a ER edet F 15 Oscilloscope WaVefOrms ho de ec bn dE PR EX dean REOR REP F 33 Replacement Procedures spera Re a 40 R et st ier e e F 61 Electrical Diagrams SOR D GR tede e n fe CO RARE CES Section G Parts Manual nio o in led
36. can cause injury Do not lift this machine using the lift bail if itis equipped with a heavy 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 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 The 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 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 5 RATING PLATE LOCATION
37. driver remove the case top and sides Loosen the appropriate diode nut and remove the diode that is to be replaced 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 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 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 Apply a thin 0 003 to 0 007 uniform layer of E1868 Dow Corning 340 heat sink com pound to the heat sink mounting surface 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 Tighten the diode nuts to the specifications in the following table 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 the nuts a minimum of 1 2 turn more while torquing Install the case top and sides IDEALARC DC 400 LINCOLN B F 53 DIODE STUD FOOT INCH SIZE POUNDS POUNDS 3 4 16 25
38. 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 the 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 6 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
39. equipment 1 e In 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 ELECTRIC AND MAGNETIC FIELDS may be dangerous ES 2 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 should 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
40. faulty Replace CAUTION If for any reason you do 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 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual 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 S2 and associated S2 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 associated control cable 3 Perform the SCR Diode Rec tifier Bridge Test 4 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
41. feeder control jumpers on Voltage Control Board See NA 5 3 Connect the electrode cable from the K597 XX Manual Input Cable Assembly to the terminal of the m welder and to the wire feeder Connect the work NOTE lt The connection diagram siown in 65 cable to the O O terminal of the weldeReverse this shows the electrode connected for positive 5 hookup for negative polarity See Figure C 6 polarity To change polarity Set the Idealarc DC 400 POWER toggle cm switch to the OFF 0 position y oy i 4 Set the welder VOLTMETER switch to the desired b Move the electrode cable to the negative polarity either DC or DC output terminal c Move the work cable to the positive output the MODE onset voltage 3 position terminal 6 Set the DC 400 OUTPUT CONTROL switch to the d iw the VOLTMETER toggle switch to negative ORemote position and the OUTPUTERMINALS switch to the ORemoteO position FIGURE C 6 IDEALARC DC 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 C 9 C 9 ACCESSORIES FIGURE C 7 IDEALARC DC 400 LN 7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM TO LN 7 INPUT CABLE PLUG 14 PIN AMPHENOL SEMIAUTOMATIC WIRE FEEDERS CONNECTING THE LN 7 TO THE
42. finishes or OneutralsO of the main secondary coils solid state electr onic cir cuitry Minimum to maximum are connected together and the thr ee starts of the output is obtained with a single potentiometer contr ol secondary windings ar e connected to the ectifier bridge assembly In addition the main transformer has INPUT LINE VOLTAGE separate and isolated 115V AC and 42VAC auxiliary CONTACTOR AND MAIN windings The 115V AC winding supplies power to the TRANSFORMER cooling fan and also fers 10 amps of auxiliary power at the terminal strip and 14 pin amphenol to operate The desir ed three phase input power is connected to Wire feeding equipment The 42V AC auxiliary power is the DC 400 thr ough an input contactor located in the available at the 14 pin amphenol only and is otected input box at the r ear of the machine T wo phases of by a 10 amp cir cuit breaker The thr ee 21VAC phase the input line ar e also connected to the contr ol trans angle windings ar e also housed in the main trans former which through the power switch supplies former assembly These windings pr ovide power and power to activate the input contactor OtimingO for the control boar d A reconnect panel allows the user to configur the machine for the desir ed input voltage This AC input voltage is applied to the primary of the main trans former NOTE Unshaded ar eas of Block Logic Diagram ar the subject of discussion IDEALARC DC 400
43. 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 16 16 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F 1 INPUT CONTACTOR CONNECTIONS X1 4232 B L TEST PROCEDURE 1 Disconnect the main input supply power to 5 Apply the correct voltage to the machine the machine and turn the power switch S1 ON 2 With the 5 16 nut driver remove the case 6 Check for 120VAC at the contactor coil top and the reconnect panel cover leads 3 Locate the two leads connected to the input If the 120VAC is NOT present wi
44. of the above voltage 9 Test with an AC voltmeter for proper main tests are incorrect check for loose or input supply voltage from the output side of faulty connections the input contactor CR1 See the Wiring b If the connections are good then the Diagram main transformer may be faulty Re T1to T2 place the main transformer 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 B 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 TERMINAL STRIP Es Co 65 14 AMPHENOL 2 o Terminal Strip Terminal Strip Lead 31 Lead 32 Uu 75 76 77 Expected VAC Amphenol Amphenol Pin K Pin n Lead 41 in 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 13 Test with an AC voltmeter for 21VAC for each phase angle winding at plug P1 on the control board as shown in Figu
45. on the fol lowing page FIGURE C 3 D REMOTE CONTROL ADAPTER CABLE K864 STRAIGHT PLUG 14 PIN TO POWER SOURCE CABLE RECEPTACLE 6 SOCKET TO 1 K857 REMOTE CONTROL 2 K812 HAND AMPTROL 3 K870 FOOT AMPTROL CABLE RECEPTACLE 14 SOCKET TO L 7 WIRE FEEDER IDEALARC DC 400 C 5 ACCESSORIES C 5 K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS Continued 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 Black and white leads not used Tape and insulate Amptol Plus Remote Limit 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 Amptol and Hi Feq Kit 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 K812 K813 POWER SOURCE or K870 Amptrol K799 Hi Freq Kit Arc start cable included with ARC START SWITCH and connect black lead to black and white lead to white Amptol and Kit Plus Remote Limit Contiol The Amptrolswitch will start the Hi Freq kit to turn on gas and high frequency starting for
46. 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 MATERIALS NEEDED NO 000 Fine Steel Wool Penetrox A 13 Lincoln E2529 or Penetrox A 7 16 Open end wrench Allen head type wrenches IDEALARC DC 400 LINCOLN B 47 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 2 Perform the SCR Diode _ Rectifier Assembly Removal an
47. to either CV FCAW GMAW mode or CV Submerged Arc mode depending on the welding pocess being used 2 Set the Idealarc DC 400 OUTPUT CONTROL switch to ORemote O Set the OUTPUT TERMINALS switch to ORemote O 4 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 6 Refer to the LN 8 Operator Manual for instruc tions on how to use the LN 8 IDEALARC DC 400 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 Idealarc 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 proximit
48. to tie pridge The starting cir cuit boar d function is to momentarily A Odry closure of leads 2 and 4 either at the termi change the inductance ef fect that the choke has nal strip or the 14 pin amphenol signals the contr ol the welding cir cuit This is accomplished by changing board to apply gate firing signals to the SCR Diode the amount of Opinch or arc contr ol windings that e Bridge which cr eates a DC voltage at the output of the active in the output choke When weld ent is bridge assembly If the Mode Switch is in the constant established the eed switch closes and the start boar d voltage FCA W GMAW mode this DC voltage is fil becomes inactive tered by the Output Capacitors NOTE Unshaded ar eas of Block Logic Diagram ar the subject of discussion IDEALARC DC 400 4 4 THEORY OF OPERATION PROTECTIVE DEVICES AND CIRCUITS Two thermostats pr otect the DC 400 fr om excessive operating temperatur es and overload conditions Excessive operating temperatur es 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 secondar
