Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i LINCOLN ® ELECTRIC IDEALARC DC-400 FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. _____________...
Page 3 - ii; ELECTRIC SHOCK can kill.
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii LINCOLN ® ELECTRIC IDEALARC DC-400 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen a...
Page 4 - iii
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii LINCOLN ® ELECTRIC IDEALARC DC-400 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iv iv LINCOLN ® ELECTRIC IDEALARC DC-400 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel au...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v LINCOLN ® ELECTRIC IDEALARC DC-400 Page Safety .................................................................................................................................................i-iv Installation ...............................................
Page 7 - TABLE OF CONTENTS; Installation; Lifting
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 LINCOLN ® ELECTRIC IDEALARC DC-400 Installation Technical Specifications Idealarc DC-400 ...........................................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - IDEALARC DC-400
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 LINCOLN ® ELECTRIC IDEALARC DC-400 TECHNICAL SPECIFICATIONS - IDEALARC DC-400 INPUT - THREE PHASE O...
Page 9 - SAFETY PRECAUTIONS; SELECT SUITABLE LOCATION; LIFTING
Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with yourskin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only qualified person...
Page 10 - INPUT CONNECTIONS; FIGURE A.1 – RATING PLATE LOCATION; GROUND CONNECTION; • Turn the input power off at the
INPUT CONNECTIONS Be sure the voltage, phase, and frequency of theinput power is as specified on the rating plate, lo-cated on the case front control panel. See FigureA.1. Input supply line entry is through a hole in the caserear top panel. A removable door covers the inputconnection box, which cont...
Page 11 - INPUT WIRE AND FUSE SIZE; FIGURE A.3 – INPUT POWER SUPPLY CONNECTIONS
Have a qualified electrician connect the input powerleads to the L1, L2, and L3 terminals of the input con-tactor. Follow all national and local electrical codes.Use a three-phase line. Refer to the connection dia-gram located on the inside cover of the access panelcover. Also see Figure A.3. INPUT ...
Page 12 - RECONNECT PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-6 A-6 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE A.4 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/4...
Page 13 - OUTPUT CONNECTIONS
OUTPUT CONNECTIONS The output (welding) cables are connected to the outputterminals marked “+” and “-”. See Table A.1 for recom-mended cable sizes for the combined lengths of elec-trode and work cables. They are located at the lowerright and lower left corners of the front panel. Strain relief for t...
Page 14 - TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE; WIRE FEEDER CONNECTIONS; Automatic Wire Feeders:
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-8 A-8 LINCOLN ® ELECTRIC IDEALARC DC-400 TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE...
Page 15 - Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section B-1 Section B-1 LINCOLN ® ELECTRIC IDEALARC DC-400 - OPERATION SECTION - Operation ............................................................................................................................
Page 16 - OPERATING INSTRUCTIONS; OPERATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC B-2 B-2 LINCOLN ® ELECTRIC IDEALARC DC-400 OPERATING INSTRUCTIONS Read and understand this entire section of operatingin...
Page 17 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; Amps; LIMITATIONS
GENERAL DESCRIPTION The Idealarc DC-400 is an SCR controlled three-phaseinput, DC output power source for welding and cut-ting. It uses a single range potentiometer control. Thewelder’s unique combination of transformer, three-phase semiconverter rectifier, capacitor bank, arc con-trol choke, and so...
Page 18 - CONTROLS AND SETTINGS; FIGURE B.1 – CASE FRONT CONTROLS; trols voltage in CV mode and current in CC mode.; OUTPUT TERMINALS “ON” OR “REMOTE”
CONTROLS AND SETTINGS All operator controls and settings are located on thecase front assembly. See Figure B.1 for their loca-tions. FIGURE B.1 – CASE FRONT CONTROLS 1. POWER SOURCE PILOT LIGHT: This light indi- cates that the power source input contactor isenergized (closed). This also means that t...
Page 19 - AUXILIARY POWER AND REMOTE CONTROL; Selects between Constant; DC VOLTMETER: Displays output voltage when
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-5 B-5 LINCOLN ® ELECTRIC IDEALARC DC-400 7. AUXILIARY POWER AND REMOTE CONTROL CONNECTIONS FOR WIRE FEEDER A...
