Lincoln Electric SVM 122-A GENERAL INFORMATION

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ELECTRICAL DIAGRAMS

IDEALARC DC400

Starting PC Board (M14520) Schematic

55A

400V

SCR2

13

2

38J

130V

TP1

D5D4D3

1N4007

D2

J6

4

4A

400V

SCR1

1.00K

R5

1.00K

R3

1.50K

R4

5W

2500

R1

SBS1

G

J6

2

10W

100

R6

2

1

160J

320V

TP2

50V

50

C1

J6

6

J6

1D7 D6

1N4007

D1

5W

2500

R2

J6

3

19686

S

START

S

= COMMON CONNECTION

IDEALARC DC400

ELECTRICAL SYMBOLS PER E1537

19686

218

32

31

228

SCHEMATIC

CAPACITORS = MFD/VOLTS

GENERAL INFORMATION

DIODES = 1 AMP/400 VOLT (UNLESS OTHERWISE SPECIFIED)

OP AMPS = LM124 (UNLESS OTHERWISE SPECIFIED)

RESISTORS = OHMS,1/4 WATT (UNLESS OTHERWISE SPECIFIED)

216215

J6

5

7.5-9.0V

MT2 MT1

11-17-95G

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not

available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result

in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

Contents

Main SVM 122-A IDEALARC DC-400 Oct. 1996 Safety Depends on You SERVICE MANUAL LINCOLN WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. iii iii IDEALARC DC-400 FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. iv iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFOR- MATEUR ET REDRESSEUR MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATION SECTION - TECHNICAL SPECIFICATIONS - IDEALARC DC-400 INPUT - THREE PHASE ONLY Standard Voltage Input Current @ Rated Output RATED OUTPUT Duty Cycle Amps Volts at Rated Amps OUTPUT SAFETY PRECAUTIONS SELECT SUITABLE LOCATION LIFTING TILTING STACKING INPUT CONNECTIONS GROUND CONNECTION INPUT SUPPLYCONNECTIONS INPUT WIRE AND FUSE SIZE A-6 A-6 { L2 { INPUT GND H3 ELECTRIC FIGURE A.4 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOLTS AC, 50/60 HZ OUTPUT CONNECTIONS . A-7 A-7 GND H3 H4 WIRE FEEDER CONNECTIONS CONNECTIONS FOR STICK, TIG, OR AIR/CARBON ARC CUTTING OPERA- TIONS - OPERATION SECTION - OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS GENERAL DESCRIPTION RECOMMENDED PROCESSES OPERATIONAL FEATURES AND CONTROLS DESIGN FEATURES AND ADVANTAGES WELDING CAPABILITY CONTROLS AND SETTINGS Page WELDING OPERATION OPERATING STEPS SEMIAUTOMATIC AND AUTOMATIC WIRE FEEDING WITH AN IDEALARC DC-400 Page Page OVERLOAD PROTECTION AUXILIARY POWER - ACCESSORIES - OPTIONS/ACCESSORIES FACTORYINSTALLED OPTION FIELD INSTALLED OPTIONS Page Page Page CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS ELECTRIC SHOCK can kill. AUTOMATIC WIRE FEEDERS Page Page SEMIAUTOMATIC WIRE FEEDERS Page Page Page Page Page MAINTENANCE SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE MAINTENANCE D-3 D-3 FIGURE D.1 GENERAL COMPONENT LOCATIONS Section E-1 Section E-1 IDEALARC DC-400 -THEORY OF OPERATION SECTION- GENERAL DESCRIPTION INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER OUTPUT MODE AND CONTROL, RECTIFICATION AND FEEDBACK PROTECTIVE DEVICES AND CIRCUITS SCR OPERATION TROUBLESHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page Page Page Page Page Page FUNCTION PROBLEMS Page Page Page Page INPUT CONTACTOR TEST INPUT CONTACTOR TEST (continued) TEST FOR CONTACT CONTINUITY CONTROL TRANSFORMER (T2) VOLTAGE TEST Page CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) MAIN TRANSFORMER (T1) VOLTAGE TEST Page Page Page Page STATIC SCR/DIODE RECTIFIER BRIDGE TEST STATIC SCR/DIODE RECTIFIER BRIDGE TEST(continued) STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) ACTIVE SCR TEST Page Page Page CONSTANT CURRENT MODE NO LOAD CONSTANT VOLTAGE FCAW/GMAW MAXIMUM OUTPUT SETTING NO LOAD MAXIMUM OUTPUT SETTING NO LOAD TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CONSTANT VOLTAGE FCAW/GMAW MODE TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CONSTANT VOLTAGE SUBARC MODE TYPICAL SCR GATE VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING NO LOAD ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM ONE OUTPUT SCR NOT FUNCTIONING INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) CLEANING PROCEDURE CONTACTOR REPLACEMENT FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT (continued) SCR REMOVAL AND REPLACEMENT SPECIAL INSTRUCTIONS PROCEDURE FOR THE 1/2 INCH WIDE SPRING CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS FOR 1/4-20 CAP SCREWS PROCEDURE FOR THE 5/8 INCH WIDE SPRING CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS AFTER REPLACING THE SCRs FOR 1/4-20 CAP SCREWS MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS (continued) MAIN TRANSFORMER REMOVAL AND REPLACEMENT REMOVAL OF LIFT BAIL REMOVAL OF CHOKE AND TOP IRON ASSEMBLY REASSEMBLYOF TRANSFORMER COILS Page Page REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE REASSEMBLE THE LIFT BAIL RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS OPEN CIRCUIT VOLTAGES RETEST AFTER REPAIR (continued) Page Page G-2 Wiring Diagram (Codes 9847, 9848) LOW VOLTAGE) DUAL & SINGLE VOLTAGE AND CIRCUIT BREAKER G-2 G-3 Wiring Diagram (Code 9850) 11 10 9 G-3 G-4 Control PC Board (G2588) Layout R150 X5 R27 G-4 G-5 Starting PC Board (M14520) Layout G-5 G-6 Snubber PC Board (M15370) Layout G-6 G-7 Control PC Board (G2588) Schematic 2586 G FIRING CIRCUIT G-7 G-8 Starting PC Board (M14520) Schematic SCHEMATIC IDEALARC DC400 GENERAL INFORMATION G-8 G-9 Snubber PC Board (M15370) Schematic MISC. USE GENERAL INFORMATION S G-9