Lincoln Electric SVM 122-A Options/Accessories, Factory Installed Option, Field Installed Options

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C-2

C-2

ACCESSORIES

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OPTIONS/ACCESSORIES

FACTORY INSTALLED OPTION

DIODE OPTION

This factory installed option allows use of the cold- start and cold electrode sensing features of the NA-3, NA-5, or NA-5R automatic wire feeders. See the topic,

Connecting the NA-3[NA-5] to the Idealarc DC-400

in this section of the manual.

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 S17062-3)

Protects the amphenol from dirt and moisture when the amphenol is not being used.

MULTIPROCESS SWITCH (K804-1. ALSO AVAILABLE AS A FACTORY INSTALLED OPTION.)

Required when using the DC-400 for both automat- ic/semiautomatic and stick/air carbon arc. This field or factory installed kit mounts on the front of the DC-400. It includes hinged covers over its output studs.

The switch has three positions.

•Wire Feeder Positive

•Wire Feeder Negative

•Stick/Air Carbon Arc

FIGURE C.1

MULTIPROCESS SWITCH

The Multiprocess Switch gives you the ability to:

•Switch between “Stick Welding/Air-Carbon Arc Cutting” or “Positive Wire Feeder” or “Negative Wire Feeder.”

•Change the polarity of a semi-automatic or auto- matic wire feeder without changing any electrical 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 “Stick Welding/ Air-Carbon Arc” position, only those terminals are energized. The wire feeder nozzle or gun and elec- trode are not electrically “hot” when in this mode.

Refer to installation instructions (M17137) included with Multiprocess Kit for installation.

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IDEALARC DC-400

LINCOLN ®

ELECTRIC

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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 500 Amp 50% Duty Wire Feeder ConnectionsCycle Operation Section OPERATIONB-2 Safety InstructionsOperating Instructions 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 Trolyte in these capacitors is Portion of your body. CleanToxic. Avoid contact with any Make sure welding process is Description Input Contactor TestMaterials Needed 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 Cleaning Procedure Input Contactor CR1 CLEANING/REPLACEMENTContactor Replacement 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 Heat Sinks Mounting of Stud Type Diodes to AluminumDiode Stud Foot Inch Size Pounds 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 WattsMode Control Settings Load Maximum Acceptable Output Voltage AT Minimum Ouput SettingsRetest After Repair 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