Lincoln Electric SVM 122-A service manual Operation, General Description

Page 17

TOC

TOC

B-3

B-3

OPERATION

GENERAL DESCRIPTION

The Idealarc DC-400 is an SCR controlled three-phase input, DC output power source for welding and cut- ting. It uses a single range potentiometer control. The welder’s unique combination of transformer, three- phase semiconverter rectifier, capacitor bank, arc con- trol choke, and solid state control system deliver out- standing arc characteristics in the constant voltage mode. For stick welding, an Arc Force Control enables the Idealarc-400 to perform much like the R3R-500.

DC Ammeter

DC Voltmeter

Voltmeter “+” Electrode or “-” Electrode Switch

DESIGN FEATURES AND ADVANTAGES

Input line voltage compensation keeps output con- stant for fluctuations of ± 10%.

SCR control extends life of mechanical contactors.

Return to Section TOC

TOC

Return to Master TOC

TOC

RECOMMENDED PROCESSES

The Idealarc DC-400 is recomended for all open arc processes including Innershield® and all solid wire and gas procedures within its capacity of 60 to 500 amps. It also can perform stick and TIG welding and air/car- bon arc gouging up to 5/16” (8 mm) diameter. A mode switch on the front control panel selects CV (FCAW, GMAW), CV Submerged Arc, or CC (stick/TIG).

The Idealarc DC-400 can be connected to wire feed- ing equipment, including:

Automatic wire feeders NA-3, NA-5, and NA-5R. (Requires the DC-400 Diode Kit option to use the cold start and cold electrode sensing features of these feeders.)

Semi-automatic wire feeders LN-7, LN-7 GMA, LN- 8, LN-9, LN-9 GMA, LN23P, LN-25, LN-742.

Tractors LT-56, LT-7.

Hinged front control panel provides easy access to printed circuit boards and other control circuitry.

Fully enclosed fan motor with permanently lubri- cated, sealed ball bearings needs no maintenance.

Fully recessed control panel protects controls and minimizes accidental contact.

Recessed output terminals and hinged terminal cover reduce chance of accidental contact.

Low profile case permits installation under a work- bench.

Removable rear access panel provides easy access to input contactor and input lead connections.

Removable case sides provide easy access for ser- vice or inspection, even when machines are stacked.

Dripproof enclosure design permits outdoor operation.

Double-dipped transformer, SCR bridge, and choke resist corrosion.

Return to Section

Section TOC

Return to Master

Master TOC

OPERATIONAL FEATURES AND CONTROLS

The following operational controls are standard on the Idealarc DC-400:

Power Source Pilot Light

ON/OFF Power Toggle Switch

Output Control Potentiometer

Output Control Switch (with Local or Remote posi- tions)

Output Terminals On or Remote Switch

Arc Force Selector (for CC stick or TIG processes only)

Auxiliary Power Connections for Wire Feeder and Other Equipment (115V and 42V)

Mode Switch

WELDING CAPABILITY

The Idealarc DC-400 has the following duty cycle ratings. If the duty cycle is exceeded, a thermal pro- tector will shut off the machine output until it cools to normal operating temperature. The amber thermal protection indicator light will turn on until the machine cools.

Duty Cycle*

Amps

Volts

100%

400

36

60%

450

38

50%

500

40

 

 

 

*Based on a 10 minute time period. For example, a 60% duty cycle means 6 minutes on and 4 minutes off.

Return to

Return to

• Arc Control

LIMITATIONS

 

• Thermal Protection Indicator Light

The Idealarc DC-400 has no provisions for paralleling.

 

 

IDEALARC DC-400

 

LINCOLN ®

 