49. very much like a switch When a gate signal is applied to the SCR it is tur ned ON and ther is current flow fr om anode to cathode In the ON state the SCR acts like a closed switch When the SCR is tur ned OFF there is no curr ent flow fr om anode to cathode thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes curr ent 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 mor e 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 r emainder of the time in the OFF state The amount of time spent in the ON state is contr olled by the gate LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED An SCR is fir ed by short burst curr ent into the gate This gate pulse must be mor e positive than the cathode voltage Since ther e is a standar d PN junc tion between gate and cathode the voltage between these terminals must be slightly gr eater than 0 6 Once the SCR has fir ed it is not necessary to contin ue the flow of gate curr ent As long as curr ent contin ues to flow fr om anode to cathode the SCR will remain on When the anode to cathode curr ent drops below a minimum value called holding curr ent the SCR will shut f This normally occurs as the su
50. 27 300 324 3 8 24 1045 12540 5 1 4 28 22 25 54 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 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 main transformer for mainte nance or replacement 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 IDEALARC DC 400 LINCOLN B 55 55 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 25 LIFT BAIL REMOVAL TRANSFORMER FIBER BAFFLES BASE MOUNTING BOLTS 4 CAPACITOR 7 STRAPS REMOVAL OF LIFT BAIL 1 Remove Remove the main input supply p
51. 600V 606 e e al 55 p di amp ow amp ow 62 OW 80 17 1609 10 10 10 150 05 320 TP6 C5 TP5 o e TP1 TP2 130V 130V 38J 38J e TP3 130 38J MISC USE SNUBBER SCHEMATIC S 19687 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 in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine IDEALARC DC400 LINCOLN
52. AC see Figure A 5 FIGURE INPUT CONNECTION DIAGRAM FOR 208 208 230 and 230 460 VOLTS 50 60 HZ WARNING VOLTAGE CAN KILL Do not operate with covers Do not touch electrically live parts remove Disconnect input power before Only qualified persons should install servicing use or service this equipment 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 LINK 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX L3 ow CRI 5 2 DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH PROVIDE AT LINES LEAST 600 INSULATION INPUT 2 9 3 CONNECT 11 12 8 L3 INPUT SUPPLY LINES AND TRANSFORMER LEADS Li TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN i 9 4 CONNECT TERMINAL GROUND PER LOCAL AND NATIONAL ELECTRIC CODES GND 5 5 MOUNT THE LINKS 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 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 og 2 DIS
53. ANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN INPUT 4 L1 olu 2 INSULATE UNUSED H3 H4 LEAD TERMINALS SEPERATELY TO PROVIDE iie 9 AT LEAST 600V INSULATION H1 e 999 3 CONNECT TERMINAL MARKED SYSTEM GROUND PER NATIONAL ELECTRIC CODES GND H2 H4 9 4 CONNECT TRANSFORMER LEADS 1 amp 7 2 amp 8 3 amp 9 4 amp 5 amp 6 TO RECONNECT PANEL PILOT 5 TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13 14 15 16 17 18 TRANSF THE LINCOLN ELECTRIC CO CLEVELAND OHIO aes TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS M15666 OUTPUT CONNECTIONS The output welding cables are connected to the output terminals marked 0 0 and 1 recom mended cable sizes for the combined lengths of elec 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 8 8 INSTALLATION
54. CAW GMAW mode and use the mode that pro Y Set toggle to OElectode Positive position if the duces the best welding results electrode is connected to the positive output 3 Air Carbon Arc Cutting Stick Welding High terminal Current Large Puddle Submerged Arc Welding 3 Set the welding MODE switch to welding process Use the CC mode When the Idealarc DC 400 is being used used for Air Carbon Arc cutting the OUTPUT Y CV FCAW GMAW CONTROL potentiometer should be set to 9 ini tially Based on the size of the carbon being used Y CV Submerged Arc or the process turn the potentiometer to a lower CC Stick Tig setting as required by the process You can use 4 Set the OUTPUT CONTROL switch to OLocal carbon rods up to 5 160 8 mm in diameter at cur Exception when using LN 9 LN 9 or rents as high as 450 amps with excellent arc con NA 5 wire feeder set the switch to Remote trol The welder protection circuit protects the Otherwise the wire feeder may automatically shut machine from extremely high short circuiting down pulses 5 Set the OUTPUT TERMINALS switch to the desired mode SEMIAUTOMATIC AND AUTOMATIC WIRE 6 Set the ARC FORCE CONTROL to midrange 5 6 This control is for CC stick or TIG welding only FEEDING WITHAN IDEALARC DC 400 Adjust for best characteristics as necessary When using the Idealarc DC 400 with semiautomatic 7 Set the ARC CONTROL to midrange 3 This con
55. CONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LINES m LEAST 600 VOLT INSULATION L2 INPUT 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS L1 9 o TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN 4 CONNECT TERMINAL GROUND PER LOCAL AND NATIONAL ELECTRIC GND 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 7 INSTALLATION FIGURE 5 INPUT CONNECTION DIAGRAM FOR 230 460 575 VOTS 60 HZ HIGH VOLTAGE CAN KILL not operate with covers remove WARNING Do not touch electrically live parts Disconnect input power before Only qualified persons should install IDEALARC 230 460 575 INPUT SUPPLY CONNECTION DIAGRAM IMPORTANT CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS servicing use or service this equipment NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 575V L3 olw olos p so E CONNECTION FOR 575 VOLTS 60 HZ LINES 1 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H4 PILOT o 0 0 2 1 PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN INPUT CONTACTO L1 olu oH Qs gt 2 INSULATE U
56. CONNECTION 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 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 18 19 IDEALARC DC 400 LINCOLN B 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 th
57. DC TIG welding The Amptrol controls current from the mini mum of the power source to a maximum set by the remote limit control K775 Remote Y Limit Control K812 K813 or K870 Amptrol K843 Adapter Bolt and nut connection 776 Insulate 76 77 andtape 1 2 Arc start cable included with K799 SWITCH and connect black lead to black and K843 white lead to white 799 IDEALARC DC 400 ACCESSORIES CAPACITOR DISCHARGE CIRCUIT K828 1 Mounts inside the DC 400 Recommended when Y 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 Y DC 400 is used with an LN 22 equipped with older K279 Contactor Voltage Control Option Eliminates electrode overrun when gun trigger is released required when later K279 above Code 8800 is used Y 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 per M17060 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
58. E WAVEFORM CONSTANT VOLTAGE SUBARC ONE OUTPUT SCR NOT FUNCTIONING 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 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 ie DC Trigger Internal IDEALARC DC 400 LINCOLN B CH1 0 volts 40 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 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 assist
59. E1868 to mating surfaces IDEALARC DC 400 LINCOLN B 57 57 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 27 EPOXY MIX APPLICATION AREAS 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 IDEALARC DC 400 LINCOLN B F 58 F 58 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 28 D COIL LEAD PLACEMENT MACHINE FRONT a SECONDAR Y COIL LEADS PRIMARY COIL LEADS 3 Install the bottom primary coils one on each of the 7 Place insulation Lincoln Electric part number three legs of the bottom iion assembly The coils 20728 on top of each of the three secondary must be in correct position left center right coils The longer side of the insulation should be Place the coils so that the leads come out at the placed toward the front of the machine where the back of the machine
60. ERATION WELDING OPERATION REMOTE CONTROL OPERATING STEPS The toggle switch on the control panel labeled OOutput Control RemoteO gives you the option of contolling LOCAL CONTROL the machine output from a remote location In the ORemoteO position a wir feeder with remote control The following procedures are for using the Idealarc MS DC 400 in the local control mode of operation For capabilities or a remote control device such as a K775 remote control of the machine see the REMOTE must be connected to the DC 400 Refer to the CONTROL section Accessories section for wire feeder installation infor mation 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 starting work It is important that you WEEDING PROCEDURE RECOMMENDATIONS follow these operating steps each time you use the Select Mode Switch position based on type of welding machine to be done 1 Turn on the main AC input power to the machine 1 FC AW GMAW Welding Other Open Arc Processes 2 Set the VOLTMETER or switch to the Use the CV FCAW GMAW mode appropriate position 2 Submerged Arc Welding Use the CV Submerged Y Set toggle to Elecwde Negative position if Arc mode If performing high speed welding the electrode is connected to the negative switch between the CV Submerged Arc and the CV output terminal F