Page 20 - WELDING OPERATION; OPERATING STEPS; LOCAL CONTROL
WELDING OPERATION OPERATING STEPS LOCAL CONTROL The following procedures are for using the IdealarcDC-400 in the local control mode of operation. Forremote control of the machine, see the REMOTECONTROL section. Before operating the machine, make sure you have allmaterials needed to complete the job....
Page 23 - NOTE: These semiautomatic wire feeders cannot; be used in the CC mode.; OVERLOAD PROTECTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-9 B-9 LINCOLN ® ELECTRIC IDEALARC DC-400 LN-7 AND LN-9 SEMIAUTOMATIC WIRE FEEDERSOR OTHER CONSTANT SPEED WIR...
Page 24 - Accessories
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories................
Page 25 - FACTORY INSTALLED OPTION; DIODE OPTION; FIELD INSTALLED OPTIONS; ACCESSORIES; MULTIPROCESS SWITCH
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-400in this section of the manual. FI...
Page 26 - Multiprocess Switch Operation; The operation of the Multiprocess Switch is as follows:; Connections; ) jumper from the work; NOTE: When a DC-400 equipped with Multiprocess; jumper
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ACCESSORIES C-3 C-3 LINCOLN ® ELECTRIC IDEALARC DC-400 Multiprocess Switch Operation The operation of the Multiprocess S...
Page 27 - • Turn the input supply power OFF
REMOTE OUTPUT CONTROL (K857 WITH K864ADAPTER PLUG OR K775) The K857 has a 6-pin MS-style connector. The K857requires a K864 adapter cable which connects to the14-pin connector on the machine. An optional “remote output control” is available. Thisis the same remote control that is used on the Lincoln...
Page 28 - K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS (Continued)
ACCESSORIES C-5 C-5 LINCOLN ® ELECTRIC IDEALARC DC-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Amptrol Only: The Amptrol provides remote currentcontrol through ...
Page 29 - NOTE: The Idealarc DC-400 must be properly
ACCESSORIES C-6 C-6 LINCOLN ® ELECTRIC IDEALARC DC-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CAPACITOR DISCHARGE CIRCUIT (K828-1) Mounts inside the DC-400. Re...
Page 31 - NOTE: The connection diagram shown in Figure C.5; Disconnect main AC input power to the Idealarc; NOTE: Welding cable must be sized for the cur-; rent and duty cycle of the application.; K597-XX INPUT CABLE ASSEMBLY
5. Extend wire feeder control cable lead #21 so it canbe connected directly to the work piece. a. Make a bolted connection using AWG #14 orlarger insulated wire. Tape the bolted connec-tion with insulating tape. b. An S-16586- X remote voltage sensing worklead is available for this purpose. c. Keep ...
Page 32 - SEMIAUTOMATIC WIRE FEEDERS; NOTE: Welding cable must be sized for the current; and duty cycle of the application.; NOTE: If optional remote control is used, place the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ACCESSORIES C-9 C-9 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE C.7 IDEALARC DC-400/LN-7 WITH K584 INPUT CABLE ASSEMBLY CO...
Page 35 - K595-XX INPUT CABLE ASSEMBLY
CONNECTING THE LN-8 OR LN-9 TO THEIDEALARC DC-400 (14-PIN AMPHENOL) 1. Disconnect main AC input power to the IdealarcDC-400. 2. Set the POWER toggle switch to the OFF (0) posi-tion. 3. Connect the electrode cable from the LN-8 or LN-9 to the “+” terminal of the welder. Connectthe work cable to the “...
Page 36 - NOTE: Welding cable must be sized for the current; NOTE: If optional remote control is used, set the
CONNECTING THE LN-742 TO THE IDEALARC DC-400 (14-PIN AMPHENOL) 1. Disconnect main AC input power to the IdealarcDC-400. 2. Set the POWER toggle switch to the OFF (0) posi-tion. 3. Connect the electrode cable from the LN-742 tothe “+” terminal of the welder. Connect the workcable to the “-” terminal ...
