Lincoln Electric SVM 122-A - Manual

Lincoln Electric SVM 122-A

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
  • Page 7 – TABLE OF CONTENTS; Installation; Lifting
  • Page 8 – INSTALLATION; TECHNICAL SPECIFICATIONS - IDEALARC DC-400
  • Page 9 – SAFETY PRECAUTIONS; SELECT SUITABLE LOCATION; LIFTING
  • Page 10 – INPUT CONNECTIONS; FIGURE A.1 – RATING PLATE LOCATION; GROUND CONNECTION; • Turn the input power off at the
  • Page 11 – INPUT WIRE AND FUSE SIZE; FIGURE A.3 – INPUT POWER SUPPLY CONNECTIONS
  • Page 12 – RECONNECT PROCEDURE
  • Page 13 – OUTPUT CONNECTIONS
  • Page 14 – TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE; WIRE FEEDER CONNECTIONS; Automatic Wire Feeders:
  • Page 15 – Operation
  • Page 16 – OPERATING INSTRUCTIONS; OPERATION
  • Page 17 – GENERAL DESCRIPTION; RECOMMENDED PROCESSES; Amps; LIMITATIONS
  • 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”
  • Page 19 – AUXILIARY POWER AND REMOTE CONTROL; Selects between Constant; DC VOLTMETER: Displays output voltage when
  • Page 20 – WELDING OPERATION; OPERATING STEPS; LOCAL CONTROL
  • Page 23 – NOTE: These semiautomatic wire feeders cannot; be used in the CC mode.; OVERLOAD PROTECTION
  • Page 24 – Accessories
  • Page 25 – FACTORY INSTALLED OPTION; DIODE OPTION; FIELD INSTALLED OPTIONS; ACCESSORIES; MULTIPROCESS SWITCH
  • 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
  • Page 27 – • Turn the input supply power OFF
  • Page 28 – K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS (Continued)
  • Page 29 – NOTE: The Idealarc DC-400 must be properly
  • 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
  • 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
  • Page 35 – K595-XX INPUT CABLE ASSEMBLY
  • Page 36 – NOTE: Welding cable must be sized for the current; NOTE: If optional remote control is used, set the
  • Page 37 – Maintenance
  • Page 38 – MAINTENANCE
  • Page 39 – FIGURE D.1 – GENERAL COMPONENT LOCATIONS
  • Page 40 – Theory of Operation; FIGURE E.1 – IDEALARC DC-400 BLOCK LOGIC DIAGRAM
  • Page 41 – THEORY OF OPERATION; FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
  • Page 42 – FIGURE E.3 – OUTPUT MODE AND CONTROL, RECTIFICATION AND FEEDBACK
  • Page 44 – SCR OPERATION; FIGURE E.4 – SCR Operation
  • Page 45 – Test Procedures
  • Page 46 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; The
  • Page 47 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 48 – Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS
  • Page 49 – Check for blown or missing
  • Page 50 – Rectifier Bridge Test.
  • Page 52 – Make certain the remote control
  • Page 53 – Check the welding Mode switch
  • Page 54 – FUNCTION PROBLEMS
  • Page 55 – Check for an internal short
  • Page 56 – WELDING PROBLEMS; Check the welding cables for
  • Page 59 – INPUT CONTACTOR TEST; DESCRIPTION
  • Page 60 – TEST PROCEDURE; Electric Shock can kill.; FIGURE F.1 – INPUT CONTACTOR CONNECTIONS
  • Page 61 – TEST FOR CONTACT CONTINUITY; Disconnect the main input supply power to; FIGURE F.2 – INPUT CONTACTOR TEST CONNECTIONS
  • Page 63 – FIGURE F.3 – CONTROL TRANSFORMER AND LEAD LOCATIONS
  • Page 64 – Read the meter for 115VAC.; FIGURE F.4 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS
  • Page 66 – FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS
  • Page 67 – Test with an AC voltmeter for proper main; FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS
  • Page 68 – Test with an AC voltmeter for 21VAC for
  • Page 69 – Plug P1 PHASE ANGLE WINDING VOLTAGES; Expected VAC; FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION; Plug P1
  • Page 71 – STATIC SCR/DIODE RECTIFIER BRIDGE TEST; FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS
  • Page 72 – Remove the red insulating paint from the; FIGURE F.11 – HEAT SINK AND SCR TEST POINTS
  • Page 74 – ACTIVE SCR TEST; FIGURE F.12 – CONTROL BOARD PLUG
  • Page 75 – FIGURE F.15 – HEAT SINK TEST POINTS
  • Page 76 – Test the voltage level of the battery. Short; FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS
  • Page 77 – SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; volts
  • Page 78 – MAXIMUM OUTPUT SETTING – NO LOAD
  • Page 80 – TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
  • Page 82 – TYPICAL SCR GATE VOLTAGE WAVEFORM
  • Page 83 – ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
  • Page 85 – FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL; CLEANING PROCEDURE
  • Page 87 – FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT; FIGURE F.18 – FAN MOTOR MOUNTING DETAILS; PROCEDURE; You may need to loosen the
  • Page 89 – SCR/DIODE RECTIFICER ASSEMBLY
  • Page 91 – FIGURE F.20 – SCR DETAILS; SCR REMOVAL AND REPLACEMENT; SPECIAL INSTRUCTIONS
  • Page 92 – FIGURE F.22 – CLAMP ASSEMBLY; Go to the procedure below that matches your
  • Page 93 – Do not turn the nuts. While holding the nuts
  • Page 94 – FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING
  • Page 95 – AFTER REPLACING THE SCRs
  • Page 97 – Install the case top and sides.; DIODE STUD; MOUNTING OF STUD TYPE DIODES TO ALUMINUM
  • Page 99 – REMOVAL OF LIFT BAIL; MAIN TRANSFORMER REMOVAL & REPLACEMENT; FIGURE F.25 – LIFT BAIL REMOVAL
  • Page 100 – FIGURE F.26 – CHOKE REMOVAL; NOTE: The coils may be “stuck” to the top iron
  • Page 101 – FIGURE F.27 – EPOXY MIX APPLICATION AREAS; Apply a coating of Lincoln Electric E2547
  • Page 102 – FIGURE F.28 – COIL LEAD PLACEMENT
  • Page 103 – Mount the primary thermostat to the lead; FIGURE F.30 – PRIMARY THERMOSTAT LOCATION
  • Page 104 – NOTE: The following procedure assumes you have; REASSEMBLE THE LIFT BAIL
  • Page 105 – RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS; Maximum Idle Amps; OPEN CIRCUIT VOLTAGES; Mode
  • Page 106 – MAXIMUM ACCEPTABLE OUTPUT VOLTAGE-
  • Page 108 – NOTES
  • Page 109 – ELECTRICAL DIAGRAMS
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SVM 122-A

Oct. 1996

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

®

ELECTRIC

World’s Leader in Welding and Cutting Products 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

For use with machine code numbers 9847, 9848 and 9850

IDEALARC DC-400

TM

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RETURN TO MAIN INDEX

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Summary

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...

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