61. G 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 the Accessories section of this manual for spe cific instructions on connecting and using the Multiprocess Switch 960CT IDEALARC DC 400 LINCOLN 5 Section 1 Section B 1 OPERATION SECTION ciem ced d og e ed cu o Dette Section B Safety Instructions cnet e eei endi exer taa B 2 General Description ia tut te bae Ra ep D ORE rA ERA EH e rd d B 3 Recommended 55 5 3 Operational Features and Controls B 3 Design Features and Advantages B 3 Welding Capability Eee tat I D Fede Aan E RENE NER ERE RE GR ARENIS B 3 Liritations be e p RE B 3 Controls Settings etc nt tu ee e e Le pte a Lee e e vex ed pea B 4 Welding Operation re tee ree teer eh e B 6 Operating Steps n ntes de tra e B 6 Local ei abe e C n P A GROVE OUS B 6 Remote Control EE 6 Welding Procedure Recommendations sssssssseeeeee memes B 6 Semiautomatic and Automatic Wire Feeding with an Idealarc 400 B 6 NA 3 Automatic Wire B 7 Good Arc Striking Guidelines for the
62. IDEALARC DC 1 400 14 PIN AMPHENOL 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 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 NOTE Welding cable must be sized for the current and duty cycle of the application TO WORK K584 XX INPUT CABLE ASSEMBLY ELECTRODE CABLE TO WIRE FEED UNIT Connect K584 XX Input Cable between the DC 400 and the LN 7 See Figure C 7 Set the welder VOLTMETER toggle switch to the desired polarity either DC or DC Set the MODE switch to a CV constant voltage position at the welder Adjust wire feed speed at the LN 7 and set the welding voltage with the OUTPUT CONTROL NOTE If optional remote control is used place the OUTPUT CONTROL and the OUTPUT TERMI NALS switch in the Remote position IDEALARC DC 400 LINCOLN B ACCESSORIES FIGURE C 8 LN 7 WIRE FEEDER CONN ECTION TO THE IDEALARC DC 400 LN 7 WIRE FEEDER CONTROL CABLE TO 3 LN 7 INPUT CABLE PLUG 210191818 2 Bg 75 76 77 NEGATIVE POSITIVE ELECTRODE TO CABLE TO WORK AUTOMATIC EQUIPMENT CONNECTING THE LN 7 TO THE NOTE If the work cable le
63. IDEALARC DC 400 SVM 122 A Oct 1996 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 Q t ASA SSS STRAT 4 SERVICE MANUAL World s Leader in Welding and Cutting Products ELECTRIC 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 SAFETY WARNING A CALIFORNIA PROPOSITION 65 WARNINGS 1 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 birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHO
64. ING 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 overheating 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 p
65. IRE 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 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 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 the machine is in opera tion 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 DC AMMETER Displays output current when welding DC VOLTMETER Displays output voltage when welding VOLTMETER ELECTRODE OR ELEC TRODE SWITCH Selects the electrode polarity forthe remote work sensing lead 21 when using automatic or semiautomatic wire feeders IDEALARC DC 400 LINCOLN B OP
66. Ifthe voltage is 3 6 volts only when the switch is closed or if there is no voltage when the switch is closed the SCR is defective NOTE Be sure the battery is function ing properly A low battery can affect the results of the test Repeat Battery Test Procedure in Step 10 if needed Open switch SW 1 Reconnect the tester leads See Figure F 16 a Connect tester lead A to the cathode b Connecttester lead C to the anode c Disconnecttest lead G from the gate Close switch SW 1 Read meter for zero voltage a If the voltage is zero the SCR is func tioning b If the voltage is higher than zero the SCR is shorted Perform the Active Test Procedure outlined in Steps 11 19 for SCRs 2 and 3 Replace all SCR assemblies that do not pass the above tests Replace all molex plugs onto the control board and snubber board Reconnect lead 204 to resistor R2 33 33 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT CURRENT MODE NO LOAD CH1 0 volts 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 SCOPE SETTI
67. LEAD 10 11 12 13 14 15 F 32 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 16 SCR TESTER CIRCUIT AND SCR CONNECTIONS SW1 R2 6 VOLT LANTERN BATTERY ES A R1 4 ohms 10 watts SCR X R2 3 ohms 10 watts UNDER TEST S 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 Test the voltage level of the battery Short leads and C Close switch SW 1 Battery voltage should be 4 5 volts or higher If lower replace the battery Connect tester to the SCR 1 as shown in Figure F 16 a Connect tester lead A to the anode b Connect tester lead C to the cathode c Connect tester lead to the gate Close switch SW 1 NOTE Switch SW 2 should be open Read meter for zero voltage a Ifthe voltage reading is higher than zero the SCR is shorted Close or keep closed switch SW 1 Close switch SW 2 for 2 seconds Release and read meter a Ifthe voltage is 3 6 volts while the switch is closed and after the switch is open the SCR is functioning IDEALARC DC 400 LINCOLN B 16 17 18 19 20 21 22 To test SCRs construct the circuit outlined above Resistor values are plus or minus ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC b
68. 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 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 MATERIALS NEEDED Analog Volt Ohmmeter Multimeter 5 16 Nut driver Idealarc DC 400 Wiring Diagrams See the Electrical Diagrams section of this manual IDEALARC DC 400 LINCOLN B 27 F 27 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE 9 CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS DC 400 CONTROL G2588 X M15370 X SNUBBER TEST PROCEDURE 1 Disconnect the main input supply power to 5 Locate and remove molex plug P5 from the the machine snubber board See Figure F 9 2 With the 5 16 nut driver remove the case 6 Ro
69. NECTION MODE INVERTER IDEALARC 00400 CONTROL BOARD SCHEMATIC 02586 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 ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine IDEALARC 0 400 ELECTRICAL DIAGRAMS Starting PC Board M14520 Schematic LINCOLN 98961 S 228 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD VOLTS J6 RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED DIODES 1 AMP 400 VOLT UNLESS OTHERWISE SPECIFIED OPAMPS LM124 UNLESS OTHERWISE SPECIFIED _ z COMMON CONNECTION NEN 100 2 1 31 J6 e gt 4 lt 03 02 5851 1 oW 7 5 9 0V 4A pen 1N4007 1 50K P IN Ri e gt Mia kn G e 1 00K 32 J6 qae wet LOK A We 7 50V 20 T R2 e 4 e e e e e W 1N4007 2500 D1 J6 8 NA 5 3 215 216 11 17 95G
70. NGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC Tigger Internal IDEALARC DC 400 LINCOLN B 34 34 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE FCAW GMAW MAXIMUM OUTPUT SETTING NO LOAD CH1 He EH 0 volts 20 volts 2 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 2 milliseconds in time 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 2 ms Div Coupling teret DC Trigger Internal IDEALARC DC 400 LINCOLN B F 35 F 35 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CONSTANT VOLTAGE SUBARC MAXIMUM OUTPUT SETTING NO LOAD CH1 0 volts 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 pr
71. NIWY SL indino ES Scc ONIGNNOYD anis 1112813 VOL quvos DNILuVIS 4 L 02 lt 21 lt SOE elt 212 lt 01 5 5 6 1 A 8 802 lt 4 lt 902 9 902 1 5 lt roz v cd e e p vic 602 1 lt 29 QUuVOS8 10Y LNOD o D 2 2 2 00 1 9 31 4700 95 HOLIMS 3313W110A 95 TOYLNOD 32803 7 su 800 AINO 22 NI 275 i aaivniov tc avs 4 indino avs 80n5 A2 22 MVW9 MV23 A2 HOLIMS 11 TOYLNOD o cv M 1H917 NOILD3LOYd TVWHU3HL vrs 5 2 5 0 22 MVW5 MV23 A2 11 5 a 144 o tu auvos u388nNS AOS 2000 1 933 32 HDLIMS u A18Wi3SSV 331311233 AV13u ADYVHISIC NOI1dO NOILdO Y
72. NUSED H2 H3 LEAD TERMINALS SEPERATELY TO PROVIDE 4 AT LEAST 600V INSULATION H1 H2 e 3 CONNECT TERMINAL MARKED SYSTEM GROUND PER NATIONAL ELECTRIC CODES GND H4 4 CONNECT TRANSFORMER LEADS 16 17 18 4 amp 13 5 amp 14 6 amp 15 RECONNECT PANEL a 5 SEPERATELY PROVIDE AT LEAST 600V INSULATION 1 2 3 7 8 9 b TRANS TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS L3 Jo w oL 19 so CONNECTION FOR 460 VOLTS 60 HZ 77 LINES 2 1 CONNECT 11 L2 amp L3 INPUT SUPPLY LINES AND H1 amp H3 PILOT 0 0 L2 M 29 PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN INPUT CONTACTO L1 m 2 INSULATE UNUSED H2 H4 LEAD TERMINALS SEPERATELY TO PROVIDE 5 9 poe 66 AT LEAST 600V INSULATION H1 T H2 e 3 CONNECT TERMINAL SYSTEM GROUND PER NATIONAL ELECTRIC CODES GND H3 4 CONNECT TRANSFORMER LEADS 1 2 3 4 amp 7 5 amp 8 6 amp 9 TO RECONNECT PANEL PILOT 5 TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13 14 15 16 17 18 TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS L3 Jo w oL o CONNECTION FOR 230 VOLTS 60 HZ S T RECONNECT LINES tul 1 CONNECT 11 L2 amp L3 INPUT SUPPLY LINES AND H2 PILOT o kcc 9 L2 2 29 PANEL TR