Page 37 - Maintenance
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section D-1 Section D-1 LINCOLN ® ELECTRIC IDEALARC DC-400 TABLE OF CONTENTS -MAINTENANCE- Maintenance ................................................................................................................
Page 38 - MAINTENANCE
SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnelshould perform this mainte-nance. • Turn the input power OFF at the disconnect switch or fusebox before working on thisequipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preven...
Page 39 - FIGURE D.1 – GENERAL COMPONENT LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAINTENANCE D-3 D-3 LINCOLN ® ELECTRIC IDEALARC DC-400 5 7 8 6 9 3 4 2 1 12 10 11 FIGURE D.1 – GENERAL COMPONENT LOCATIO...
Page 40 - Theory of Operation; FIGURE E.1 – IDEALARC DC-400 BLOCK LOGIC DIAGRAM
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section E-1 Section E-1 LINCOLN ® ELECTRIC IDEALARC DC-400 Theory of Operation ............................................................................................................. Section E General Descr...
Page 41 - THEORY OF OPERATION; FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
GENERAL DESCRIPTION The DC-400 is a multiprocess welder power sourcecapable of both constant voltage and constant currentoperation. Its power system is SCR controlled withsolid state electronic circuitry. Minimum to maximumoutput is obtained with a single potentiometer control. INPUT LINE VOLTAGE,CO...
Page 42 - FIGURE E.3 – OUTPUT MODE AND CONTROL, RECTIFICATION AND FEEDBACK
OUTPUT MODE AND CONTROL,RECTIFICATION AND FEEDBACK The three-phase AC output from the main transformersecondary is rectified and controlled through the SCR/diode bridge. Output current and voltage is sensed atthe shunt and output terminals. This feedback infor-mation is processed in the control boar...
Page 44 - SCR OPERATION; FIGURE E.4 – SCR Operation
SCR OPERATION A silicon controlled rectifier (SCR) is a three terminaldevice used to control rather large currents to a load.An SCR acts very much like a switch. When a gatesignal is applied to the SCR, it is turned ON and thereis current flow from anode to cathode. In the ONstate, the SCR acts like...
Page 45 - Test Procedures
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section F-1 Section F-1 LINCOLN ® ELECTRIC IDEALARC DC-400 Troubleshooting & Repair Section .................................................................................Section F How to Use Troubleshootin...
Page 46 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; The
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personn...
Page 47 - PC BOARD TROUBLESHOOTING PROCEDURES
ELECTRIC SHOCK can kill. Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electrically hot parts. Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced to poor electrical connections. ...
Page 48 - Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE ...
Page 49 - Check for blown or missing
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-5 F-5 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines ...
Page 50 - Rectifier Bridge Test.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-6 F-6 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE ...
Page 52 - Make certain the remote control
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-8 F-8 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE ...
Page 53 - Check the welding Mode switch
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-9 F-9 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines ...
Page 54 - FUNCTION PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-10 F-10 LINCOLN ® ELECTRIC IDEALARC DC-400 Observe Safety Guidelines TROUBLESHOOTING GUID...
Page 55 - Check for an internal short
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-11 F-11 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING GUIDE Observe Safety Guideline...
Page 56 - WELDING PROBLEMS; Check the welding cables for
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-12 F-12 LINCOLN ® ELECTRIC IDEALARC DC-400 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guideline...
Page 59 - INPUT CONTACTOR TEST; DESCRIPTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-15 F-15 LINCOLN ® ELECTRIC IDEALARC DC-400 INPUT CONTACTOR TEST WARNING Service and repai...
Page 60 - TEST PROCEDURE; Electric Shock can kill.; FIGURE F.1 – INPUT CONTACTOR CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-16 F-16 LINCOLN ® ELECTRIC IDEALARC DC-400 INPUT CONTACTOR TEST (continued) TEST PROCEDUR...
Page 61 - TEST FOR CONTACT CONTINUITY; Disconnect the main input supply power to; FIGURE F.2 – INPUT CONTACTOR TEST CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-17 F-17 LINCOLN ® ELECTRIC IDEALARC DC-400 TEST FOR CONTACT CONTINUITY 1. Disconnect the ...
