Lincoln Electric SVM 122-A service manual Cylinder may explode if damaged

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SAFETY

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WELDING SPARKS can cause fire or explosion.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. 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.

6.c. 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.

6.d. 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).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective 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.

6.g. 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.a. 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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” 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.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

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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-400Safety Precautions Select Suitable LocationLifting TiltingInput Connections Ground ConnectionInput Supply Connections 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 500 Amp 50% Duty Wire Feeder ConnectionsCycle Operation Section OPERATIONB-2 Safety InstructionsOperating Instructions Operation General DescriptionControls and Settings Figure B.1 Case Front ControlsOperation Remote Control Welding Procedure RecommendationsWelding Operation 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 OPTIONS/ACCESSORIES Factory Installed OptionField Installed Options Diode OptionMultiprocess Switch Operation ConnectionsRemote Control Adapter Cable K864 K843 Amptrol Adapter Installation InstructionsRemote Output Control K857 with K864 Adapter Plug or K775 Amptrol Adapter Cable K843K843 Amptrol Adapter Installation Instructions Amptrol and Hi-Freq. Kit The Amptrol will startAutomatic Wire Feeders Connecting the NA-3 to the Idealarc DC-400 Terminal StripCapacitor Discharge Circuit K828-1 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 Theory of Operation Input Line VoltageContactor and Main 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 Trolyte in these capacitors is Portion of your body. CleanToxic. Avoid contact with any Make sure welding process is Description Input Contactor TestMaterials Needed 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 Cleaning Procedure Input Contactor CR1 CLEANING/REPLACEMENTContactor Replacement 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 Heat Sinks Mounting of Stud Type Diodes to AluminumDiode Stud Foot Inch Size Pounds 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 BailInput volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW Mode Input Hertz Open Circuit VoltsRetest 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 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