73. OD 182 Po L SINIT AlddNSOL ZH aN 3802 1 21812313 1VNOILVN OL SLIOA SVE 319 15 YOLIVLINOD 182 N LET 123NNOO3U 3905 1V21Uu12313 TVNOILVN Yad OL e EN 1 g S3NI1 Alddfs OL 13NVd 123NNO23U H e _ 3402 1v2Iu12313 TVNOILVN Yad OL CA 3123 02 NMOHS 35V110A 00 0 e LIX EA SIN cH Aldds 01 39V110A 303 03123NNO2 NMOHS S110A 9 19 110 319 15 Ine de one of the enclosure panels of your machi insi is pasted ic to your code iagram speci The wiring di is manual is for reference only It may not be accurate for all machines covered by th iagram This d NOTE IDEALARC DC400 LINCOLN E G 3 10161 3 6 6 01 NOILdO NO LN3S3Hd AYLINIUD NOILVINSNI A 009 15931 3GdlAOUd OL A131VHUVdidS AINO JDYVHISIC NO LN3S3Ud 5310 auvos 724 30 JAIS LNINOdWO D 32 300145 ONIYIGWNN ALIAVO HOLO3NNOO er sf 9r 21 8 Nid 9 Nid v v 2 LL t 1 01 46513 834 SIOSWAS 21312313 NOILdO
74. OLIDVdVD YyOLIDVdVD U3WHUOJSNVUL T0U1NOOD ZL LEZ Lzx ASLL LH L NOIL23NNO2 NO NMOHS SV aLVINSNI 123NNOD uq3WHOdSNVHUL NIVW L1 AYVWIYd wollog 1105 1VISOWHU3H t d 1 1VISOWH3HI dOl 235 EEZ YOLIVINOD A 182 1102812 dWVOL 1102 OL uadwnr aval YOLIVINOD 182 EET gu 1v21812313 TVNOILVN Yad OL v S3NI1 OL 13NVd CA 022 Q3123NNOO NMOH S 39V110A 0 086 022 5102 AYVWIYd OL REC ord 914 182 ti 816 pem nonc xf uva zd 13NVd 123NNO23H S3NI1 at Alddns OL H 8 N 3009 121415313 TVNOILVN Yad OL CA 08 803 Q3123NNO2D NMOH 5 A 005 086 ASLL YOLOW 51102 01 S3NIH VW 00 062 A0vv 08 07C NO 4 LON 30 NOII23NNOO SIHL ON uayvaus QA 1102812 6 OL LH EEZ 1102 7 YOLIVIN
75. OTE 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 carbon arc torch User supplied 4 0 107 mm jumper IDEALARC DC 400 LINCOLN B 4 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 Or emote output contr ol is available This is the same r emote contr ol that is used on the Lincoln and DC 600 power sour ces K775 The K775 consists of a contr ol box with 28 ft 8 5m of four con ductor cable This connects to terminals 75 76 and 71 on the terminal strip and the case gr marked with the symbol on the machine These terminals ar e located behind the contr ol panel on the front This device will give the same contr ol as the out put contr ol on the machine REMOTE CONTROL ADAPTER CABLE K864 A cable 12 inches 30 m long to connect K857 Remote Contr ol K812 Hand Amptr ol or K870 Foot Amptr ol 6 pin connector wit
76. RC DC 400 59 F 59 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 30 PRIMARY THERMOSTAT LOCATION TOP VIEW INSULATION FRONT VIEW 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 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 IDEALARC DC 400 LINCOLN B 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 Carefully position the lift bail onto the machine NOTE The following procedure assumes you have base Using the 9 160 socket wench attach the completely reassembled the transformer coils lift bail to the base of the machine with four bolts as described in the procedure above The flat washers and lock washers lower iron has_remained in place in the 2 Using the 9 160 socket wench attach the lift bail machine Figures F 25 fand F 26 to the transformer top and bottom irons with four 1 Resolder the choke
77. TAGE STABILIZER 044 144004 Lo 012 034 0 i Hug z 3 68 067 015 018 2 sw 144004 1N4004 14004 184004 10V FORCE ONTROL Y 028 POT 1N4004 Ros ARC FORCE AMP HBV a A RI 4 M M A MIN OUTPUT BUFFER 10K V IN 033 03 g 0 1N4004 184004 x f 4 ay NG CIRCUIT 2 i M E 144004 1N4004 50V 2 4857 yY 15K 15 ov R149 R316 R328 68 1k 1 4W R150 15K GENERAL INFORMATION 2 184004 076 VOLTAGE NET D ORGUT BOARD SOURCE POINT 1N4004 M FILE G2586 1BD EARTH GROUND CON
78. TER PROBE CASE BACK 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 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 probes 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 IDEALARC DC LINCOLN B 8 400 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 Lincol
79. ULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING 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 Z49 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines 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 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
80. agrams See the Electrical Diagrams section of this manual IDEALARC DC 400 LINCOLN B 30 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 DC 400 CONTROL G2588 X M15370 X SNUBBER FIGURE F 14 RESISTOR R2 LOCATION TEST PROCEDURE 1 Disconnect the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Remove the screws holding the front panel and lower the panel Disconnect the welding cables from the welding output terminals Locate and remove molex plugs P1 and P3 from the control board See Figure F 12 IDEALARC DC 400 LINCOLN B Locate and remove molex plug P5 from the snubber board See Figure F 13 Rotate the mode switch S4 to the constant current CC position Locate and remove lead 204 from resistor R2 40 ohms 50 Watts See Figure F 14 31 31 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 15 HEAT SINK TEST POINTS INSULATING PAINT 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 B 32 ANODE CATHODE GATE
81. ance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in inspecting cleaning and replacing the input contactor MATERIALS NEEDED Phillips head screwdriver 5 16 socket wrench Flat heat screw driver Low pressure air source IDEALARC DC 400 LINCOLN B 41 41 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT continued FIGURE F 17 INPUT CONTACTOR CLEANING AND REMOVAL 3 12 ie C1 4 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL CLEANING PROCEDURE 1 Remove the main input supply power to the machine 2 Locate and get access to the input contac tor CR1 in the input box See Figure F 17 3 Remove the input contactor cover plate using a phillips head screwdriver WARNING ZR Do not apply input power to the machine with the input contactor cover plate re moved 4 Blow out any dirt or dust in or around the contacts with a low pressure air stream 5 Inspect the contacts for signs of excessive wear pitting or contacts fused stuck together a If any of these conditions are present replace the input contactor assembly 6 Replace the input contactor cover plate CONTACTOR REPLACEMENT PROCEDURE 1 Disconnect main input supply power to the machine Locate and get access
82. ase 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 S 1 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 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 5 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 Perform the Input Contactor 2 Check the associated leads for loose or faulty conn
83. ays 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 6 c and 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 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 fum
84. 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 GLASTIC STIFFENERS THRU BOLTS REMOVAL OF CHOKE AND TOP 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 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 4 Label and cut or desolder the 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
85. ble 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 start where the wire tends to Oblast of 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 OOn the 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 Set start time at 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 8
86. 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source IDEALARC DC 400 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 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 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 wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment 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 Alw
87. control coil leads to the arc bolts control switch 3 Attach the sheet metal screw that holds the 2 Attach the bottom choke lead to the negative recti 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 Connect the 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 to the main trans former 11 Install the machine case top and sides IDEALARC DC 400 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 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 60 200 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 Constant Voltage 42 5 46 5 FCAW GM AW 42 5 46 5 Consta
88. d 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 5 Clean the area on the heat sink around the SCR mounting surface using 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 A 13 Lincoln Electric 2529 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 48 48 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 21 1 2 WIDE LEAF SPRING SPRING CURVATURE EXAGGERATED
89. d 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 10A 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 TERMINALSTRIP 1 Disconnect main AC input power to the Idealarc DC 400 2 Set Idealarc DC 400 POWER toggle switch to the OFF 0 position 3 Connect the wire feeder control cable leads to the Idealarc DC 400 terminal strip as shown in Figure 4 Connect the wire feeder control cable ground lead to the frame terminal marked 777 NOTE The ldealarc DC 400 must be properly grounded IDEALARC DC 400 7 ACCESSORIES FIGURE C 4 D NA 3 WIRE FEEDER CONNECTION TO THE IDEALARC DC 400 NA 3 WIRE FEEDER CONTROL CABLE AUTOMATIC CONTROL BOX amp NEGATIVE POSITIVE ELECTRODE WORK AUTOMATIC EQUIPMENT