Page 63 - FIGURE F.3 – CONTROL TRANSFORMER AND LEAD LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-19 F-19 LINCOLN ® ELECTRIC IDEALARC DC-400 CONTROL TRANSFORMER (T2) VOLTAGE TEST (continu...
Page 64 - Read the meter for 115VAC.; FIGURE F.4 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-20 F-20 LINCOLN ® ELECTRIC IDEALARC DC-400 CONTROL TRANSFORMER (T2) VOLTAGE TEST (continu...
Page 66 - FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-22 F-22 LINCOLN ® ELECTRIC IDEALARC DC-400 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)...
Page 67 - Test with an AC voltmeter for proper main; FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-23 F-23 LINCOLN ® ELECTRIC IDEALARC DC-400 8. Read the meter. a. If proper voltage is pre...
Page 68 - Test with an AC voltmeter for 21VAC for
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-24 F-24 LINCOLN ® ELECTRIC IDEALARC DC-400 12. Test for 115VAC between leads #31 and #32 ...
Page 69 - Plug P1 PHASE ANGLE WINDING VOLTAGES; Expected VAC; FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION; Plug P1
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-25 F-25 LINCOLN ® ELECTRIC IDEALARC DC-400 Plug P1 PHASE ANGLE WINDING VOLTAGES From Lead...
Page 71 - STATIC SCR/DIODE RECTIFIER BRIDGE TEST; FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-27 F-27 LINCOLN ® ELECTRIC IDEALARC DC-400 STATIC SCR/DIODE RECTIFIER BRIDGE TEST (contin...
Page 72 - Remove the red insulating paint from the; FIGURE F.11 – HEAT SINK AND SCR TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 LINCOLN ® ELECTRIC IDEALARC DC-400 STATIC SCR/DIODE RECTIFIER BRIDGE TEST (contin...
Page 74 - ACTIVE SCR TEST; FIGURE F.12 – CONTROL BOARD PLUG
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-30 F-30 LINCOLN ® ELECTRIC IDEALARC DC-400 ACTIVE SCR TEST (continued) TEST PROCEDURE 1. ...
Page 75 - FIGURE F.15 – HEAT SINK TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-31 F-31 LINCOLN ® ELECTRIC IDEALARC DC-400 ACTIVE SCR TEST (continued) 8. Remove the red ...
Page 76 - Test the voltage level of the battery. Short; FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-32 F-32 LINCOLN ® ELECTRIC IDEALARC DC-400 ACTIVE SCR TEST (continued) 9. Construct the c...
Page 77 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; volts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-33 F-33 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuitvoltage wav...
Page 78 - MAXIMUM OUTPUT SETTING – NO LOAD
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-34 F-34 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuitvoltage wav...
Page 80 - TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-36 F-36 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical DC open circuitvoltage wav...
Page 82 - TYPICAL SCR GATE VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-38 F-38 LINCOLN ® ELECTRIC IDEALARC DC-400 This is the typical SCR gate pulsevoltage wave...
Page 83 - ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-39 F-39 LINCOLN ® ELECTRIC IDEALARC DC-400 This is NOT the typical DC outputvoltage wavef...
Page 85 - FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL; CLEANING PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-41 F-41 LINCOLN ® ELECTRIC IDEALARC DC-400 INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (co...
Page 87 - FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT; FIGURE F.18 – FAN MOTOR MOUNTING DETAILS; PROCEDURE; You may need to loosen the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-43 F-43 LINCOLN ® ELECTRIC IDEALARC DC-400 FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (c...
Page 89 - SCR/DIODE RECTIFICER ASSEMBLY
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-45 F-45 LINCOLN ® ELECTRIC IDEALARC DC-400 SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPL...
Page 91 - FIGURE F.20 – SCR DETAILS; SCR REMOVAL AND REPLACEMENT; SPECIAL INSTRUCTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-47 F-47 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F.20 – SCR DETAILS SCR REMOVAL AND REPL...
