Idealarc TMDC-400 | Lincoln Electric SVM 122-A instruction

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SVM 122-A

IDEALARCTMDC-400	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.

SERVICE MANUAL

LINCOLN ®

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

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Lincoln Electric SVM 122-A service manual Idealarc TMDC-400, Safety Depends on You

Contents

Idealarc TMDC-400 Safety Depends on You California Proposition 65 Warnings Safety Electric 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 Installation Select Suitable Location Safety PrecautionsLifting Tilting Ground Connection Input ConnectionsInput Supply Connections Electric Shock can kill Figure A.3 Input Power Supply Connections Input Wire and Fuse Size Input Supply Connection Diagram Reconnect Procedure Figure A.6 Output Terminal Connections Output Connections Cycle 500 Amp 50% Duty Wire Feeder ConnectionsCycle Operation Section OPERATIONB-2 Safety InstructionsOperating Instructions General Description Operation Figure B.1 Case Front Controls Controls and Settings Operation Welding Procedure Recommendations Remote ControlWelding Operation Operating Steps ARC Striking with the NA-3 Start Board NA-3 Automatic Wire Feeder LN-8 Semiautomatic Wire Feeder NA-5 Automative Wire Feeder Overload Protection Auxiliary Power Table of Contents Accessories Factory Installed Option OPTIONS/ACCESSORIESField Installed Options Diode Option Connections Multiprocess Switch Operation K843 Amptrol Adapter Installation Instructions Remote Control Adapter Cable K864Remote Output Control K857 with K864 Adapter Plug or K775 Amptrol Adapter Cable K843 Amptrol and Hi-Freq. Kit The Amptrol will start K843 Amptrol Adapter Installation Instructions Connecting 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 only Connecting 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-400 Connecting the LN-7 to the Idealarc DC-400 14-PIN Amphenol Semiautomatic Wire Feeders Connecting 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 Transformer Output Mode and CONTROL, Rectification and Feedback Protective Devices and Circuits Figure E.4 SCR Operation SCR Operation Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board can be damaged by static electricity PC Board Troubleshooting Procedures Output Problems Troubleshooting Guide Perform 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 Procedure Figure F.2 Input Contactor Test Connections Test for Contact Continuity Control Transformer T2 Voltage Test Figure F.3 Control Transformer and Lead Locations Control Transformer T2 Voltage Test Troubleshooting & 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 Voltages Static SCR/DIODE Rectifier Bridge Test Figure F.9 Control Board and Snubber Board Plug Locations Static SCR/DIODE Rectifier Bridge Test SCR Test Active SCR Test P1 and P3 Locations Plug P5 Location Active SCR Test Figure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections CH1 Scope Settings Maximum 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 Replacement SCR/DIODE Rectifier Assembly Removal and Replacement Removal and Replacement SCR/DIODE Rectificer Assembly SCR Removal and Replacement Special Instructions SCR Removal and Replacement Figure F.21 1/2 Wide Leaf Spring Procedure for the 1/2 Inch Wide Spring Clamping Procedure For 1/4-20 CAP Screws Clamping Procedure For 1/4-28 CAP Screws Inch Wide Spring Procedure for After 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 & Replacement Figure F.26 Choke Removal Removal of Choke and TOP Iron Assembly Figure F.27 Epoxy MIX Application Areas Reassembly of Transformer Coils Figure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassemble the Lift Bail Reassembling the Main Transformer Into the Machine Mode Input Hertz Open Circuit Volts Input volts/Phase/Hertz Maximum Idle Amps Maximum Idle KWRetest After Repair Input Idle Amps and Watts Mode 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 9847 Only. It may not be accurate for all Wiring Diagram Code Control DC400 Control PC Board G2588 Layout TP2 Starting PC Board M14520 Layout Snubber PC Board M15370 Layout 2586 Control PC Board G2588 Schematic General Information Starting PC Board M14520 Schematic General Information Snubber PC Board M15370 Schematic