90. e 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 9 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 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 tifier Bridge Test 6 The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely
91. e 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 capacitor 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 46 46 TROUBLESHOOTING amp REPAIR SCR 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 If for any reason you do not understand
92. ections between the input contactor CR 1 the reconnect panel and the main transformer See Wiring Diagram 3 Perform the Main Transformer 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 6 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
93. erated 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 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 IDEALARC DC 400 LINCOLN B 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 The 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 4 probe to gate probe to cathode SCOPE SETTINGS Volts Div 2V Div Horizontal Sweep 5 ms Div Coupling oe DC Trigger Internal IDEALARC DC 400 LINCOLN B 39 39 TROUBLESHOOTING amp REPAIR ABNORMAL OPEN CIRCUIT VOLTAG
94. es 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 irritating 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 B SAFETY WELD
95. es and the reconnect panel Inspect the input contactor reconnect panel and primary leads to the main trans former for loose or faulty connections See Figure F 5 a Confirm that the reconnect panel is connected properly for the three phase main input supply power supplied to the machine See the reconnect panel connection diagram located on the inside of the input box assembly access door IDEALARC DC 400 LINCOLN B MAIN TRANSFORMER d LEADS H H SIDE VIEW Connect main input supply power to the machine Set the ON OFF power switch to ON a Make sure the input contactor CR1 energizes and the fan runs Test with an AC voltmeter for proper main input supply voltage to the line side of the input contactor CR1 See the Wiring Diagram a L1to L2 b L2 to L3 c L1to L3 23 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 11 Test with an AC voltmeter for approximate ly 42VAC across each of the three main proper ra RE secondary str leads located at the age is being supplied SCR Diode Rectifier Bridge Remove the red insulating paint to achieve good con b If proper voltage is not present in any tact if necessary See Figure F 6 See the or all of the three phases check input Wiring Diagram fuses and leads a If one or more
96. h wir e feeder 14 pin connector and the machine 14 pin connector If a remote contr ol or amptr ol is used alone the wir e feed er connection is not used Figur e ADAPTER CABLE K843 A five wir e cable 12 inches 30 m long is available for easy connection of standar d K812 Hand Amptr ol or K870 Foot Amptr ol The cable has a 6 pin MS style connector which connects to the Amptr ol and termi nals which connect to 75 76 and 77 on the machine terminal strip and to the case gr ounding scr ew The Amptr ol will contr ol the same range of output as the curr ent contr ol on the welder If a smaller range of contr ol is desir ed for finer adjustment a K775 Remote may be used in conjunction with the Amptr ol Adapter Cable Kit Connection information is included with the Amptrol Adapter Cable Kit The Amptr ol arc start Switch does not function in this application ounding scr ew K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS WARNING A ELECTRIC SHOCK can kill Y 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 Amptr ol K812 K813 or K870 r emote contr ol K775 and Hi Fr eg K799 accessories to the DC 400 The OUTPUT CONTROL switch must be ORemote for ol to contr ol curr ent Accessories may be combined and connected in four dif ferent ways as shown
97. high the input con tactor is faulty Replace the input contactor 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 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 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 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 M ultimeter 5 16 Nut driver IDEALARC DC 400 Wiring Diagrams See the Electrical Diagrams section of this manual IDEALARC DC 400 LINCOLN B 19 19 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST con
98. his 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 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 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 specif
99. his can cause the elec trode to stub Set N43 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 7 Start and make the weld NA 5 AUTOMATIVE WIRE FEEDER When using the Idealarc DC 400 with the NA 5 wie feeder set the controls on the Idealarc DC 400 as fol lows for the best performance 1 Turn OFF main AC input power to the Idealaic DC 400 2 Connect the electrode cables to the terminal polarity to be used 3 the VOLTMETER or switch to the same polarity as the electrode cable connection 4 Set the OUTPUT CONTROL switch to ORemote O Set the OUTPUT TERMINALS switch to ORemote O Set the Idealarc DC 400 welding MODE switch to the position that matches the welding pocess being used a For submerged arc welding set welding MODE SWITCH TO CV SUBMERGED ARC position b For all open arc welding processes set weld ing MODE switch TO CV FCAW GMAW posi tion 7 Set the ARC CONTROL to midrange 3 welding starts adjust as necessary After LN 8 SEMIAUTOMAIC WIRE FEEDER To use the LN 8 Semiautomatic Wire Feeder with the Idealarc DC 400 1 Set the DC 400 welding MODE switch
100. ic 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 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 B TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A WARNING Remove the PC Boar d from the static shielding bag and place it dir ectly into the equipment DonO t set the PC Board or near paper plastic or cloth which o va could have a static char ge If the PC Boar d be Have an electrician install and service installed immediately put it back in the static this equipment T urn the machine OFF shielding bag before working on equipment Do not touch electrically hot parts Y f the PC Boar d uses protective shorting jumpers don remove them until installation is complete Y f you return a PC Board to The Lincoln Electric Sometimes machine failur es appear to be due to Company for cr edit it must be in the static shielding board failures These pr oblems can sometimes be bag This will pr event further damage and allow
101. ions dirt may clog the cooling air channels causing the machine to run hot Blow out the machine atr egular intervals with low pressur e air Clean the following parts See Figur e D 1 Y Main transformer and choke Y SCR diode bridge Y Control PC boar d Y Starting PC boar d Y Electrode and work cable connections Y Fan assembly NOTE The fan motor has sealed bearings that r no service equir e Y Remote contr ol terminal strip TS1 NOTE Keeping r emote contr ol terminal strip TS1 clean is especially important in damp locations IDEALARC DC 400 0 3 C SS MAINTENANCE FIGURE D 1 GENERAL COMPONENT LOCATIONS IDEALARC DC 400 LINCOLN 5 D 3 an oS z lt lt OFS x _ Ano rit 2 1 5 E 4 zo i lt uec pose S xm 5 3 ING Aus lt 2 lt 2 4 545 2002 2 20 Oo lt lt 1 2 3 4 5 6 7 8 9 10 11 12 Section 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation tree Section E General DescriptiOn et RR e Ret nde Do E 2 Input Line Voltage Contactor and Main 5
102. ld result in damage to the machine ELECTRICAL DIAGRAMS Snubber PC Board M15370 Layout LINCOLN ITEM REQD DESCRIPTION 1 2 3 68 400 C4 C5 05 600 H1 R2 R3 10 2W 38 4 1 5 160 NOTE Lincoln Electric assumes responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components 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 Improper PC board repairs could result in damage to the machine TP6 GO 80J G 6 IDEALARC DC400 ELECTRICAL DIAGRAMS G 7 Control PC Board G2588 Schematic 3 A 184004 144004 POWER UP OUTPUT CLAMP a A ose 144004 061 144004
103. n 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 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 MATERIALS NEEDED Volt Ohmmeter M ultimeter 5 16 Nut driver IDEALARC DC 400 Wiring Diagram See Electrical Diagrams section of Manual IDEALARC DC 400 LINCOLN B F 22 F 22 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 5 INPUT CONTACTOR RECONNECT PANEL AND PRIMARY LEADS TO MAIN TRANSFORMER LOCATIONS INPUT SUPPLY INPUT RECONNECT CABLE ENTRY CONTACTOR PANEL OPENING CR1 ASSEMBLY FRONT VIEW TEST PROCEDURE 1 Setthe ON OFF power switch to OFF 5 2 Disconnect main input supply power from the machine With the 5 16 nut driver remote the case top and sid