Page 92 - FIGURE F.22 – CLAMP ASSEMBLY; Go to the procedure below that matches your
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-48 F-48 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F.21 – 1/2” WIDE LEAF SPRING FIGURE F.2...
Page 93 - Do not turn the nuts. While holding the nuts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-49 F-49 LINCOLN ® ELECTRIC IDEALARC DC-400 SCR REMOVAL AND REPLACEMENT (continued) CLAMPI...
Page 94 - FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-50 F-50 LINCOLN ® ELECTRIC IDEALARC DC-400 SCR REMOVAL AND REPLACEMENT (continued) PROCED...
Page 95 - AFTER REPLACING THE SCRs
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-51 F-51 LINCOLN ® ELECTRIC IDEALARC DC-400 CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE:...
Page 97 - Install the case top and sides.; DIODE STUD; MOUNTING OF STUD TYPE DIODES TO ALUMINUM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-53 F-53 LINCOLN ® ELECTRIC IDEALARC DC-400 PROCEDURE 1. Remove the main input supply powe...
Page 99 - REMOVAL OF LIFT BAIL; MAIN TRANSFORMER REMOVAL & REPLACEMENT; FIGURE F.25 – LIFT BAIL REMOVAL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-55 F-55 LINCOLN ® ELECTRIC IDEALARC DC-400 REMOVAL OF LIFT BAIL 1. Remove the main input ...
Page 100 - FIGURE F.26 – CHOKE REMOVAL; NOTE: The coils may be “stuck” to the top iron
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-56 F-56 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F.26 – CHOKE REMOVAL MAIN TRANSFORMER R...
Page 101 - FIGURE F.27 – EPOXY MIX APPLICATION AREAS; Apply a coating of Lincoln Electric E2547
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-57 F-57 LINCOLN ® ELECTRIC IDEALARC DC-400 FIGURE F.27 – EPOXY MIX APPLICATION AREAS MAIN...
Page 102 - FIGURE F.28 – COIL LEAD PLACEMENT
3. Install the bottom primary coils, one on each of the three legs of the bottom iron assembly. The coilsmust be in correct position (left, center, right).Place the coils so that the leads come out at theback of the machine. See Figure F.28 for properpositioning. 4. Place insulation (Lincoln Electri...
Page 103 - Mount the primary thermostat to the lead; FIGURE F.30 – PRIMARY THERMOSTAT LOCATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-59 F-59 LINCOLN ® ELECTRIC IDEALARC DC-400 MAIN TRANSFORMER REMOVAL & REPLACEMENT (co...
Page 104 - NOTE: The following procedure assumes you have; REASSEMBLE THE LIFT BAIL
REASSEMBLING THE MAINTRANSFORMER INTO THE MACHINE NOTE: The following procedure assumes you have completely reassembled the transformer coilsas described in the procedure above. Thelower iron has remained in place in themachine. See Figures F.25 and F.26. 1. Resolder the choke control coil leads to ...
Page 105 - RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS; Maximum Idle Amps; OPEN CIRCUIT VOLTAGES; Mode
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-61 F-61 LINCOLN ® ELECTRIC IDEALARC DC-400 RETEST AFTER REPAIR Retest a machine: • If it ...
Page 106 - MAXIMUM ACCEPTABLE OUTPUT VOLTAGE-
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-62 F-62 LINCOLN ® ELECTRIC IDEALARC DC-400 RETEST AFTER REPAIR (continued) MAXIMUM ACCEPT...
Page 108 - NOTES
NOTES IDEALARC DC400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 109 - ELECTRICAL DIAGRAMS
G-2 ELECTRICAL DIAGRAMS IDEALARC DC400 Wiring Diagram (Codes 9847, 9848) L9106 12-9-94F H2 H3 H4 ELECTRICAL SYMBOLS PER 1 1 24 3 1 6 PIN 4 PIN 8 PIN 12 PIN J6 J3 J2 CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) NOTES 225 4 2 31 32 75 76 77 225 TS1 TS2 C6 .0047MFD/1400V 10K /2W A...
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