ELECTRIC

Image 17
Contents Idealarc TMDC-400 Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Idealarc DC-400 InstallationSelect Suitable Location Safety PrecautionsLifting TiltingGround Connection Input ConnectionsInput Supply Connections Electric Shock can killFigure A.3 Input Power Supply Connections Input Wire and Fuse SizeInput Supply Connection Diagram Reconnect ProcedureFigure A.6 Output Terminal Connections Output ConnectionsCycle Wire Feeder ConnectionsCycle 500 Amp 50% Duty Operation Section Operating Instructions Safety InstructionsOPERATIONB-2 General Description OperationFigure B.1 Case Front Controls Controls and SettingsOperation Welding Procedure Recommendations Remote ControlWelding Operation Operating StepsARC Striking with the NA-3 Start Board NA-3 Automatic Wire FeederLN-8 Semiautomatic Wire Feeder NA-5 Automative Wire FeederOverload Protection Auxiliary PowerTable of Contents Accessories Factory Installed Option OPTIONS/ACCESSORIESField Installed Options Diode OptionConnections Multiprocess Switch OperationK843 Amptrol Adapter Installation Instructions Remote Control Adapter Cable K864Remote Output Control K857 with K864 Adapter Plug or K775 Amptrol Adapter Cable K843Amptrol and Hi-Freq. Kit The Amptrol will start K843 Amptrol Adapter Installation InstructionsConnecting the NA-3 to the Idealarc DC-400 Terminal Strip Automatic Wire FeedersCapacitor Discharge Circuit K828-1 HI-FREQ KIT K799 for Codes 8634 and Above onlyConnecting the NA-5 to the Idealarc DC-400 Terminal Strip To NA-3 or NA-5 Input Cable Plug K597-XX Input Cable Assembly Idealarc DC-400Connecting the LN-7 to the Idealarc DC-400 14-PIN Amphenol Semiautomatic Wire FeedersConnecting the LN-7 to the Idealarc DC-400 Terminal Strip Accessories Accessories Figure C.11 Idealarc DC-400/LN-742 Connection Diagram Table of Contents Maintenance Routine and Periodic Maintenance Figure D.1 General Component Locations Table of Contents Theory of Operation Section Input Line Voltage Theory of OperationContactor and Main TransformerOutput Mode and CONTROL, Rectification and Feedback Protective Devices and Circuits Figure E.4 SCR Operation SCR OperationTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuidePerform the Main Transformer Rectifier Bridge Test Tifier Bridge Test Output Problems Test Perform the SCR/Diode Rec Tifier Bridge Test Function Problems Form the SCR/Diode Rectifier Welding Problems Toxic. Avoid contact with any Portion of your body. CleanTrolyte in these capacitors is Make sure welding process is Materials Needed Input Contactor TestDescription Input Contactor Test Test ProcedureFigure F.2 Input Contactor Test Connections Test for Contact ContinuityControl Transformer T2 Voltage Test Figure F.3 Control Transformer and Lead Locations Control Transformer T2 Voltage TestTroubleshooting & Repair Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Main Secondary Lead Test Points Troubleshooting & Repair Figure F.8 Control Board Plug P1 Location Plug P1 Phase Angle Winding VoltagesStatic SCR/DIODE Rectifier Bridge Test Figure F.9 Control Board and Snubber Board Plug Locations Static SCR/DIODE Rectifier Bridge TestSCR Test Active SCR Test P1 and P3 Locations Plug P5 Location Active SCR TestFigure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections CH1 Scope SettingsMaximum Output Setting no Load Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair 2V/Div Troubleshooting & Repair Input Contactor CR1 CLEANING/REPLACEMENT Contactor Replacement Procedure Input Contactor CR1 CLEANING/REPLACEMENTCleaning Procedure FAN Motor and Blade Removal and Replacement Procedure FAN Motor and Blade Removal and ReplacementSCR/DIODE Rectifier Assembly Removal and Replacement Removal and Replacement SCR/DIODE Rectificer AssemblySCR Removal and Replacement Special Instructions SCR Removal and ReplacementFigure F.21 1/2 Wide Leaf Spring Procedure for the 1/2 Inch Wide SpringClamping Procedure For 1/4-20 CAP Screws Clamping Procedure For 1/4-28 CAP ScrewsInch Wide Spring Procedure forAfter Replacing the SCRs Mounting of Stud Type Diodes to Aluminum Heat Sinks Diode Stud Foot Inch Size Pounds Mounting of Stud Type Diodes to AluminumHeat Sinks Main Transformer Removal and Replacement Removal of Lift Bail Main Transformer Removal & ReplacementFigure F.26 Choke Removal Removal of Choke and TOP Iron AssemblyFigure F.27 Epoxy MIX Application Areas Reassembly of Transformer CoilsFigure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassemble the Lift Bail Reassembling the Main Transformer Into the MachineMode Input Hertz Open Circuit Volts Input volts/Phase/Hertz Maximum Idle Amps Maximum Idle KWRetest After Repair Input Idle Amps and WattsRetest After Repair Maximum Acceptable Output Voltage AT Minimum Ouput SettingsMode Control Settings Load Table of Contents Electrical Diagrams Section Idealarc DC400 LOW Voltage Wiring Diagram Codes 9847Only. It may not be accurate for all Wiring Diagram CodeControl DC400 Control PC Board G2588 LayoutTP2 Starting PC Board M14520 LayoutSnubber PC Board M15370 Layout 2586 Control PC Board G2588 SchematicGeneral Information Starting PC Board M14520 SchematicGeneral Information Snubber PC Board M15370 Schematic