104. ngth is less than 25 feet IDEALARC DC 400 TERMINAL STRIP 1 Disconnect main AC input power to the Idealar DC 400 2 Set Idealar DC 400 POWER toggle switch to the OFF 0 position 3 Connect the wir e feeder contr ol cable leads to the Idealar c DC 400 terminal strip as shown in Figur e C 8 4 Connect the wir e feeder contr ol cable gr ound lead to the frame terminal marked PE NOTE The DC 400 must be pr operly grounded 5 PERFORM THIS STEP ONL Y IF THE LN 7 IS EQUIPPED WITH A METER KIT Extend wir e feeder contr ol cable lead 21 so it can be connected dir ectly to the work piece a Make a bolted connection using WG 14 or larger insulated wir e Tape the bolted connec tion with insulating tape IDEALARC and the connections to the work piecear e secur e then wir e feeder contr ol cable lead 21 can be connected dir ectly to the DC 400 terminal strip b An 5 16586 X remote voltage sensing work lead is available for this purpose Keep the 21 lead electrically separate fr the work cable cir cuit and connection d Tape the 21 lead to work cable for ease of use NOTE The connection diagram shown in Figur C 8 shows the electr ode connected for positive polarity To change polarity a Set the IDEALARC DC 400 POWER toggle switch to the OFF 0 position b Move the electr ode cable to the negative output terminal c Move the work cable to the
105. ns 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 B Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES Accessories cti deeper dee ead wal ond a e Section C o op pe RR iA haan C 2 Factory Installed Option ice cet eg ed eh ie de ipe C 2 Field Installed Options ot oh ee e e d t nde C 2 Cover 14 Pin 2 01 1 enne nen C 2 Multiprocess Switch 804 1 C 2 Remote Output Adapter Cable 6857 C 4 Remote Control Adapter Cable K864 sss nmn C 4 Amptrol Adapter Cable 843 4 Capacitor Discharge Circuit 828 1 nennen C 6 HieFregq Kit K799 eee tee op e nnb e e A o ERR E rr Ee RE de C 6 Amptrol Adapter for K799 K915 C 6 Undercarriages K817 K817R 841 C 6 Connection of Lincoln Electric Automatic or Semiautomatic Wi
106. nt Voltage 43 5 47 5 SUB ARC 43 5 47 5 Auxiliary Output 31 32 114 124 Auxiliary Output 231 3432 109 119 Auxiliary Output 441 442 43 8 47 5 Auxiliary Output 441 442 42 0 45 6 IDEALARC DC 400 LINCOLN 5 F 62 F 62 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR continued 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 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 Constant Voltage Output Control at Maximum 525 Amps 9 41 5 Volts Min SUB ARC IDEALARC DC 400 LINCOLN B TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagram Section Section G Wiring Diagram Codes 9847 9848 G 2 Wiring Diagram Code 9850 G 3 Control PC Board G2588 G 4 Starting PC Board M14520 Layout G 5 Snubber PC Board M15370 G 6 Control PC Board G2588
107. o 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 gaining access to the fan blade and fan motor for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 3 8 Wrench Allen head type wrench IDEALARC DC 400 LINCOLN B 43 43 TROUBLESHOOTING amp REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continued FIGURE F 18 FAN MOTOR MOUNTING DETAILS MOUNTING BRACKETS PROCEDURE 1 Remove the main input supply powerto the machine 2 Using the 5 16 nut driver remove the case top and sides 3 The fan blade can be removed using the Allen head wrench NOTE You may need to loosen the machine case back to gain clearance to remove the fan See Figure F 18 4 Ifthe fan motor is to be removed the leads to the motor must be disconnected This will require cutting the wires or breaking the splice IDEALARC DC 400 LINCOLN B SHROUD ATTACHED TO CASE BACK Remove the four mounting nuts and associ ated flat and lock washers that hold the motor to the mounting bracket See Figure F 18 Carefully remove the fan motor To replace the fan motor mount the motor to its mounting bracket using the four nut and associated flat and lock washers Resplice any motor leads cut for remo
108. obes 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 DC Internal IDEALARC DC 400 LINCOLN B F 36 F 36 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CONSTANT VOLTAGE FCAW GMAW MODE CH1 0 volts 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 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 Internal IDEALARC DC 400 LINCOLN B 37 37 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CONSTANT VOLTAGE SUBARC MODE CH1 0 volts 20 volts 5 ms This is the typical DC open circuit voltage waveform gen
109. oltage with the WIRE FEEDER VOLTAGE CONTROL Place the OUTPUT CONTROL switch in the ORemote position and the OUTPUT TERMINALS switch in the ORemoteO position FIGURE C 10 D IDEALARC DC 400 LN 8 OR LN 9 WITH K595 XX CABLE TO LN8 LN9 INPUT CABLE PLUG 14 PIN AMPHENOL K595 XX INPUT CABLE ASSEMBY ELECTRODE CABLE TO WIRE FEED UNIT TO WORK IDEALARC DC 400 ACCESSORIES CONNECTING THE LN 742 TO THE IDEALARC DC 400 14 PIN AMPHENOL 1 Disconnect main AC input power to the Idealar 5 set the welder VOL TMETER switch to the desir ed DC 400 2 Setthe POWER toggle switch to the OFF 0 posi tion 3 Connect the electr ode cable fr om the LN 742 to the O terminal of the welder Connect the work cable to the O O terminal of the welder Reverse this hookup for negative polarity See Figur e C 11 NOTE Welding cable must be sized for the and duty cycle of the application 4 Connect the K592 Contr ol Cable to the 14 pin amphenol on the IDEALARC DC 400 and to the input cable plug on the LN 742 See Figur e C 11 polarity either DC or DC 6 Set the MODE switch to a CV constant voltage position Adjust wir e feed speed at the LN 742 and set the welding voltage with the output ARC CONTROL to constant voltage position at the welder NOTE If optional emote contr ol is used set the OUTPUT CONTROL switch to the ORemote position and the OUTPUT TERMINALS switch
110. or 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 small 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 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 14 14 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The Arc Force control R5 has no effect on the arc POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS 1 The Arc Force control is active only in the Stick Mode 2 The effect of the Arc Force con trol will be less noticeable at high welding currents Weld at low current
111. ower 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 left 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 29 5 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 B Remove the lift
112. p ply voltage passes thr ough zer o into the negative por tion of the sine wave If the SCR is tur ned on early in the positive half cycle the conduction time is longer resulting in gr eater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output IDEALARC DC 400 Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section mee Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting F 3 Troubleshooting 4 F 14 Test Procedures Input n eere dna A hr IR RE Ce RR OH au dean RETE F 15 Control Transformer T2 Voltage F 18 Main Transformer T1 Voltage F 21 Static SCR Diode Rectifier Bridge F 26 Active S ohio ote deret el F 29 Oscilloscope Waveforms 33 Normal Open Circuit Voltage Waveform Constant Current F 33 Normal Open Circuit Voltage Waveform Constant Voltage FCAW GMAW F 34 Normal Open Circuit Voltage Waveform Constant Voltage F 35 Typical Output Voltage Waveform Constant Voltage
113. p REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Poor arc striking when using semi 1 Make surethe correct weld pro 1 Check reed switch CR3 for automatic or automatic wire cedures are being used proper operation Switch feeders Electrode Gas Etc should be normally open until 2 Check the welding cables for weld current is established loose or faulty connections 2 The start board may be faulty Replace 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 B 13 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 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 f
114. positive output terminal d Set the VOLTMETER toggle switch to nega tive DC 400 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 INPUT CABLE 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 Idealar DC 400 Set the Idealar c DC 400 POWER toggle switch to the OFF 0 position Connect the wir e feeder contr ol cable leads to the Idealar c DC 400 terminal strip as shown in Figur e C 9 Connect the wir e feeder contr ol cable gr ound lead to the frame terminal marked nm Extend wir e feeder contr ol cable lead 21 so it can be connected dir ectly to the work piece Make bolted connection using WG 14 larger insulated wir e Tape the bolted connec tion with insulating tape b An 5 16586 X remote voltage sensing work lead is available for this purpose Keep the 21 lead electrically separate fr the work cable cir cuit and connection d Tape the 21 lead to work cable for ease of use NOTE The connection diagram shown in Figur 7 om ELECTRODE CABLE TO AUTOMATIC EQUIPMENT NOTE Using the extended 21 lead eliminates the need to use the LN 9 s
115. r 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 Ne jamais plonger le porte lectrode dans l eau pour le refroidir e Ne jamais toucher simultan ment les parties sous ten sion des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 2 Dans le 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 3 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 ble
