Lincoln Electric SVM 122-A service manual Multiprocess Switch Operation, Connections

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C-3

C-3

ACCESSORIES

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Multiprocess Switch Operation

The operation of the Multiprocess Switch is as follows:

A semiautomatic or automatic wire feed unit electrode and work cables are connected to the terminals on the left side of the box. Stick or air carbon arc electrode and work cables are connected to the terminals on the switch. With the switch in the left position, the wire feed terminals are electrode negative. In the center position, the wire feeder terminals are electrode posi- tive. In both the left and center switch position, the right side stick terminals are 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 a 4/0 (107 mm2) 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 C.2.

To change stick polarity, reverse the leads at the (+) and (-) terminals on the right side of the Multiprocess Switch.

NOTE: When a DC-400 equipped with Multiprocess Switch is mounted on an undercarriage, the undercarriage handle in the resting position can hit the case of the Multiprocess Switch. This does no harm, but if the user desires, a 1/4” or 3/8” bolt and nut may be placed in the hole in the undercarriage tow bar to limit the travel of the undercarriage handle.

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FIGURE C.2 – SINGLE WORK CABLE WITH JUMPER

To stick electrode holder or air carbon arc torch

To semi-auto or auto equipment

User supplied 4/0 (107 mm2) jumper

IDEALARC DC-400

LINCOLN ®

ELECTRIC

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Contents Safety Depends on You Idealarc TMDC-400Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Idealarc DC-400Lifting Safety PrecautionsSelect Suitable Location TiltingInput Supply Connections Input ConnectionsGround Connection Electric Shock can killInput Wire and Fuse Size Figure A.3 Input Power Supply ConnectionsReconnect Procedure Input Supply Connection DiagramOutput Connections Figure A.6 Output Terminal ConnectionsCycle Wire Feeder ConnectionsCycle 500 Amp 50% Duty Operation Section Operating Instructions Safety InstructionsOPERATIONB-2 Operation General DescriptionControls and Settings Figure B.1 Case Front ControlsOperation Welding Operation Remote ControlWelding Procedure Recommendations Operating StepsNA-3 Automatic Wire Feeder ARC Striking with the NA-3 Start BoardNA-5 Automative Wire Feeder LN-8 Semiautomatic Wire FeederAuxiliary Power Overload ProtectionTable of Contents Accessories Field Installed Options OPTIONS/ACCESSORIESFactory Installed Option Diode OptionMultiprocess Switch Operation ConnectionsRemote Output Control K857 with K864 Adapter Plug or K775 Remote Control Adapter Cable K864K843 Amptrol Adapter Installation Instructions Amptrol Adapter Cable K843K843 Amptrol Adapter Installation Instructions Amptrol and Hi-Freq. Kit The Amptrol will startCapacitor Discharge Circuit K828-1 Automatic Wire FeedersConnecting the NA-3 to the Idealarc DC-400 Terminal Strip HI-FREQ KIT K799 for Codes 8634 and Above onlyConnecting the NA-5 to the Idealarc DC-400 Terminal Strip Cable Plug K597-XX Input Cable Assembly Idealarc DC-400 To NA-3 or NA-5 InputSemiautomatic Wire Feeders Connecting the LN-7 to the Idealarc DC-400 14-PIN AmphenolConnecting 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 Contactor and Main Theory of OperationInput Line Voltage TransformerOutput Mode and CONTROL, Rectification and Feedback Protective Devices and Circuits SCR Operation Figure E.4 SCR OperationTable of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityTroubleshooting Guide Output ProblemsPerform 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 Test Procedure Input Contactor TestTest for Contact Continuity Figure F.2 Input Contactor Test ConnectionsControl Transformer T2 Voltage Test Control Transformer T2 Voltage Test Figure F.3 Control Transformer and Lead LocationsTroubleshooting & Repair Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Main Secondary Lead Test Points Troubleshooting & Repair Plug P1 Phase Angle Winding Voltages Figure F.8 Control Board Plug P1 LocationStatic SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test Figure F.9 Control Board and Snubber Board Plug LocationsSCR Test Active SCR Test Active SCR Test P1 and P3 Locations Plug P5 LocationFigure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections Scope Settings CH1Maximum 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 FAN Motor and Blade Removal and Replacement ProcedureSCR/DIODE Rectifier Assembly Removal and Replacement SCR/DIODE Rectificer Assembly Removal and ReplacementSCR Removal and Replacement SCR Removal and Replacement Special InstructionsProcedure for the 1/2 Inch Wide Spring Figure F.21 1/2 Wide Leaf SpringClamping Procedure For 1/4-28 CAP Screws Clamping Procedure For 1/4-20 CAP ScrewsProcedure for Inch Wide SpringAfter 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 Main Transformer Removal & Replacement Removal of Lift BailRemoval of Choke and TOP Iron Assembly Figure F.26 Choke RemovalReassembly of Transformer Coils Figure F.27 Epoxy MIX Application AreasFigure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassembling the Main Transformer Into the Machine Reassemble the Lift BailRetest After Repair Input volts/Phase/Hertz Maximum Idle Amps Maximum Idle KWMode Input Hertz Open Circuit Volts 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 Wiring Diagram Codes 9847 LOW VoltageWiring Diagram Code Only. It may not be accurate for allControl PC Board G2588 Layout Control DC400Starting PC Board M14520 Layout TP2Snubber PC Board M15370 Layout Control PC Board G2588 Schematic 2586Starting PC Board M14520 Schematic General InformationSnubber PC Board M15370 Schematic General Information