116. re C 6 Automatic Wire Feeders etes tener c De e Den p C 6 NA 3 TermitalS trip uade C 6 NA 5 T rminal Strip iie oett eter C 7 NA 3 NA 5 14 Pin C 8 Semiautomatic Wire C 9 ENZZ 14 Pin eue Medaka c te eoe C 9 LNE Terminal add e ra E C 10 LN 8 or LN 9 Terminal 5 2 nnns C 11 LN 8 or LN 9 14 Pin C 12 742514 perve bue Fan guo C 13 IDEALARC DC 400 LINCOLN B ACCESSORIES OPTIONS ACCESSORIES FACTORY INSTALLED OPTION DIODE OPTION This factory installed option allows use of the cold start ps cold eo ine of the 5 th Connecting the TET to the idealarc DC Sod in this section of the manual 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 17062 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 au
117. re F8 and the accompanying table a Remove the sheet metal screws from NOTE f the main input supply voltage the control box cover with the 5 16 varies the main transformer voltages will nut driver and flip the cover down It vary proportionately does not have to be completely removed to perform the tests a If the voltage is low remove plug P1 and recheck the voltage for 21VAC If b Ifthe above voltage checks are incor the reading is normal the control board rect check for loose or faulty wiring may be faulty Replace the control Check continuity board c If the wiring is good then the main b If one or more of the voltage tests are transformer may be faulty Replace the incorrect check for loose or faulty main transformer wiring the wiring is good then the main IDEALARC DC 400 LINCOLN 5 transformer may be faulty Replace the main transformer 25 25 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 8 CONTROL BOARD PLUG P1 LOCATION Plug P1 DC 400 CONTROL Plug 3 G2588 X 3201 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 26 26 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST WARNING Service and repair should be performed by only
118. remote work lead accessory which has a dir ect work lead jack 6 Connect LN 9 wir e feeder contr ol jumpers on Voltage Contr ol board See LN 9 Operator s Manual e C 9 shows the electr ode connected for positive polarity To change polarity Set the Idealar c DC 400 POWER toggle switch to the OFF 0 position b Move the electr ode cable to the negative output terminal Move the work cable to the positive output terminal d Setthe VOLTMETER toggle switch to negative 9 Set the OUTPUT CONTROL switch to the ORemoteO position and the OUTPUT TERMINALS switch to the ORemoteO position IDEALARC DC 400 ACCESSORIES CONNECTING THE LN 8 OR LN 9 TO THE NOTE Welding cable must be sized for the ent IDEALARC DC 400 14 PIN AMPHENOL and duty cycle of the application 1 Disconnect main AC input power to the Idealar 4 Connect the input cable K595 XX between the DC 400 14 pin amphenol on the DC 400 and the input 2 Setthe POWER toggle switch to the OFF 0 posi cable plug onthe ENS Or PINES SEE FIGUR tion 5 Set the welder VOL TMETER switch to the desir ed 3 Connect the electr ode cable from the LN 8 or Polarity y Den or Deren LN 9 to the terminal of the welder Connect 6 Set the MODE switch to a CV constant voltage the work cable to the O O terminal of the welder position 2 hookup Tor S88 7 Adjust wir e feed speed at the LN 8 or LN 9 and 9 ad set the welding v
119. rotective 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 if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the 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 Oylinders 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 o
120. s 4 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 5 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 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie tincelles 7 Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie 8 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 cables jusqu ce qu ils se rompent 9 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 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage netto
121. s less than 150 amps and check the Arc Force control function RECOMMENDED COURSE OF ACTION 1 Check the Arc Force control potentiometer R5 for correct resistance 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 Check the welding Mode switch 54 the microswitches and the associated wiring 2 Perform the SCR Diode Rec tifier Bridge Test 3 Perform the Main Transformer 4 The control board may be faulty Replace CAUTION If for any reason you do not understand 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 15 15 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained person
122. s a single range potentiometer control The welderG 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 Y 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 Y Semi automatic wire feeders LN 7 LN 7 GMA LN 8 LN 9 LN 9 GMA LN23P LN 25 LN 742 Y Tractors LT 56 LT 7 OPERATIONAL FEATURES AND CONTROLS The following operational controls are standard on the Idealarc DC 400 Y Power Source Pilot Light Y ON OFF Power Toggle Switch Y Output Control Potentiometer Y Output Control Switch with Local or Remote posi tions Y Output Terminals On or Remote Switch Y Arc Force Selector for CC stick or TIG proce
123. sses only Y Auxiliary Power Connections for Wire Feeder and Other Equipment 115V and 42V Y Mode Switch Y Arc Control Y Thermal Protection Indicator Light Y DC Ammeter Y DC Voltmeter Y Voltmeter or Switch DESIGN FEATURES AND ADVANTAGES Y Input line voltage compensation keeps output con stant for fluctuations of 10 SCR control extends life of mechanical contactors Y Hinged front control panel provides easy access to printed circuit boards and other control circuitry Y Fully enclosed fan motor with permanently lubri cated sealed ball bearings needs no maintenance Y Fully recessed control panel protects controls and minimizes accidental contact Y Recessed output terminals and hinged terminal cover reduce chance of accidental contact Y Low profile case permits installation under a work bench Y 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 machines are stacked Y Dripproof enclosure design permits outdoor operation Y 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 indica
124. tate the mode switch S4 to the constant top and sides current CC position 3 Disconnect the welding cables from the 7 Locate and remove lead 204 from resistor welding output terminals 4 Locate and remove molex plugs P1 and P3 from the control board See Figure F 9 R2 40 ohms 50 Watts See Figure F 10 FIGURE F 10 RESISTOR R2 LOCATION DY IDEALARC DC 400 LINCOLN B 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 IDEALARC DC 400 LINCOLN 5 a Reverse the meter leads and measure the resistance from cathode
125. th the contactor coil 233 and X1 232 top See power switch S1 on check the power Figure F 1 for location switch S 1 and associated circuitry See the 4 Connect an AC voltmeter to the leads tm the Control Transformer T2 Voltage Test WARNIN If the 120VAC is present and the contactor does NOT activate then the input contactor Electric Shock can kill is faulty Replace the input contactor 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 IDEALARC DC 400 LINCOLN 5 F 17 APPLY EXTERNAL 120 VAC HERE X1 4232 AND 233 F 17 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F2 INPUT CONTACTOR TEST CONNECTIONS X1 232 TEST FOR CONTACT CONTINUITY 1 2 3 Disconnect the main input supply power to the machine Remove the two leads connected to the input contactor coil 233 and 1 232 See Figure 1 location 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 IDEALARC DC 400 LINCOLN 5 With the contactor activated check the con tinuity across the contacts Zero ohms or very low resistance is normal See Figure F 2 If the resistance is
126. tinued FIGURE F 3 CONTROL TRANSFORMER AND LEAD LOCATIONS INPUT CONTACTOR CR1 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 Diagram NOTE Unused leads should be taped a Inspect for broken or incorrect con nections IDEALARC DC 400 LINCOLN 5 CONTROL TRANSFORMER T2 LEAD X1 CONNECTION Locate control transformer leads X1 top and X2 a Lead 1 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 See Figure 4 20 20 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continued FIGURE F 4 CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS MACHINE INSULATED FRONT LEAD 231 ALLIGATOR CLIP INPUT CONNECTION CABLE CONTACTOR CONTROL PANEL ME
127. to the ORemote position FIGURE C 11 D IDEALARC DC 400 LN 742 CONNECTION DIAGRAM 14 PIN AMPHENOL TO WORK TO LN 742 INPUT CABLE PLUG 592 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT IDEALARC DC 400 Section 0 1 Section 0 1 TABLE CONTENTS MAINTENANCE Maintehalce s Section D Safety e e ge n EO C He o E ei e ERR D 2 Routine and Periodic Maintenance D 2 General Component 5 D 3 IDEALARC DC 400 LINCOLN B 0 2 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Y Only qualified personnel should perform this mainte nance Y Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Y Do not touch electrically hot parts ROUTINE AND PERIODIC MAINTENANCE Perform the following pr eventative maintenance at least once every six months Perform the following daily e around ea 1 Check that no combustible materials ar the machine or in the welding or cutting ar Remove any debris dust dirt or materials that could block cooling air flow to the machine Inspect the electr ode cables for any slits or punc tures in the cable jacket Also check for any other condition that could af fect the pr oper operation of the machine Perform periodically 1 In extremely dusty condit
128. 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 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 B install it following the procedures in reverse order NOTE Be sure to reconnect all leads cor rectly 42 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 If for any reason you do not understand the test procedures or are unable t
129. tomat 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 Y Wire Feeder Positive Y Wire Feeder Negative Y 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 Y Switch between OStick V lding Air Carbon Arc CuttingO or OPositive Wer FeederO or ONegative Wer Feeder Y Change the polarity of a semi automatic or auto matic wire feeder without changing any electrical cable 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 OStick V lding Air Carbon Arc position only those terminals ae energized The wire feeder nozzle or gun and elec trode are not electrically Ohot when in this mode Refer to installation instructions M17137 included with Multiprocess Kit for installation IDEALARC DC 400 C 3 C 3 ACCESSORIES Multiprocess Switch Operation The operation of the Multiprocess Switch is as follows
130. tor light will turn on until the machine cools Duty Cycle Amps Volts 10096 400 36 6096 450 38 5096 500 40 Based on a 10 minute time period For example a 6096 duty cycle means 6 minutes on and 4 minutes off LIMITATIONS The Idealarc DC 400 has no provisions for paralleling IDEALARC DC 400 LINCOLN 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 D CASE FRONT CONTROLS a KA o KQ OF 20 2400 1 Power Source Pilot Light 8 Mode Switch 2 ON OFF Power Toggle Switch 9 Arc Control 3 Output Control Potentiometer 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 Elec de Switch 7 Auxiliary Power Connections for Wire Feeder and Other Equipment 115V and 42V POWER SOURCE PILOT LIGHT This light indi cates that the power source input contactor is energized closed This also means that the main power transformer and all auxiliary control trans formers are energized ON OFF POWER TOGGLE SWITCH Energizes
131. traced to poor electrical connections T o avoid prob proper failur e analysis lems when tr oubleshooting and r eplacing PC boar ds please use the following ocedur e 4 Test the machine to determine if the failur symp tom has been corr ected by the r eplacement PC board 1 Determine to the best of your technical ability that NOTE Allow the machine to heat up so that all elec the PC boar d is the most likely component caus trical components can r each their operating ing the failur e symptom temperatur e 2 Check for loose connections at the PC boar d to 5 Remove the eplacement PC boar d and substitute assur e that the PC boar d is properly connected it with the original PC boar d to recreate the original 3 If the problem persists r eplace the suspect PC problem board using standar d practices to avoid static a the original pr oblem does not eappear electrical damage and electrical shock Read the by substituting the original then the war ning inside the static esistant bag and perform PC board was not the pr oblem Continue the following pr ocedur es to look for bad connections in the contr ol PC Board be damaged by wiring har ness junction blocks and termi static electricity nal strips Y Remove your body s static char ge b If the original pr oblem is r ecreated by the before opening the static shield substitution of the original boar d then the ing bag Wear an anti static
132. un abdito dad uibem td ne P 234 IDEALARC DC 400 LINCOLN B Section 1 Section 1 TABLE CONTENTS INSTALLATION SECTION Installation Technical Specifications Idealarc 400 2 Input and Output Specifications 2 A 2 Gablesand Fuse 51265 oe eet ee e eee e A 2 Physical Dimensions edere ebd edam ir cca i o Db c ab eux A 2 Safety Precautions coche A 3 Select Suitable Location det tei ec eR e e Lee e A 3 55 oro e A 3 Tiltinig ede cm A 3 STACKING A 3 Input Cornnectloris nero oer e a ge 4 Ground Cornnectlon o edt eee e oe OR OPER E D 4 Input Supply Connections cei aged Re e Li ER ER TERR A 4 Input Wire and Fuse oae dedere ede duc t e i date A 5 Reconnect Procedure otn dee eet dade a p ER e ng daga A 6 Output Go nhectioris etel bo Re CRI dio ani A 7 Wire Feeder A 8 Connections for Stick TIG Air carbon Arc Operations A 8 IDEALARC DC 400 LINCOLN B INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC DC 400 INPUT THREE PHASE ONLY Standard Voltage Input Current Rated Output 208V 87A 230V 78A 460V 39A 575
133. utlet 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 Electrical Code and the manufacturer s recommendations IDEALARC DC 400 LINCOLN B 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 pou
134. val Soldering the wires is recommended 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 44 44 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER ASSEMBLY 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 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 MATERIALS NEEDED 5 16 Nut driver 7 16 Wrench 1 2 Wrench 9 16 Wrench 3 8 Wrench Slot head screw driver 1 2 Socket and extension IDEALARC DC 400 LINCOLN B 45 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
135. wrist PC board was the pr oblem Reinstall the strap For safety use a 1 Meg e te PC boar d and test the Static Sensitive ohm resistive cor d connected to a 5 Devices grounded part of the equipment 6 Always indicate that this ocedur e was followed Handle only at frame when warranty eports ar e to be submitted you have a wrist strap NOTE Following this pr ocedure and writing on the touch an unpainted gr ounded warranty r eport OINSTALLED AND SWITCHED part of the equipment frame PC BOARDS TO VERIFY PROBLEM will help Reusable Keep touching the frame to e avoid denial of legitimate PC boar d warranty Container vent static build up Be sur e not claims Do Not Destoy to touch any electrically live parts at the same time Y Tools which come in contact with the PC Boar must be either conductive anti static or static dissipative IDEALARC DC 400 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 ph
136. y coils together will open either with an excessive overload or insuf ficient cooling The machine will not have output the amber pr otection light will be on and the fan should continue to oper ate When the thermostats r eset the amber pr otec tion light will be of f IDEALARC Upon restart if the fan does not tur n or the air intake louvers ar e obstructed the input power must be removed and the fan pr oblem or air obstruction cor rected The DC 400 is also pr otected against overloads on the SCR diode bridge assembly thr ough an electr onic protection cir cuit located on the contr ol board This circuit senses an overload on the power sour ce and limits the output to 550 amps by phasing back the SCRs A circuit is also pr ovided to pr otect the cir cuitry fr om accidental gr ounds If the exter nal remote contr ol leads 75 76 or 77 ar e accidentally connected to the positive output welding lead the DC 400 output will be educed to a low level thus pr eventing damage to the machine If an oneous connection is made between the r emote contr ol leads and the negative output welding lead the contr ol board self r estoring fuses will blow preventing damage to the machine DC 400 5 5 THEORY OF OPERATION FIGURE E 4 D SCROperation INPUT OUTPUT SCR OPERATION A silicon contr olled rectifier SCR is a thr ee terminal device used to contr ol rather lar ge curr ents to a load An SCR acts
137. y 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 POWER 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 pi
138. yage 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 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispostifis de s ret a leur place IDEALARC DC 400 LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety oou en oet Ln e UR ee i iv Installation tee ete D de rd shag AUR chutes Section A Installation Section Table of lt 2 nennen A 1 Technical S pecific ations ee m eee e c e ba boe dd lee eae Preces A 2 Safety Precautions ot PE t RR ee A 3 Select Suitable Location Stacking Tilting Lifting m A 3 Input ConriectiOns cc eri Me eb 4 Reconnect npe eame ee a edd d ain A 6 onere e
139. you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC DC 400 LINCOLN 5 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 1 Check the Output Control potentiometer R4 and associ ated wiring See Wiring Diagram 2 Check the welding Mode switch 54 the microswitches and the associated wiring 3 Check the Output Control switch S2 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 are unable to perform the test repairs safely con tact th

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